Actuator sizing is crucial for efficiency, proper device function and avoiding damage. It involves selecting an actuator mechanically suitable for mountings, shaft dimensions, output specifications, torque, drive type and range of motion requirements. When planning new installations or upgrading existing ones, comprehensive actuator sizing should be undertaken, including consideration of mounting and drives, power ratings and electrical requirements. Control specifications must also be matched to the actuator.
Actuator sizing is the practice of correctly matching new or replacement actuators to their operating environment and the devices they drive. This procedure is critical if efficiency is to be maintained, devices are to function properly, and losses due to damage are to be avoided. The process generally consists of selecting an actuator that will be mechanically suitable in terms of mountings, shaft dimensions and output specifications. The actuator output must also be considered to ensure it is suitable for the torque, drive type and range of motion requirements of the application. Matching the existing supply and control voltages is another of the critical considerations involved in actuator sizing.
When actuators are replaced or new installations are planned, one of the first steps in the process is actuator sizing. This exercise ensures that the actuators you choose will operate efficiently and economically without sustaining damage or damaging the actuated device. If a damaged actuator is being replaced, the exercise is relatively straightforward as the details of the actuator are known. That is, of course, if the incorrect sizing of the actuator didn’t cause the old device to fail in the first place.
When planning new installations or upgrading an existing actuator assembly, a comprehensive actuator sizing exercise should be undertaken. This typically involves consideration of several relevant areas, including mounting and drives, power ratings, and electrical requirements. Mounting and actuation requirements are critical details although generally quite simple to establish. The actuator housing mounting points must be compatible with those of the installation supports and the output shafts must match the power transfer mechanism both in terms of sizing and connection types. In this regard, points such as mounting hole numbers, sizes and configurations as well as drive transfer joint types, keyway details and shaft dimensions should be checked.
One of the most important and complex steps for the correct sizing of the actuator is the determination of the correct power ratings. Many actuated devices have mechanisms that require a range of torque inputs during operation. For example, the torque required to turn a large ball valve is usually significantly less than that required to drive it in. When considering the power of a potential actuator, a thorough understanding of the total power requirements of the driven device is therefore necessary.
The type of output of the new actuators is easy enough to determine: a rotary actuator will obviously not do well where a linear output is required. The extent, or scope, of that movement is, however, a far more complicated matter. If the output range of a replacement or new actuator is somewhat longer than necessary, damage to the activated device and the actuator is inevitable. If it is too short, the driven device may malfunction or may cause loss of production or process efficiency.
The control specifications are the last of the critical steps for actuator sizing. Existing systems typically have a set supply voltage and control protocol standards to which the actuator must be matched. A 110 volt actuator motor will have life measured in milliseconds when plugged into a 500 volt power source, so these issues should be given close attention during the actuator sizing process.
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