12 Volt Linear Actuators: Types, Uses and Features

Chapter 1: Understanding the Basics of 12V Linear Actuators

In this chapter, we delve into the mechanics and functioning of 12V linear actuators, examining their operation and various uses.

Defining 12V Linear Actuators

A linear actuator transforms rotational motion into linear movement, enabling the actuation of machinery or materials through pushing, pulling, lifting, lowering, sliding, or tilting actions. These devices provide dependable, low-maintenance motion control that is both eco-friendly and secure. Powered by a 12-volt DC source, 12V linear actuators are characterized by three main types: screw, wheel and handle, and cam. Screw-type actuators achieve movement as the screw mechanism winds and unwinds.

In wheel and handle actuators, motion results from the tension of a belt or chain attached to a shaft. Meanwhile, cam actuators employ an eccentric circle to shift the shaft. The definition of a linear actuator may vary by industry. Often, it is understood as a device engineered to transform rotary force into linear movement, with initial forces derived from motors or hand cranks.

Working Mechanism of 12V Linear Actuators

At the heart of a 12V linear actuator lies a compact DC gear motor that applies a screw-drive mechanism and gears to electromechanically manage heavy loads. Due to their robustness, ease of installation, and compact nature, these 12V DC actuators are exceptionally versatile. Each actuator includes two wires (positive and negative), mounting holes at each extremity, and built-in limit switches. With stroke lengths ranging from 1 inch to 24 inches, these actuators can exert force capabilities of 15 lbs, 50 lbs, or 150 lbs. Customization of these actuators in terms of specific sizes, currents, and speeds is common to meet distinct client needs.

Linear actuators move in a straight trajectory, with various methods achieving such motion. They are integral to numerous applications, from facilitating wheelchair access and toys to complex space technology equipment.

A DC motor powers these actuators, typically using a 12V DC voltage. In brush DC actuators, a switch can reverse the motor’s polarity, altering the actuator's motion. Servo and stepper motors necessitate control electronics to electrically manage current direction within the motor. For proper BLDC and servo motor commutation, rotor feedback is crucial, using devices like Hall effect sensors or encoders.

An actuator's control electronics may be integral or externally accessible. The force applied by an actuator is influenced by its speed, with a trade-off between the two: reducing the actuator's speed through a gearbox enhances the force output. Differentiation among actuators can be seen in the screw and shaft length, which determines stroke length.

The actuator's speed is determined by the gears between the motor and the screw. Stroke length is controlled using devices like limit switches, encoders, linear potentiometers, or LVDT sensors. Microswitches at the shaft's ends may control the stroke, responding to the screw’s movement for precise management.

Chapter 2: What should you consider when using 12V linear actuators?

This chapter will cover the key design considerations for linear actuators, as well as the important factors to consider when selecting the right actuator for your needs.

• Power: The first factor to take into account while developing a linear actuator is power. It is important to have power in order to get mechanical power out. The force or load that has to be moved determines how much mechanical power is expended. The force (F), speed (V), and current draw (I), which decide what load the actuator will be able to move, are found in performance graphs and charts that the various manufacturers provide data on.

• The duty cycle determines how frequently and for how long the actuator will operate. Since power is lost through heat, the duty cycle is determined by the actuator's temperature while it is in motion. By adhering to the duty cycle recommendations, you can prevent motor overheating and component damage in the actuator. There is variance in the duty cycles of actuators because they are not all created equally. Age, loading characteristics, and ambient temperature are all important variables to consider that might affect duty cycle motors.

  

  
  
• Understanding an actuator's efficiency will help you predict how it will behave when in use. The effectiveness of a ball screw actuator will determine whether holding brakes are required. Calculating an actuator's efficiency involves dividing the mechanical power generated by the electrical power and the resulting number is its efficiency rating expressed as a percentage.

Considerations When Selecting a Linear Actuator

• It's critical to consider the sort of motion needed while analyzing the location of the actuator. Starting a procedure on a machine is different from simply opening and closing a door or valve. Actuators can move things in a circular motion or in a straight line. It is crucial to evaluate these motions and how they fit within your workflow.
• Electrical actuators have been refined and enhanced to match any application. Despite being the most well-liked and often-used type of actuator, this does not guarantee that they are suitable for all circumstances. When power is scarce or unavailable, it could be important to take a pneumatic or hydraulic actuator into account.

• Even though speed is crucial when choosing an actuator, it's also crucial to take the weight that needs to be moved into account. An actuator will move more slowly when a lot of force is needed to move a weight. An actuator measures speed in terms of distance traveled per second. By calculating the required duty cycle, you can get information that will assist you when choosing the suitable actuator for the job.

  

  
  
• Most actuators struggle to function in surroundings that are unclean, wet, moist, or dusty. Although there are actuators that are made to function underwater, most require some kind of cover or enclosure to function in dirty, rough, or demanding environments.
• Given that aerospace equipment needs extreme precision and accuracy, an actuator that is used to activate equipment in space may not be the best choice for heavy duty use in a factory. The type of actuator required is frequently determined by the amount of the work it used for. Operating a valve or stacking pallets, for example, may not require the same actuator as tasks performing precise,l sensitive actions.
• Delivering force in the form of work is one of an actuator's primary roles. Actuators are devices that move, lift, tilt, activate, and slide materials and objects. In order to move a weight, an actuator needs to exert a certain amount of force, which is specified by its load capacity. Manufacturers supply statistics and information on the load capacities of their products, which should be examined to see if the capacity offered is appropriate for the task.
• You might assume that you can't install an actuator because of its size or length if the area where one is required seems constrained and limited. There are actuators that are made specifically to work in small areas. Telescoping actuators come in a variety of designs from various manufacturers, and they can be used in nearly any size setting. Maximum misalignment tolerance is possible when pin-to-pin attachment is used, together with spherical bearings on both sides. Design elements of higher quality limit roll about the actuation axis by giving one of the spherical bearings only two degrees of freedom.

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Chapter 3: What are the different types of 12V linear actuators?

12V linear actuators are available in various types and orientations, including:

Mechanical or Electro-Mechanical Linear Actuators

The primary function of mechanical or electromechanical linear actuators is to convert rotational motion into linear motion. This conversion is achieved through mechanisms such as screws, wheels and handles, or cams, which are commonly used in linear actuators.

Mechanical linear actuators are powered by either AC or DC motors. In screw-type mechanical linear actuators, various screw designs are utilized, such as ball screws or roller screws. The actuator features a rotating screw shaft that moves linearly along its axis. This linear motion is achieved by the rotation of the shaft, which is controlled by a stator assembly.

The wheel and handle type of linear actuator utilizes a belt, chain, rack, or cable connected to the shaft. This variant often employs various guide systems, such as recirculating bearings, cam roller guides, and plain bearings. Due to their long strokes and high operating speeds, these actuators are usually enclosed. In the cam variant, linear motion is generated by an eccentrically shaped wheel that rotates, creating thrust that moves the shaft. This type of linear motion is commonly used in automotive applications.

Servo Linear Actuators

A servo controller is an integral component of a servo linear actuator, responsible for continuously monitoring the actuator's performance and comparing the desired outcomes with the actual results. If discrepancies are detected, the controller adjusts the actuator to correct them. Servo linear actuators are widely used in automated and remote operations, such as flipping switches or adjusting the position and focus of lenses. They are capable of handling a wide range of tasks, from moving large amounts of material to making precise adjustments of just a fraction of an inch. The operation and performance of a servo linear actuator are directly influenced by the data it receives.

The controller assesses the received data against the expected ideal conditions. This data is sourced from a variety of sensors and equipment. Due to their capabilities, servo linear actuators are employed in advanced automation, robotic control, beam steering, remote-controlled vehicles, marine applications, and aerospace manufacturing. As technology advances in manufacturing, servo linear actuators are becoming increasingly prevalent and essential.

Lead Screw Linear Actuators

Lead screw linear actuators convert rotary motion from a motor into linear motion. They are designed for strength and efficiency, thanks to their thread profile and rolled thread structure. To ensure smooth operation, the nut of a lead screw actuator should be made from low-friction materials or a lubricated metal.

Lead screw actuators can be used for open-loop control with various motor types, including stepper motors. Additionally, linear actuators powered by brushless DC motors are available in multiple sizes, offering excellent speed efficiency at a cost-effective price.

A threaded rod and a corresponding nut are part of the lead screw actuator's construction. The motor turns either the rod or the nut by mounting them directly, connecting them through gears or a belt, or both. The component that has to be moved is connected to the element that is not a part of the motor.

Electric Linear Actuators

Electric linear actuators are devices that convert electrical energy into mechanical energy to create linear motion. They are commonly used to operate valves powered by external sources. These actuators typically utilize single-phase or three-phase AC motors, as well as DC motors, for their actuation.

The same fundamental elements are found in the majority of electric linear actuators. In many instances, these parts consist of an electric motor, a screw, a nut, and gears. When the nut rotates along the screw in an electric actuator, it enables the conversion of electrical energy to mechanical energy. Electric rotary actuators spin from open to closure using butterfly, ball, and plug valves.

Pneumatic Linear Actuators

Like hydraulic linear actuators, pneumatic linear actuators use air pressure to move a piston instead of fluid. In a pneumatic linear actuator, the piston is contained within a cylinder and is designed to form a tight seal against the cylinder walls. As pressurized air enters the cylinder, it forces the piston to move. The amount of force exerted by a pneumatic linear actuator is determined by both the size of the piston and the pressure of the compressed air.

The strength of a pneumatic actuator increases as the pressure on the piston rises. This process is straightforward and efficient, allowing pneumatic linear actuators to operate swiftly. They are well-suited for use with electrical and microprocessor components, as they are not affected by magnetic forces. Pneumatic linear actuators can function effectively in a wide temperature range, from -40°F to 250°F, and are adaptable to environments with significant temperature fluctuations. Additionally, because they do not generate magnetic interference, they pose no explosive or incendiary risks.

Ball Screw Linear Actuators

Ball screw actuators, also known as drive screws, convert rotary motion into linear mechanical energy using a ball screw and ball nut. This mechanism provides highly accurate and precise linear motion due to the tight manufacturing tolerances and the incompressibility of the ball bearings.

These actuators are known for their durability, capable of lasting up to 5,000 kilometers under moderate loads and speeds, or 3,000 kilometers under high loads and speeds. The speed of a ball screw actuator is controlled by its pitch. The screw lead, which defines the linear travel of the ball nut per screw rotation, is calculated by multiplying the screw pitch by the number of threads.

Ball screw linear actuators with a lower screw lead generate greater linear thrust, while those with a higher screw pitch move the nut more axially and quickly for a given screw RPM. The ball bearings travel in opposing, hardened rod tracks or grooves carved into the axially moving ball nut, which is designed with a specific helix angle. This motion is facilitated by various drive mechanisms, such as belt, direct, or worm gear drives.

Ball screw linear actuators are widely used in the manufacturing of aircraft, missiles, and laboratory and medical equipment. They are commonly found in dialysis machines and blood separation device pumps. These actuators can handle substantial dynamic loads and efficiently convert a motor's torque into linear thrust.

Hydraulic Linear Actuators

Hydraulic linear actuators share several components with hydraulic motors, including a cylinder, a piston, and an incompressible fluid that applies uneven pressure on the piston. These actuators are ideal for applications requiring substantial force, as they provide significant mechanical power. They are commonly used in lifting mechanisms of machines designed to handle tons of material.

Hydraulic linear actuators are likely to be found in machinery that requires significant lifting or the transport of heavy loads. These actuators derive their power from hydraulic fluid, and their movement can be adjusted by varying the fluid level. Various types of hydraulic oils are available for this purpose. Like other linear actuators, hydraulic linear actuators offer exceptional accuracy and reliability. They are also versatile and adaptable, allowing them to function like an arm to push and pull machine components.

Chapter 4: What are the advantages and applications of 12V linear actuators?

This chapter will explore the applications and advantages of linear actuators, including 12V linear actuators.

Applications of Linear Actuators

The following applications are ideal for 12V linear actuators:

• Auto components
• Kitchenware
• The maritime and aviation sectors
• Knobs and doors
• Drawers and manually-operated gadgets
• Computer accessories
• Dampers and valves
• Pneumatic or hydraulic cylinders

Linear actuators have a variety of applications, including:

• Solar panel use has increased at the same time that efforts to develop alternative energy sources have. Traditional solar panels employ hydraulics or other similar technologies, but more recent developments have improved the efficiency of solar energy harvesting. In order to increase the quantity of direct absorption, solar panels can track the sun using electric linear actuators. These practical devices can also resist the hot and demanding working conditions while absorbing more solar energy. So, the most efficient use of solar panel users' money is to install linear actuators. Even high-pressure jets, debris, and dust are no match for linear actuators.

• The many applications for a linear actuator have increased workplace automation. It reduces production costs while streamlining manufacturing. For the best material handling, electric linear actuators have evolved into a crucial and essential instrument. Loads are moved from point A to point B via linear actuators. The capacity to halt the action mid-stroke is an additional feature of the electromechanical version. Industrial, high-speed, and micro models are a few of the other kinds of actuators used in material handling.

  

  
  
• Sorting devices, feed mechanisms, and clamps are a few examples of the obvious applications for various linear actuators. A more specific illustration is the combination of conveyor belts served by pneumatic linear actuators. Since an electric actuator doesn't hinder control skills, meanwhile, it offers more efficiency for other applications.
• Without linear valve actuators, which convert electric, pneumatic, and hydraulic energy into a push and pull motion, modern industry would not be conceivable. An appealing alternative to manual operation is provided by these reasonably priced products. With optional capabilities for integrated control, they use a variety of rising stem valves. Actuators with a diaphragm and a piston are the two main models. A strip of rubber that encircles the edges of a cylinder or chamber is present in the diaphragm version. They are best used in low-pressure environments since their diaphragm's connecting rod moves when the device is under pressure. A piston moves along the cylinder's body in piston actuators. The valve opens and closes as a result of the rod's translation of force applied to the piston. Compared to diaphragm actuators, piston actuators can move further, generate more thrust, and endure higher pressure demands.
• Robotic movement is made feasible by linear actuators. They give robotic technology the wheels, clamps, arms, and legs needed to interact with its surroundings. Take into consideration a robotic arm with a gripper at the end. A sensor tells the arm to clasp the box in position A when the operator clicks a button. The box is moved to position B by the clamp, which secures it there before releasing it to the specified work area or conveyor belt. The linear actuator is what makes the gripping mechanism function. When the clamp reaches the necessary restrictions, it communicates with the smart technology and maintains it to prevent the package from dropping or shifting during travel. A linear actuator is an improved, and more dependable, alternative to a hydraulic actuator.
• Linear actuators protect people since they assist machines that take on laborious or dangerous occupations that call for more stamina and strength than people possess. For example, linear actuators power many devices which perform countless cutting operations while assuring perfect cuts are created with every slice. Cutting devices for wood, glass, metal, and paper are frequent applications for large linear actuators. The actuator's setup will determine whether the blade cuts jigsaw patterns or straight lines. The same is true for cutting metal, which calls for a lot of mechanical strength. Machines employing linear actuators also keep people safer by limiting their exposure to dangerous, unhealthy environments.
• High levels of automation are needed in the food and beverage industry nowadays because of its industrial scale to meet demand. To achieve prompt delivery, manufacturers must streamline the processing, handling, packing, and other procedures. These actions are made possible in large part by linear actuators.The desire for automated sanitation is frequently connected to the processing of food and beverages. For dairy and beverage industries, rod-style linear actuator devices are the best choice since they keep production areas clean. Additionally, one of the underrated advantages of linear actuators in a cutting environment is cleanliness.The quantity of trash and debris that would otherwise slow down manufacturing is significantly decreased, while also helping to maintain a sterile environment by the precise cuts provided by linear actuators. Due to their adaptability and range of profile options, electric rod-style linear actuators are perfect for various food processing instruments. The likelihood of contamination is decreased while efficiency is increased using linear actuators. They can also be found in commonplace applications related to food production like conveyors and bag makers.
• Because of linear actuators, modern agricultural equipment is now more dependable than ever. In addition to withstanding adverse weather conditions and exposure to herbicides, pesticides, and fertilizers, the gadgets help farmers, workers, and other employees complete a variety of agricultural jobs. The fields are where linear actuators start. For extensive and reliable coverage, they provide operators control over the height and angle of sprayers. Actuators can help open and close hatches while reducing the complexity of equipment operation systems. Tractors have linear actuators to enhance productivity and decrease labor; an actuator controls ventilation, adjusts the rearview windows into the proper operational position, and provides precise steering wheel adjustments. Operators may boost control of their tractors without compromising performance thanks to the simple integrations. Both combine harvesters and seed drills use many of the same mechanisms. When planting seeds, drills need to be precise in order for farmers to maximize efficiency and reduce loss. Through the incorporation of linear actuators in grain tank extensions, grain tank coverings, and concave adjustments, combine harvesters gain from the seamless functionality they provide.
• Linear actuators are a component found in cutting-edge medical technology. Lifting patients is a crucial task for healthcare workers, and beds and recliners with linear actuators make this task simpler. The bed's height can be simply changed by nurses to accommodate a patient's therapy. Linear actuators are also used to change the height of monitoring equipment like ventilators and temperature control devices.
• Every component of spacecraft must be used to its fullest potential while minimizing weight. Micro linear actuators are useful for controlling robotics and doing little jobs while saving space. They are used for tracking, fastening locking systems, opening and closing valves, and moving robotic arms.
• Powered tailgates are one of the most typical applications for linear actuators in automobiles. Self-opening and -closing tailgates are becoming very common and practical. Additionally, side doors and air brakes are opened and closed by linear actuators.

Advantages of Linear Actuators

• Electric linear actuators only draw energy from electrical sources. The healthcare and medical industries favor these actuators because they can't contaminate anything and don't produce any by-products when used. High-pressure fluids travel through hoses in hydraulic systems, and these hoses must be kept in good condition. Products or the facility itself may become contaminated if one component is broken. Pneumatic actuators, meanwhile, use compressed air that can release pollutants into the surrounding area.
• As a self-contained unit positioned where motion is needed, an electric linear actuator is then connected to the system controller by a short wire. It requires less room than its competitors to operate effectively. As a result, users have additional options when integrating this type of actuator into the space. In comparison, a hydraulic actuator system with the same capabilities would typically require more space since it has more components. A reservoir with a motor needs to be linked through hoses to the main actuator. Planning carefully would be necessary to allocate room for these units, especially for those who have smaller facilities.
• When looking for actuators, noise pollution is another aspect to take into account. Hydraulic systems may produce more power, but because of their powerful motors, they are also noisier. Because of the noise they create when in use, this is the main reason why many people refer to them as "bang-bang" devices. Silent electrical motors are used in electric actuators.
• Since users won't need to deal with pumps and hoses with linear actuators, assembly will be simpler. They merely need simple wiring to be installed. This streamlined assembly procedure allows for a quicker integration into the facility's complete ecosystem. As a result of the time saved, labor costs are also decreased.
• Aside from being simple to install in a facility, an electric linear actuator is also very simple to interface with other equipment and systems. It is simpler to program the controllers that control the facility's machinery than it is to do it with a hydraulic or pneumatic system.
• Owners don't need to have a large supply of spare parts on hand because this type of actuator has few components. Since it's simpler to install, run, and maintain, one can also save labor costs. Finally, since it uses less energy than others, users won't need to invest much. Electric linear actuators can now be found in a variety of sizes thanks to technological advancements. But since they all have a motor, gears, and a leadscrew, they are all essentially the same machine. The size of the internal motor is the only thing that varies. This is one way that this device can be applied in several sectors. Some incorporate it into goods like lift desks, while others employ it in manufacturing and heavy equipment.
• It is unlikely that an accident will occur when a skilled operator is in total control, but it is always preferable to take safety measures. Electric linear actuators excel in this situation. Limit switches are typically included with these actuators. When it reaches full extension and retraction, they are intended to signal the drive to stop motion. When a machine hits its limit, limit switches help prevent the unit from halting. The motors will continue to run if it stalls until they burn out.
• A linear actuator can work for more than 200 million cycles before needing to be changed. With applications finished with outstanding accuracy and efficiency, it won't need to be fixed, adjusted, or given any kind of maintenance during those millions of cycles.
• Linear actuators make motion safe, secure, and precise, especially when users pair them with sensors or other intelligent technologies. This combination enables employees to finish previously repetitious jobs with little physical assistance.

Conclusion

In order to lift, lower, slide, or tilt machines or materials, a linear actuator converts rotational motion into push or pull linear motion. They provide clean, safe, and effective motion control that doesn't require any maintenance. 12 Volt DC voltage sources are used to power 12 Volt linear actuators. The three different varieties of linear actuators are the screw, wheel and handle, and cam. The kind of screw is determined by the upward and downward motion of the screw winding and unwinding. Benefits, design considerations and applications need to be understood when choosing 12V linear actuators.

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