Linear Actuator Troubleshooting Guide | Common Problems & Solutions

Linear actuators are critical components in many automated systems. Whether it’s for adjusting positions, lifting heavy loads, or controlling movements with precision, linear actuators provide reliable functionality. But when they malfunction or fail, the results can be costly in terms of both time and resources. To prevent unnecessary downtime, it’s crucial to identify and address common issues before they develop into large problems. This post explores the most common problems encountered with linear actuators and provides practical solutions to help you keep your systems running smoothly.

Common Problems with Linear Actuators

Below are some of the most frequently encountered issues with linear actuators:

Actuators not responding or moving: When actuators fail to respond or exhibit movement, multiple factors may be responsible. These can include an inadequate power supply, defective wiring or connections, a damaged motor, or the failure of internal components. To address this issue, verifying the power supply is essential. For instance, if utilizing a 12V linear actuator, one must ensure sufficient voltage. Additionally, inspecting wiring and connections and replacing or repairing any damaged internal components as necessary is advisable.
Overheating of electric linear actuators: Continuous operation without proper cooling can cause the actuator to overheat. If the actuator is tasked with handling more than sufficient weight, this can cause excessive heat buildup. Operating in extreme temperatures can also contribute to overheating. In such conditions, there are a few things that you should take care of. First, ensure the electric linear actuator is given adequate time to cool down between cycles. Make sure the actuator is not being overloaded beyond its rated specifications. In high-demand environments, consider adding external cooling systems.
Jerky or unstable movements: If the linear actuator has any jerk or unstable movements, possible causes could be mechanical obstructions, worn-out tears or components, or improper installation. That’s why it is better to implement a few things. Inspect the actuator’s path and remove any debris or obstacles. Inspect and replace worn components and ensure that the actuator is installed correctly and aligned.
Inconsistent actuator speed: This is also one of the common issues in actuators. Inconsistent actuator speed happens due to few reasons like voltage fluctuations, faulty motor controllers or overloading. To avoid such issues, ensure few things. Check the voltage and ensure that the power source is providing a consistent flow of electricity. Inspect the motor controller for faults and make sure that the actuator is not overloaded.
Noise during operations: This issue can occur due to a few reasons. If the moving parts of the actuator are not properly lubricated, friction can create noise and cause wear on the components. Any loose or misaligned components within the actuator can generate noise during operation. That’s why it is essential to regularly lubricate the actuator’s moving parts, tighten loose components, and replace any kind of worn bearings or bushings.

When should you contact an actuator manufacturer for help?

While many issues with linear actuators can be solved through basic troubleshooting and maintenance, there are times when it’s necessary to seek help from the actuator manufacturer. Here are some situations where contacting the actuator manufacturer is the best course of action:

Persistent issues despite troubleshooting: If you’ve gone through the common troubleshooting steps, but your actuator still isn’t functioning correctly, it might be time to reach out to the manufacturer.
Need for replacement or custom parts: Over time, some components of the actuator may wear out and require replacement. In situations where a part is no longer available through standard suppliers, or if the damage is severe, you may need to contact the manufacturer for replacement parts.
Warranty or manufacturer defects: If your actuator is still under warranty, and the issue seems to be caused by a manufacturing defect, it’s crucial to contact the manufacturer for assistance.
Complex technical issue: Some problems with linear actuators might involve complex technical issues that require specialized knowledge and experience. If you’re unsure about diagnosing or fixing the issue on your own, it’s always better to consult the actuator manufacturer.
Any ongoing support or guidance: If you’re using electric linear actuators in a critical application, having access to expert guidance from the manufacturer can ensure smooth operation and performance.
Emergence time-sensitive situations: If the actuator failure significantly impacts production or safety, you need a professional response to get the system back online as quickly as possible.

Linear actuators are powerful components that are vital in various automation and mechanical systems. By understanding the common problems, you can quickly identify and resolve many of these issues yourself. However, there are times when problems go beyond simple fixes or when your actuator requires customization for a unique application. In these instances, contacting a trusted actuator manufacturer is essential.

Don’t let actuator issues disrupt your operations. Whether you need expert advice, replacement parts, or a custom linear actuator, Venture Manufacturing is here to help. Contact our team of experts now to keep your systems running smoothly and efficiently.