Our sales team is often asked how long our actuators last. Today we’re going to address that question. When selecting components to integrate into a product design, one of the most important things to ascertain is how long the components will last. We’re going to discuss how you can determine how long your actuator will last in your application, as well as show you a few things you can do to get the longest possible lifespan from your linear actuator investment.
What Could Cause Actuators to Prematurely Fail?
Actuators are designed to provide reliable motion control, but like any mechanical component, they can fail prematurely if not used correctly. Application-specific testing is crucial to ensure that your actuators operate within their intended parameters. Even high-quality actuators can break down quickly when subjected to misuse or excessive stress. Understanding the most common causes of failure can help you take preventive measures to extend the lifespan of your actuators and maintain optimal performance in your application.
Failures can result in costly downtime and replacement of the actuator. Whether you're working with industrial automation, robotics, automotive systems, or medical devices, preventing premature failure is key to reducing costs and ensuring smooth operation. Below, we’ll cover the most common causes of premature actuator failure and provide solutions to help you avoid them.
Overloading
Every actuator has a rated load capacity, and exceeding this limit is one of the quickest ways to cause failure. Overloading can lead to stalling, motor burnout, excessive wear on gears, and structural damage.
How to avoid it: Choose an actuator that matches or exceeds your required load and avoid stalling wherever possible. If a single actuator isn't enough, consider using multiple actuators to distribute the load more evenly.
Side Loading
Linear actuators are designed to handle force along their axis of motion, but they cannot tolerate significant side loads. Side loading occurs when an external force is applied perpendicular to the actuator’s movement, which can cause bending, binding, and premature wear on internal components.
How to avoid it: If your application introduces side loads, mount the moving load on a slide rail and use an actuator to drive it. Alternatively, a track actuator may be a better solution than a rod-style actuator, as it is designed to handle side loads more effectively.
Incorrect Input Voltage
Using the wrong input voltage can severely damage an actuator. Running an actuator at a higher voltage than recommended can overheat the motor, burn out internal components, or cause erratic performance. Even using a lower voltage than specified can lead to poor efficiency and inconsistent operation.
How to avoid it: Always use the voltage recommended by the actuator manufacturer.
Water Ingress
Moisture and electronics do not mix, and water ingress can quickly lead to actuator failure. Even units with some level of water resistance can suffer damage if exposed to rain, high humidity, or direct water contact over time.
How to avoid it: If your actuator will be exposed to the elements, mount it in a location where it is shielded from rain or direct water exposure. In harsher environments, consider using a waterproof enclosure to protect the actuator from moisture damage.
Duty Cycle Too High
The duty cycle of an actuator refers to the amount of time it can run within a given period without overheating. Exceeding the rated duty cycle can cause the motor to overheat, shortening its lifespan and leading to failure.
How to avoid it: Always adhere to the manufacturer's recommended duty cycle. Running an actuator at its maximum duty cycle continuously will wear it out faster, so if possible, operate below the maximum rating to extend its lifespan.
Actuators are designed to provide long-lasting, reliable performance when used correctly. However, improper use, environmental factors, and excessive strain can cause premature failure. By selecting the right actuator for your load, properly mounting it to avoid side loading, using the correct input voltage, protecting it from water damage, and adhering to duty cycle recommendations, you can maximize the lifespan of your actuator.
While actuators are built to endure significant usage, they are still mechanical components that will wear out over time. If you’re trying to figure out what could cause actuators to prematurely fail, chances are good that your answer is in the list above. Even when using an actuator within its rated limits, you have to consider that an actuator will degrade faster when run continuously at its maximum rated limits compared to one operated within conservative limits.
If you're thinking of integrating Actuonix Motion Devices into your product design, here is a quick guide on application-specific testing.
Common Questions About Actuator Failures
What causes actuators to fail prematurely?
Common causes of premature actuator failure include overloading, side loading, incorrect input voltage, water ingress, and exceeding the recommended duty cycle. These factors put excessive stress on actuators, leading to wear, overheating, and eventual failure.
How can I prevent actuator failure due to overloading?
To prevent overloading, always choose an actuator that matches or exceeds the required load capacity for your application. If necessary, use multiple actuators to distribute the load more evenly and avoid stalling.
What is side loading and how does it affect actuators?
Side loading occurs when an external force is applied perpendicular to the actuator’s motion. This can cause bending, binding, and wear on internal components, leading to premature failure. To prevent this, consider using a slide rail or a track actuator designed to handle side loads.
How do I ensure my actuator is protected from water ingress?
To protect against water ingress, mount the actuator in a location shielded from rain or direct water exposure. For harsher environments, consider using a waterproof enclosure to prevent moisture damage.
Explore Actuonix Linear Actuators Today
We hope this article has helped you better understand the factors that affect actuator lifespan and how to improve it. To find out more about our actuators and explore our full range of products, visit our actuators by model page. As a leading manufacturer and innovator in the micro motion marketplace, Actuonix services companies big and small in a number of industries including aerospace, medical, robotics, and more. Get in touch with us today to submit an order or to submit an inquiry.