You want to automate something; it turns out you need two bits of information to get started. You need to know the weight of your load, and how far you want the load-object to move. If you have even an approximate idea of these two variables; you will be able to plan an actuator system like a pro. Yes, you still might want your calculator handy.
We can sum this process up in the following way: Design, Measure, Match, Order, Build.
Step One: Define the motion
The best applications could work without an actuator - meaning the object will move through the motion before automation is installed. For example; If you are moving an object on a hinge, the hinge and object are already assembled and able to move. If you are sliding an object, the object is already capable of sliding (on whatever structure currently exists) - the actuator is just there to make it a hands free operation. The point is, even if you are not physically strong enough to move the object by hand, it could move if enough force was applied. This is where the machines come in.
Each application works differently and each specific project will have different restrictions.
Step Two: Quantify the motion
Now that your structure is built (or conceptualized), it’s time to measure! As with anything engineering-related; it’s best to draw out your project and track your dimensions on the drawing. Be precise.
From our previous sliding example; if your object needs to move 20”, you need at least 20” of motion from the actuator, which is called the ‘stroke length’. The same is true for vertical motion. The stroke is the maximum amount of motion the unit will provide. We can restrict the motion of a longer actuator, but we can’t lengthen a shorter actuator.
This quantification can be difficult to determine on hinged applications. The actuators are linear, but the motion of the hinge is rotary - which means: TRIG. Oh yes. Everybody's favorite.
Draw triangles. Use online tools as needed. In the interest of keeping this overview brief, here’s an article with details on defining motion in several types of projects. Over the years, Firgelli has built some Engineering Calculators for public use. One of those is a hinged-lid calculator which works for up to 90* openings, and we are continually developing more.
Step Three: Select Actuators based on Specifications
By now, you should know approximately how much force and motion is required from your units; with this info, you can peruse the available products to find one that exceeds your force requirements while having enough stroke length for your motion.
Some projects have a specification or requirement for Actuator Speed. Actuator movement speed and force rating are (generally) inversely related. Our actuators are powerful and precise, but relatively slow, due to the gear reduction ratio between the motor and the drive screw.
The chart below contains the maximum force rating and full/no load speeds of our standard lines of actuators; excluding a couple special cases (for readability). As the force of the actuator increases, the speed per second decreases, with 1" per second @ 100 lbs. as the general 'cross point' - if the load is above 100 lbs. the actuator's speed will be slower than 1" per second. The physical size of the actuator does have an effect on speed as well, for example Micro Actuators are simply too small to be quick moving [and are not included in the chart].
This is also where you must start making decisions about your system and how you’d like to control it. In general, the more precise or specific behaviors you want from your system will result in a more complicated build. At a certain point, it’s easier to use a PLC and Motor Driver to serve as a ‘brain’ for the project – particularly when dealing with timing, set distances, or multi-step, sequential operations.
Do you need multiple actuators? Then you need to make sure your power supply is big enough, and maybe should include some extra components.
Do they need to work precisely together? Then you also need feedback actuators and computer-guided control. We have a Synchronizing Control Box for just this purpose - it even has additional features.
Do you want them to be individually controlled as well as moving together? Then you also need a PLC and some programming knowhow.
If you answer yes to any of the above questions, your system will be planned and designed differently from the actuators on.
Step Four: Build the Rest of the System Around the Actuator’s Needs
Before jumping into electrical considerations; we have one more component for the physical motions - the Mounting Brackets. Brackets are actuator-specific. Refer to actuator product pages for proper brackets.
Most projects will use a Clevis Mount bracket, connected through the clevis-holes at the end of the actuators. Some projects may require a different type of mounting set up, so we have developed some alternative bracket types for these uses. Here's a guide on various mounting brackets and the actuators they work with.
The motor of the actuator is the most restrictive component of these systems. This is due to a principle called In-Rush Current, which is a thing that happens with all DC motors. In order to get the rotary motor of the actuator spinning, the motor will draw a lot of power for the first moments of operation (not a full second). This in-rush current can be as high as the maximum current draw of the actuator motor. In all other parts of operation, the current draw is correlated to the load or resistance experienced by the actuator.
This is why we recommend selecting the appropriate actuator first. Some actuators may not work with other components that we also sell. For example: Power Max and Industrial Heavy Duty Actuators draw much more electrical power than anything else we have - these units are super strong, but they will not operate correctly when used with components that aren’t designed to handle electrical loads that high.
You will need to verify that the voltage and amperage of your actuators will work with any other components you select. Many of our control boxes can work on 12v or 24v systems, but not all of them. Most of our components are primarily built for 12v DC circuits as they are most common in for North American house-projects (with 24v unofficially being the ‘bonus option’ used in Industrial Settings.)
Step Five: Order Online
All orders are placed directly online and ship the following business day. We ship worldwide, direct to consumer with FedEx as standard.
All actuators come with a 12-month standard warranty. This will protect you against manufacturer defects only. User error and misuse will not be covered under standard warranty. Shipping and all costs pertaining to shipping will not be refunded.
You may also opt for Warranty Plus coverage when you add you actuators to your cart. Which entitles you to a (1) replacement actuator in the event of failure under any conditions, including user error and misuse during the 12-month warranty period. We recommend this for any experimental or trial applications.
We accept returns within the first 30 days. As long as the product is in new and unused condition, is in original packaging, and passes a thorough inspection, you will be eligible for a refund minus a 20% re-stocking fee (unless a replacement order is placed). Customer is responsible for the return shipping for any item ordered in error or no longer suitable.
Step Six: Wiring and Install
When you receive your order; it is prudent to give the system a dry-run or bench test to ensure all components are functioning correctly and working together.
Each component will have its specific instruction manual; we also have a wiring diagram generator in the ‘resources’ section of the website. The generator is somewhat limited to simple schematics; email tech support if your components are not ‘generating’ a diagram.
Some projects will require additional wire lengths, as the actuators only have up to a few feet of cable included. As far as wiring goes, this online calculator is effective for estimating the appropriate wire size. The wire gauge depends on the distance of the wire run as well as the power traveling through it. When in doubt, go heavier. We also have this handy voltage-drop calculator to review any existing wiring you have for retro-fitting applications.
Once your system is wired and powered, you should be good to go!
Example Wiring Diagrams:
One of the simplest systems possible is a rocker switch, power supply, and single actuator.
And one of the most complicated 'standard' systems: (Multi-input control system; 2 rocker switches and a PLC controlling a single actuator.)
