In which application would a hydraulic rotary actuator be most commonly used?

What are Rotary Actuators? 

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In its simplest form, a rotary actuator is a device that uses hydraulic fluid to generate rotary motion without a linkage. These devices come in handy when applications call for any form of transporting, securing, or positioning of parts. 

How Do Rotary Actuators Work?

In terms of design, rotary actuators are most often configured as vane type, rack-and-pinon type, or helical spline actuators. 

Our rotary actuators are the helical spline design. This means, a piston and a helix, or sliding spline, work together to convert the linear motion of the piston into rotational motion. Helical spline actuators function when the piston is axially displaced using hydraulic pressure causing simultaneous rotation of the piston. 

Hydraulic rotary actuators are typically designed to operate at low speeds and produce high torque through arc lengths ranging between 90°, 180°, 270°, and 360°. They also can be configured up to 720° or more by making the spline gears longer while maintaining the same diameter.

Common Applications of Rotary Actuators

From manipulating the angle of a boom in construction applications to opening or closing flaps in the aircraft and aerospace industries, rotary actuators are dependable and durable devices used for a wide range of uses.  

One common application is using a rotary actuator for tipping devices. A helical rotary actuator, for example, would be a suitable option for bin tippers in waste management applications due to its high torque in a compact package. 

Additionally, rotary actuators can function as simple tool changers. One example of this is using a rotary-linear actuator for a pallet changer that weighs 1,000 kg. This device is a combination of a rotary actuator and a dual-action linear cylinder, allowing for full flexibility in a minimal amount of space. Since the rotary actuator and the linear cylinder are hydraulically driven separately, any movement sequences can be selected: for example, rotating to the left and right, extending linearly, and retracting.

A rotary actuator could also be used for gate valve control too. While a hydraulic rotary actuator may be more expensive than pneumatic actuators, these devices have a higher level of precision, require less space, and can achieve high torque outputs.  

Graphic of Common Rotary Actuator Applications

Other uses for rotary actuators include linear actuation, bending machines, work piece positioning, rotational devices, and transport applications.

Hydraulic Rotary Actuator Benefits

Hydraulic rotary actuators are known for their strong ability to produce power quickly. In comparison to pneumatic and electric rotary actuators, hydraulic actuators are the most powerful and have the capacity to achieve a torque output up to 2,200,000 Ibs-in (250,000 Nm) as a helical spine actuator and even higher as a rack and pinion actuator.

Rotary actuators also require a minimal amount of space while delivering high performance and flexibility due to its compact design. They also have high-efficient end cushioning and wear-resistant sliding surfaces.  

How To Choose the Type of Hydraulic Rotary Actuator

Different actuator models typically depend on the system&#;s operating pressure. This is why it&#;s important to know the pressure required, along with other key factors including load capacity, rotation angle, rotation speed, and more. 

Dynamic Movement

First, determine if the rotary actuator will be used in highly dynamic applications, such as torque/torsion testing of axial loads and other drive line components. If so, end-cushioning is important to have, along with a servo valve that can be mounted to the actuator to offer more control to the device. 

End-cushioning

End-cushioning is an important factor to consider for highly dynamic applications, such as when the actuator needs to function as an end stop in a load. End-cushioning acts as a hydraulic break to slow down the movement of the actuator so that it doesn&#;t slam into the end position causing damage to the device or the workpiece. The end-cushioning effect can be finely tuned using orifices and set screws. 

Mounting 

Actuators can be mounted in different ways, along with shaft style. The actuator might have a flange mount, foot mount, or threaded holes in the actuator body. The shaft could be male or female with splines (keyed or a different shape). 

Temperature

Typical hydraulic systems operate in an oil temperature range from -4°F to +240°F (-20°C to +60°C) in the same range. Actuators operate in the same range. If actuators need to operate above or below the standard temperature range, then special steels or special seal material may need to be used.

Mediums

The same applies to different mediums. Different mediums could require non-standard seals and different actuator materials. 

Side Loads

If the application and actuator have side loads, the side loads need be absorbed separately from the actuator, or the actuator needs to be designed to accommodate the side loads. This is often done through the use of bearings. 

Eckart usually includes 4-point contact bearings as standard. 

General Applications

Finally, it&#;s important to understand the general application. For example, will the device be going offshore? This might require special paint and special seals to protect the actuator from harsh seawater environments. As mentioned above, it&#;s important to know if the actuator will be used in testing applications, as special attention would be needed to make low-friction seals and a servo valve adapter plate. 

Rotary actuators are mechanical devices that take energy in the form of either electricity, or high pressure hydraulic fluid or air, to create an angular rotary motion to produce torque. The Rotary motion can be in either direction, but its main purpose is to create useful Torque that can be used to turn something. They can be found in a wide range of applications, from industrial automation to robotics and home automation. In this blog post, we will explore the different types of rotary actuators and their uses.

What is a rotary actuator?

A rotary actuator is a device that converts energy (typically electrical or pneumatic) into torque via rotary motion. They are commonly used in industrial and manufacturing settings to control valves, doors, and other mechanical systems that require precise, linear movement. Some examples of rotary actuators include DC electric gear motors with gear reducers, pneumatic cylinders, and hydraulic motors.

The most common type of rotary actuator is the electric motor-driven actuator, which uses an electric motor to rotate a shaft that is connected to a mechanical linkage. This linkage converts the rotary motion of the shaft into linear motion, which can be used to move a load or perform a specific task. Electric motor-driven actuators are available in a wide range of sizes and styles, from small, compact units to large, heavy-duty models.

Another type of rotary actuator is the pneumatic actuator, which uses compressed air to rotate a shaft. Pneumatic actuators are commonly used in industrial applications, such as controlling valves in manufacturing plants or opening and closing flaps on aircraft. They are also used in robotics, as they are able to provide a high level of force with a low level of energy consumption.

Hydraulic actuators are similar to pneumatic actuators, but instead of using compressed air, they use a fluid, typically oil, to generate motion. They are typically found in heavy industrial equipment and machinery where high force and power are required. They are particularly useful in applications where high force is needed and electricity is not readily available.

One of the most popular types of rotary actuator is the micro linear actuator. They are small and compact, typically used in robotics and home automation. They are used to open and close flaps, move objects, or perform other simple tasks. They are available in a wide range of sizes, and can be powered by electricity, batteries or even solar power. They are available in different stroke lengths, and can be controlled by switches, power supplies, remote controls, and even smartphones.

How does a Hydraulic or Pneumatic Rotary Actuator work

A rotary actuator is a type of hydraulic or pneumatic device that converts linear force and motion into rotary motion. It typically consists of a cylinder that contains a piston connected to a rotating shaft. When fluid (such as oil or air) is applied to the piston, it moves in the cylinder and rotates the shaft. The amount and direction of rotation can be controlled by adjusting the pressure and flow of the fluid. This makes rotary actuators useful for a wide range of applications, such as controlling valves, positioning machinery, and driving actuators in various industrial and manufacturing processes.

How does an electric Rotary Actuator work

An electric rotary actuator is a type of actuator that uses an electric motor to generate rotary motion. It consists of a motor (such as a DC or AC motor), a gear train (to reduce the speed and increase the torque of the motor), and a rotating shaft (to transmit the rotary motion to the load) otherwise known as a DC Gear Motor. 

The motor is controlled by an electronic circuit that regulates the voltage and current applied to the motor. The circuit can be programmed to perform specific rotary movements or to respond to inputs from sensors or control systems.

Electric rotary actuators are commonly used in various applications, such as controlling valves, positioning machinery, and driving actuators in various industrial and manufacturing processes. They offer precise control, quick response time, and the ability to operate in harsh environments, making them a popular choice for automation and control systems.

Various Types of Rotary Actuators and their Applications

A. 

Manual Rotary Actuators

Manual rotary actuators are commonly used to control valves, such as ball valves and quarter-turn butterflies. These actuators use a worm drive to increase the torque that can be applied by a manual operator. This allows the valve to be closed and held securely in place. These actuators typically have large hand wheels to make it easier for operators to apply the necessary force. They are also sometimes referred to as manual overrides or gear operators in the valve industry.

What is a typical application for a Manual Rotary Actuator

A manual rotary actuator is a type of actuator that is manually operated, typically by means of a handle or lever. They are commonly used in applications where manual control is sufficient and cost-effective, or where electrical power is not available.

Some typical applications of manual rotary actuators include:

1. Valve control: Manual rotary actuators can be used to control fluid flow through valves in piping systems, HVAC systems, and other applications.
2. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.
3. Dampers and louvers: Manual rotary actuators can be used to control the flow of air or fluid in ducts, air handling units, and other systems.
4. Testing equipment: Manual rotary actuators can be used in testing equipment, such as tensile testers, hardness testers, and other machines.
5. Emergency control: Manual rotary actuators can be used as a backup or emergency control option in safety critical systems, such as fire suppression systems, oil and gas pipelines, and other applications.

Figure 1: Manual Rotary Actuator

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B. 

Electric Rotary Actuators

Electric rotary actuators (DC Gear motors) use electric power from a motor to rotate components. They are used to control and move components to specific positions. The rotating element in these actuators can be a circular shaft or a table. The circular shafts often have keyways, while tables have bolt patterns for mounting additional components. The specifications of an electric rotary actuator include the voltage supply, maximum torque, repeatability, load capacity, operating temperature, rotation angle and linear stroke. Electric rotary actuators are used in various industries such as high-power switching gears, electric power, automotive, and packaging applications.

What is a typical application for an electric Rotary Actuator

An electric rotary actuator is a type of actuator that uses an electric motor to generate rotary motion, and it offers precise control, quick response time, and the ability to operate in harsh environments. As such, it is commonly used in a wide range of industrial and manufacturing applications.

Some typical applications of electric rotary actuators include:

1. Automation and control systems: Electric rotary actuators can be used in various automation and control systems, such as assembly lines, material handling systems, and packaging machinery.
2. Automotive use: They are widely used in vehicles, for example to operate the windscreen wipers. these motors that make the wipers go back and forth utilize DC Gear motors. 
3. Valve control: Electric rotary actuators can be used to control fluid flow through valves in piping systems, HVAC systems, and other applications.
4. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.
5. Dampers and louvers: Electric rotary actuators can be used to control the flow of air or fluid in ducts, air handling units, and other systems.
6. Robotics: Electric rotary actuators are widely used in robotics, particularly for end-of-arm tooling and material handling.
7. Aerospace and defense: Electric rotary actuators are used in various aerospace and defense applications, such as control surfaces and landing gear systems.

Figure 2: Electric DG Gear Motor Actuator

C. 

Fluid-Powered Rotary Actuators

Fluid-powered rotary actuators, also known as pneumatic or hydraulic rotary actuators, use fluid power to rotate components. These actuators use either cylinders or rotors to convert the fluid power into rotational motion. They are typically powered by either hydraulic oil or compressed air. They are used to rotate components between 90 to 360 degrees depending on the specific requirements of the component or valve.

What is a typical application for a Fluid-Powered Rotary Actuator

A fluid-powered rotary actuator is a type of actuator that uses hydraulic or pneumatic pressure to generate rotary motion. It is commonly used in a wide range of industrial and manufacturing applications where linear force and motion need to be converted into rotary motion.

Some typical applications of fluid-powered rotary actuators include:

1. Industrial machinery: Fluid-powered rotary actuators can be used in various types of industrial machinery, such as cranes, hoists, and material handling equipment.
2. Process control: They are widely used in process control applications, such as controlling the flow of fluids in chemical, oil and gas, and pharmaceutical processing plants.
3. Valve control: Fluid-powered rotary actuators can be used to control fluid flow through valves in piping systems, HVAC systems, and other applications.
4. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.
5. Dampers and louvers: Fluid-powered rotary actuators can be used to control the flow of air or fluid in ducts, air handling units, and other systems.
6. Robotics: Fluid-powered rotary actuators are used in various industrial and manufacturing robots, particularly for heavy-duty tasks and applications that require high force.
7. Aerospace and defense: Fluid-powered rotary actuators are used in various aerospace and defense applications, such as control surfaces and landing gear systems.

Figure 3: Fluid Powered Rotary

D. 

Rack & Pinion Rotary Actuators

Rack and pinion actuators are mechanical devices that are used to control dampers or valves in industrial applications. They use a system of gears to convert linear motion into rotational motion. The rack is a linear gear bar that has teeth, and it meshes with a round gear called the pinion. When a linear force is applied to the rack, it causes the pinion to rotate. This motion is then used to control the position of the valve or damper.

What is a typical application for a Rack & Pinion Rotary Actuator

A rack and pinion rotary actuator is a type of actuator that converts linear motion into rotary motion by means of a gear set. The actuator consists of a rack, which is a linear gear, and a pinion, which is a small circular gear that rotates in mesh with the rack.

Some typical applications of rack and pinion rotary actuators include:

1. Industrial machinery: Rack and pinion rotary actuators can be used in various types of industrial machinery, such as cranes, hoists, and material handling equipment.
2. Automation and control systems: They are widely used in automation and control systems, such as assembly lines, material handling systems, and packaging machinery.
3. Robotics: Rack and pinion rotary actuators are used in various industrial and manufacturing robots, particularly for applications that require precision and high accuracy.
4. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.
5. Aerospace and defense: Rack and pinion rotary actuators are used in various aerospace and defense applications, such as control surfaces and landing gear systems.
6. Medical devices: They can be used in various medical devices, such as hospital beds, operating tables, and patient positioning systems.
7. Testing equipment: Rack and pinion rotary actuators can be used in testing equipment, such as tensile testers, hardness testers, and other machines.

Figure 4: Rack and Pinion Type Actuator

E. 

Scotch Yoke Rotary Actuators

This specific type of actuator has a yoke attached at one end with a groove for a block that merely slides back and forth and a sliding bar attached to a valve at the other end. The sliding block is simply attached to a piston, so as the piston moves, the block drives, which rotates the yoke and ultimately causes the bar to move to open the valve.

This actuator is used in the mining industry to separate nozzles inside rock washing lines, in the oil and gas industry to separate flow within pipelines, and in the water and wastewater industry to separate feed lines, tanks, and filters.

What is a typical application for a Scotch Yoke Rotary Actuator

A Scotch yoke rotary actuator is a type of actuator that converts linear motion into rotary motion. It consists of a reciprocating linear motion of a slider and a rotating motion of a crank arm. The actuator is typically used in applications where high torque and low speed are required.

Some typical applications of Scotch yoke rotary actuators include:

1. Industrial machinery: Scotch yoke rotary actuators can be used in various types of industrial machinery, such as pumps, compressors, and material handling equipment.
2. Automation and control systems: They are widely used in automation and control systems, such as assembly lines, material handling systems, and packaging machinery.
3. Robotics: Scotch yoke rotary actuators are used in various industrial and manufacturing robots, particularly for heavy-duty tasks and applications that require high force.
4. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.
5. Aerospace and defense: Scotch yoke rotary actuators are used in various aerospace and defense applications, such as control surfaces and landing gear systems.
6. Medical devices: They can be used in various medical devices, such as hospital beds, operating tables, and patient positioning systems.
7. Testing equipment: Scotch yoke rotary actuators can be used in testing equipment, such as tensile testers, hardness testers, and other machines.

Figure 5: Scotch-Yoke Rotary Actuator

F. 

Helical Actuators

A set of helical gears and a cylinder are used by the helical rotary actuator to transform a linear input into an oscillating, rotating output. Three revolving pins and three helical grooves are cut into the outermost tube of the actuator's cylinder. To prevent it from passing too far into grooves inside the central cylinder, this tube likewise has three keys on its minor half. Air pressure presses down on the outermost cylinder once the cylinder is moving, opening the valve and compressing a spring on the exterior of the outermost tube. The spring forces the valve to close once the air pressure is removed.

What is a typical application for a helical Rotary Actuator

A helical rotary actuator is a type of actuator that converts linear motion into rotary motion by means of a helical cam. The actuator typically consists of a linear motion input and a helical cam that rotates as the linear motion is applied, resulting in rotary motion output.

Some typical applications of helical rotary actuators include:

1. Industrial machinery: Helical rotary actuators can be used in various types of industrial machinery, such as pumps, air compressors.
2. Automation and control systems: They are widely used in automation and control systems, such as assembly lines, material handling systems, and packaging machinery.
3. Robotics: Helical rotary actuators are used in various industrial and manufacturing robots, particularly for applications that require precision and high accuracy.
4. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.
5. Aerospace and defense: Helical rotary actuators are used in various aerospace and defense applications, such as control surfaces and landing gear systems.

Figure 6: Helical Actuator

G. 

Electrohydraulic Actuators

While electro-hydraulic actuators employ pressurized hydraulic fluid to operate a valve, electricity is their only available energy source. The supplied electrical energy is used to power an electric motor that operates a hydraulic pump, which then feeds pressurized fluid to operate a hydraulic actuator that operates the valve. Because the entire system is self-contained, there is no need for a separate hydraulic power unit, which simplifies system construction and increases dependability and safety.

Depending on the needs of the application, this actuator uses rotary or linear valves. When high operating speeds or fail-safe systems are required to operate valves that need significant thrusts or torques, these actuators are ideal.

Figure 7: Electrohydraulic Actuators

H. 

Vane Rotary Actuators

Simply put, the pneumatic and hydraulic vane type actuators use a minimum of one or two vanes that are attached to a hub in a circular chamber or wedge-shaped area, anywhere the vane can turn from 90 to 280 degrees. These actuators use oil or air pressure to create motion at the output stem, which causes the hub to simply rotate between stops. While a single-vane actuator can rotate much more freely than a double-vane actuator within a fully circular chamber, the double-vane actuator has two opposed vanes that produce higher torque. When this actuator is pressurized, the vane begins to rotate and keeps going until the stroke is completed. When air pressure is applied to one end of the vane, the shaft may begin to rotate anticlockwise. Due to their large solid size, these actuators are typically employed to transfer, clamp, or position light weights in medium-speed applications.

What is a typical application for a vane Rotary Actuator

A vane rotary actuator is a type of actuator that converts linear motion into rotary motion by means of a sliding vane. The actuator typically consists of a cylindrical housing that contains a rotating cam and a sliding vane, which is attached to the cam. As the cam rotates, the vane moves in and out of the housing, generating rotary motion.

Some typical applications of vane rotary actuators include:

1. Industrial machinery: Vane rotary actuators can be used in various types of industrial machinery, such as pumps, compressors, and material handling equipment.
2. Automation and control systems: They are widely used in automation and control systems, such as assembly lines, material handling systems, and packaging machinery.
3. Robotics: Vane rotary actuators are used in various industrial and manufacturing robots, particularly for applications that require high force and low speed.
4. Machine positioning: They can be used to adjust the position of machinery, such as conveyor belts, positioners, and material handling equipment.

Figure 8: Vane Type

What are some future technologies regarding rotary actuators

The field of rotary actuators is constantly evolving, and there are several future technologies that are likely to impact the design, performance, and application of rotary actuators. Some of these include:

1. Smart actuators: The development of smart actuators, which incorporate sensors and control systems, is likely to lead to more intelligent and self-diagnosing systems. This will enable more precise control, real-time monitoring, and improved reliability.
2. Mechatronic systems: The integration of rotary actuators with other mechatronic systems, such as motors, drives, and control systems, is likely to lead to more advanced and integrated systems. This will result in improved efficiency, higher accuracy, and more flexible control.
3. Advanced materials: The use of advanced materials, such as carbon fiber composites, lightweight metals, and ceramics, is likely to lead to lighter and more durable rotary actuators. This will result in improved performance and longer lifespan.
4. Artificial intelligence: The application of artificial intelligence (AI) and machine learning algorithms to rotary actuators is likely to lead to more intelligent and adaptive systems. This will enable real-time optimization, improved efficiency, and better performance in demanding environments.
5. Electromechanical actuators: The development of electromechanical actuators, which combine the advantages of electrical and mechanical actuators, is likely to result in more efficient, compact, and flexible systems. This will enable a wider range of applications and improve overall performance.
6. Wireless connectivity: The integration of wireless connectivity, such as Bluetooth or Wi-Fi, is likely to allow for remote control and monitoring of rotary actuators. This will result in improved convenience and reduced maintenance requirements.

FIRGELLI Rotary Actuators

FIRGELLI offer a wide range of  DC Gear motor rotary actuators for different applications, from micro linear actuators to heavy-duty high torque industrial actuators. They can be used in robotics, home automation, opening and closing flaps, and other industrial applications. Our actuators are available in a wide range of sizes and styles, and can be powered by electricity, batteries, or solar power. They can be controlled by switches, power supplies, remote controls, and even smartphones. If you're looking for a rotary actuator for your next project, be sure to check out the FIRGELLI product page at https://www.firgelliauto.com/collections/rotary-actuators.

At FIRGELLI, we offer a wide range of rotary actuators that can be used in a variety of applications, including robotics, home automation, and industrial automation. Our rotary actuators are high-quality, durable, and easy to use, making them the perfect choice for any application.

Controls of Rotary Actuators

In terms of controlling rotary actuators, there are several options available depending on the specific application and the type of actuator being used. The most common method is to use a switch or power supply to control the electric motor. For pneumatic and hydraulic actuators, a valve or other control device is used to regulate the flow of air or fluid. Remote controls can also be used to control rotary actuators, allowing for remote operation of the device.

When it comes to controlling rotary actuators, there are several options available. The most common methods include:

1. Switches: These are manual controls that allow you to turn the actuator on and off. They are often used in simple applications, such as opening and closing a window or door.

Figure 11: Rocker Switch for Linear Actuators

1. Power supplies: These provide the actuator with the electrical energy it needs to function. They are often used in applications that require a lot of power, such as industrial machines.

Figure 12: DC Power Supply 12v

1. Remote controls: These allow you to control the actuator from a distance, using a wireless signal. They are often used in home automation systems, such as controlling window blinds or curtains.

Figure 13: 2 Channel Remote Control System

1. Relays, timers, and controllers: These devices allow you to control the actuator in more advanced ways, such as setting a specific position or timing the movement. They are often used in precision motion control applications, such as in medical equipment and laboratory instruments.

Figure 14: 12-volt-double-pull-double-throw-relay.

Conclusion

At FIRGELLI, we offer a wide range of DC Gear motor actuators, switches, remotes, relays, timers, and controllers to help you control your actuator. Our selection includes manual switches, wireless remote controls, and advanced controllers for precise motion control.

In addition to our DC Gear motor actuators, we also offer a wide range of controlling devices, including switches, power supplies, remote controls, and more. These devices can be used to control and operate our rotary actuators, making them even more versatile and easy to use.

Overall, Gear motor rotary actuators are an essential component in a wide range of applications, including robotics, home automation, and industrial automation. With the different types of RA's that FIRGELLI offers, it is easy to find the perfect actuator for your application, and our controlling devices provide an easy way to operate them. With our high-quality, durable, and easy-to-use products, you can be sure that your application will run smoothly and efficiently.

To learn more about our rotary actuators and controlling devices, please visit our website at https://www.firgelliauto.com/collections/rotary-actuators and https://www.firgelliauto.com/collections/actuator-switches-remotes-relays-timers-controllers-power-supplies.

Here you can find detailed information about each product, including specifications, features, and applications. If you have any questions or need help choosing the right product for your application, please don't hesitate to contact us.

 

 

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