Almost all industries utilize motion control technologies to precisely move and control machinery and systems. These technologies employ a range of components for managing the position, velocity, and force of mechanical systems, one of which are actuators. Actuators convert energy into mechanical motion, and play important roles in various industries, including aerospace, industrial automation, healthcare, and the renewable energy industry. Over the years, different types of actuators have gained popularity. Mechanical, hydraulic, electric linear, pneumatic, and piezoelectric linear actuators are only a few. Among these, mechanical and electrical linear actuators are extremely popular. Electric linear actuators are gaining prominence as a viable alternative to traditional hydraulic systems. While hydraulic actuators have been favored for their power and durability, electric linear actuators offer several advantages that make them increasingly attractive. This post explores what makes electric linear actuators a suitable hydraulic replacement alternative.
Benefits of Electric Linear Actuators
Which is the best electric or hydraulic actuators? There has been an ongoing debate on this topic for several years now. It has been proven that electric linear actuators offer several benefits over their hydraulic alternatives. The below section will help you understand it better.
- Safety: These devices feature built-in sensors that can gauge actuator overloads or when they encounter an obstruction during the operation. In these scenarios, the actuators will stop functioning, preventing motor damage and ensuring operator safety.
- Easy integration: An electric linear actuator can be easily installed and integrated with other systems and equipment. Programming the commands for the controllers is very easy, and they are simpler compared to hydraulic or pneumatic systems.
- Precision and control: An electric linear actuator assures great control throughout the whole process. An operator can completely control the position of the piston and apply force with just a few keystrokes on the controller. On the other hand, hydraulic systems can’t provide the same level of control and accuracy.
- Environmentally Friendly: An electric linear actuator is powered by electricity. It’s clean and does not create any by-products during the operation. This variant is often preferred by the medical and healthcare industry as it doesn’t contaminate anything. While Hydraulic systems, with their high-pressure fluids, pose a potential risk. A single damaged part can lead to leaks, potentially contaminating products or the facility. This underscores the importance of diligent maintenance.
- Faster assembly time: Putting everything together is easier with an electric linear actuator because you won’t have to deal with pumps and hoses. It only requires simple wiring for installation, which means faster integration into the facility’s ecosystem and reduced labor costs due to time saved.
- Quiet motor: When choosing actuators, you must consider noise pollution. Hydraulic systems are powerful but loud due to their high horsepower motors. However, electric linear actuators work best in this case as they use silent electrical motors.
- Low maintenance: This type of actuator requires minimal maintenance due to its simplified design and fewer points of failure. The parts of this actuator are easier to troubleshoot, repair, or replace. In contrast, hydraulic setups demand continuous review to mitigate the risks of leaks and contamination, further highlighting the superiority of the low-maintenance actuator.
You can realize many more benefits by choosing the right electric linear actuators. Are you currently using hydraulic actuators? Have you been considering the conversion of hydraulic actuators to electric linear actuators? If that sounds yes, the next section offers you the tips for conversion.
Related Blog: Benefits of Using Electric Linear Actuators
Explain How to Convert Hydraulic Actuators to Electric linear actuators
Various steps are involved in the conversion of hydraulic actuators to electric linear actuators. Here’s a detailed guide on how to perform this conversion:
- Assess the existing system first: Assess the current system’s requirements, including load, speed, stroke length, precision, and operating environment. Document the specifications of the existing hydraulic actuators and define the performance goals and any specific improvements desired from the conversion.
- Choose the right electric linear actuators: Now, it’s time to choose electric linear actuators. The electric linear actuators you choose should match or exceed the force and speed capabilities of the hydraulic actuators. Ensure the electric linear actuators possess the stroke length and control system required to meet your application needs. Also, consider the operating environment, such as temperature, humidity, and exposure to dust or chemicals.
- Designing and engineering: In this step, you must modify or design new mounting brackets and mechanical interfaces to accommodate the electric linear actuators. Then, plan for the electrical power supply requirements, such as installing new power lines and connectors, and ensure the power supply matches the voltage and current specifications of the electric linear actuators. Now, update or replace control units, install new sensors, and ensure proper communication between the actuators and the control system.
- Installation: Now, it’s time for installation. All you need to do is carefully remove the existing hydraulic actuators, hoses, and associated components and ensure that hydraulic fluid is properly drained and disposed of. Then, properly install the electric linear actuators in place of the hydraulic ones and secure them with mounting brackets and interfaces. Lastly, connect the actuators to the power supply and control system, ensuring all wiring is correctly and safely installed.
- Calibration and testing: After installing electric linear actuators, and it’s time to calibrate and test them. For calibration, all you need to do is set the correct stroke lengths, force limits, and speed settings. Then, test actuators to verify their functionality and ensure they meet the performance specifications. Conduct load testing to confirm the actuators can handle the required loads and operate under actual working conditions.
- System optimization: Ensure the electric linear actuators are fully integrated into the system, with all control signals, feedback loops, and safety features functioning correctly. Fine-tune control algorithms, adjust power settings, and ensure synchronization with other system components to optimize the system for performance and efficiency.
- Documentation: Maintain a document covering the new actuator specifications, wiring diagrams, and maintenance procedures. Additionally, provide training to maintenance and operational staff on the new system. This should include instructions on how to operate, troubleshoot, and maintain the electric linear actuators.
- Tracking and maintenance: Implement a monitoring system to continuously check the electric linear actuators’ performance. Use sensors and data logging to track key parameters and detect anomalies. Schedule regular maintenance to ensure the actuators remain in optimal condition. This includes periodic inspections, lubrication, and software updates, if applicable.
Are you planning to invest in electric linear actuators for hydraulic replacement? Do you want electric linear actuators in custom specifications? You must source them from trusted brands like Venture Manufacturing. The company has been at the forefront of actuation technologies since 1971. Contact their team today to discuss your requirements.