🔧 How to Increase Duty Cycle by Running at Lower Loads and Keeping Temperature Low 🔥
Linear actuators are essential in automation, but their performance is often limited by duty cycle—the percentage of time they can run before needing to rest. One of the biggest factors affecting duty cycle is temperature. The good news? By reducing the load and keeping temperatures low, you can significantly extend the duty cycle. Let’s explore how! 🚀
📌 What is Duty Cycle?
Duty cycle represents the ratio of ON time to OFF time in a given period, expressed as a percentage.
| Duty Cycle | Example Run Time | Required Rest Time |
|---|---|---|
| 10% | 1 min ON | 9 min OFF |
| 25% | 1 min ON | 3 min OFF |
| 50% | 2 min ON | 2 min OFF |
| 100% (Continuous) | Unlimited | None |
🔥 Why Does Temperature Affect Duty Cycle?
Actuators generate heat due to:
- ⚡ Electrical resistance in motor windings
- ⚙️ Friction in gears and bearings
- 🔌 Power losses in control electronics
🔴 If the actuator overheats, it may shut down or degrade faster, reducing lifespan.
🔼 Higher duty cycle = More heat generated
✅ How to Increase Duty Cycle by Reducing Heat
1️⃣ Reduce Load on the Actuator
Operating under **lighter loads** decreases current draw and reduces heat generation. For instance, an actuator rated for 200 lbs running at 50 lbs generates **less heat and runs longer**.
2️⃣ Use a Larger Actuator
If an actuator is **constantly running at max load**, it will heat up faster. Using a higher-rated actuator at a lower percentage of its capacity can extend its duty cycle significantly.
3️⃣ Improve Cooling & Heat Dissipation
- 🌀 Mount actuators in **open airflow areas** to enhance cooling.
- 💨 Add **heat sinks or cooling fans** to assist with temperature control.
- 🌡️ Utilize **aluminum housings** for better heat dissipation.
4️⃣ Use Low-Friction Lubricants & Bearings
Effective lubrication **reduces internal resistance** and prevents heat buildup. Ensure actuators are maintained properly to maximize their performance.
🚀 Summary: How to Maximize Duty Cycle
| Method | Effect |
|---|---|
| ⬇ Reduce Load | Less current draw = Less heat |
| ⬆ Use Larger Actuator | Lower stress per cycle = Longer duty cycle |
| 🌀 Improve Cooling | More heat dissipation = Extended runtime |
| ⚙️ Use Better Lubrication | Less friction = Less heat buildup |
🏆 The Bottom Line
By reducing **load, improving cooling, and selecting efficient actuators**, you can **significantly increase duty cycle without overheating**.
💡 Want help selecting an actuator for **continuous operation**? Contact us today! 🚀
