The advancements in automation systems in this digital era have been remarkable. Rapid development has increased industrial demand as companies recognize the many roles and functions these systems can perform.
The ability to quickly and effectively tackle complex and complicated processes has only added to their appeal. Automation systems are essential for businesses looking to optimize their operations and succeed in today’s competitive landscape.
One of the critical components in these automation systems is the actuator.
Actuators are essential in transitioning towards Industry 4.0 by involving various complex modern technologies.
Among the technologies involved are the Internet of Things (IoT), Big Data, Cyber Security, Artificial Intelligence (AI), Additive Manufacturing, System Integration, Cloud Computing, and others.
This article will discuss actuators’ roles and critical applications in various automation systems. To learn more about actuators, please refer to our previous article, What an Actuator Is and Its Role in Industrial Automation.
Why are Actuators Essential in Automation Systems?
Since their discovery in the 19th century, actuator innovations in function and technology have been relentless. Entering the modern era as we know it, humans have become heavily dependent on actuator devices to elevate productivity levels to new heights.
Actuators’ versatility in collaborating with technology makes them valuable tools for connecting the digital and physical worlds. Actuators have become indispensable by enabling automation systems to work tirelessly with exceptional accuracy and precision.
Here are ten key reasons why actuators are essential in automation systems:
- Precision: Actuators can move with high levels of accuracy, which is very important in applications such as robotics and CNC machines.
- Efficiency: Actuators can operate continuously without fatigue, thus helping to increase productivity.
- Flexibility: Can be used in various applications, ranging from industrial machines to household appliances.
- Safety: Automation using actuators can perform dangerous tasks, thus reducing the risk of human injury.
- Cost savings: Although the initial investment is relatively high, it is not higher than the long-term employee salary costs.
- Speed: Actuators can operate at high speeds, far exceeding the capabilities of the human hand.
- Reliability: Actuators can be relied upon to perform repetitive tasks without errors, thus ensuring consistent quality.
- Adaptability: Actuators can now be reprogrammed to adapt to changes in production needs.
- Maintenance: Actuators generally require less maintenance compared to manual systems, thus reducing unpredictable downtime.
- Environmentally friendly: Automation systems can produce more efficient resource usage, reducing waste and environmental impact.
These ten benefits are just the beginning. When combined with creative innovation, actuators can fulfill even more roles.
In conclusion, actuators are essential in modern automation systems as they significantly enhance productivity, cost efficiency, and the quality and quantity of production. They also contribute to creating a safer and more comfortable working environment.
Examples of Actuator Applications and Their Functions in Automation Systems
Here are over 35 applications of actuators and their functions in automation systems, compiled exclusively by Bawalaksana.co team. We have systematically categorized them based on the industry type.
Additionally, we have included valid references as an additional source of information for those interested in further exploring the role of actuators in industrial automation.
We plan to discuss the use of actuators in various industries and their technological advancements in more detail.
Actuator Applications in Robotics
Actuators play a crucial role in the field of robotics. They are responsible for the movement of robot joints, enabling them to perform precise and accurate motions.
According to Roboticsbiz, robotic actuators are extensively used in various industries for various tasks. These tasks include welding, painting, assembly, material handling, and more.
Using actuators in robotics is of utmost importance, as it allows robots to carry out complex operations efficiently and precisely.
Servo actuator to move robots
When it comes to moving robots, servo or electric actuators are commonly preferred due to their numerous advantages. Electric actuators offer efficiency, accuracy, speed, and ease of control. They can reach speeds of 1,000-10,000 rpm while still being manageable in terms of power.
However, it’s important to note that their complexity can sometimes make them cumbersome.
Benefits of Using Robotic Actuators
Now, let’s explore the benefits of using robotic actuators. One significant advantage is that they significantly increase productivity and reduce the need for human involvement in high-risk situations.
Robotic actuators are crucial in manufacturing companies that produce electronic devices, watches, automotive components, and F&B items. To illustrate the capabilities of robotic actuators, check out the video below showcasing their integration with Artificial Intelligence (AI) to serve a cup of coffee with a high selling value.
Robotics Actuator Applications and Their Functions in the Automotive Industry
According to a case study mentioned by Wevolver, robotic actuators are extensively used in the automotive industry. These actuators serve various crucial functions, ranging from the production line to quality control.
Production Line
In the assembly or production line, robotic actuators play vital roles in the welding, painting, and installation stages.
Welding operation: Both electric and pneumatic actuators control the robot arm and are responsible for precise and efficient welding, which is of the utmost importance in the manufacturing of cars and automotive vehicles.
Painting process: Electric actuators are responsible for moving the robot arm, ensuring an even painting process that can adapt to the unique contours of different vehicles.
Device installation: Hydraulic actuators, known for their strength, are well-suited for tasks like device installation. Hydraulic-driven robotic actuators can easily handle heavy devices such as windshields or car doors. This technology has been successfully implemented at Tesla’s electric car Gigafactory for quite some time now.
Quality Control and Inspection
Robotic actuators are designed with complexity during the quality control and inspection stage. The combination of technology between actuators and sensors enables them to exhibit extraordinary work capabilities.
Integrated inspection system: Robotic actuators are equipped with sensors and cameras to conduct detailed inspections of welding and painting results. This system is highly beneficial in ensuring consistent production quality.
Quality testing and product simulation: Robotic actuators can perform durability testing tasks on various products, including electronic devices like laptops. Acting as users in natural conditions, these actuators repeatedly perform the same movements hundreds to thousands of times to test the durability of components, such as laptop hinges and keyboards.
Material Handling and Logistics
Robotic actuators excel in material handling and logistics, even when subjected to heavy loads and long hours of repetitive work.
In the automotive industry, robotic actuators can handle the following tasks:
Part feeding and handling: Pneumatic actuators are the optimal choice for moving car door parts, dashboards, or seats between production stages.
Loading and unloading: Hydraulic actuators are well-suited for lifting heavy loads. Robotic actuators with hydraulic arms can transport significant car components, such as car bodies and engine blocks.
Customization and Flexible Manufacturing
Manufacturing companies can produce a wide range of products with different sizes and designs. This applies not only to the automotive industry but also to sectors such as electronics and F&B.
In such cases, electrically powered robotic actuators play a crucial role. Firstly, they can be easily reprogrammed to adapt to various designs and models. Secondly, they can collaborate with humans to enhance work quality and efficiency.
Adaptive production lines: One critical advantage of electric robotic actuators is their ability to manage flexible models and shapes in adaptive production lines. By reprogramming the robots, tasks can be accomplished efficiently, promptly, and on a large scale.
Collaborative robots: Depending on the industry and the tasks at hand, collaborative robots are powered by electric or pneumatic actuators and work alongside humans to complete their assignments. This collaboration ensures high accuracy, while a layered security system guarantees safety. In case of an emergency, the devices can be quickly stopped.
Actuator Applications in the Food and Beverage Industry
The role and function of actuators for the food and beverage (F&B) industry is to support clean and efficient production processes. Branham mentions several values that can be obtained when involving actuators for F&B automation systems, as follows:
Movement Control
Actuators are primarily responsible for controlling machine movement per the production cycle. This control of movement is particularly crucial in production processes that prioritize consistency.
Low Noise Level
Of course, the electric or pneumatic actuator is recommended for the F&B industry because it is not noisy. This type of actuator can also reduce air pollution and noise in the manufacturing environment, contributing to a safe and comfortable work environment.
Guaranteed Cleanliness
Applying electric actuators for F&B is not without reason. This device was deliberately designed with a few gaps to avoid bacteria or dirt accumulating around the actuator work device.
Why is this important?
Cleanliness is a critical factor in the F&B industry, where the regulations in cleanliness standards are very high.
Resistant to Corrosion or Rust
Actuators currently available in the market have been designed to have minimal gaps and can endure exposure to various corrosive substances and disinfectant solutions.
Some substances in food and drinks have corrosive properties. As a result, it is recommended to use electric actuators that are resistant to rust rather than hydraulic or pneumatic actuators.
Can Meet Washdown Protocol
In the F&B industry environment, the Washdown Protocol is mandatory for cleaning and disinfecting equipment in the industrial environment. The aim is to eliminate food residues, dirt, and other microorganisms that can cause contamination.
The Washdown Protocol is essential in actuator use because actuators often operate in environments that require high cleanliness standards. They must withstand this intensive cleaning process without experiencing damage or function decline.
System Runs Automatically
Actuators can be leveraged in the F&B sector to enhance efficiency and mitigate the possibility of human errors. They can manage the production process or equipment operations automatically without human intervention. Integrating actuators in the F&B industry can create value by improving the production process’s efficiency, safety, and hygiene.
Actuator Applications in Automotive Products
Whether we realize it or not, actuators are widely applied in the industrial sector and in various products we often use, including automotive products.
Have you ever seen a luxury car with an automatic door feature? Or have you tried a high-end vehicle with an adjustable driver’s seat horizontally and vertically?
These features are two simple examples of the application of actuators in automotive products.
In other examples, actuators are also involved in completing several tasks, such as the following:
Automatic Brake System
Complex technologies, such as ultrasonic wave transmitters and receivers installed in front of the car, support the actuator’s role in the automatic brake system.
The wave reflected by the transmitter determines the distance between the obstacle and the vehicle. Then, the microprocessor controls the vehicle speed based on the detected wave information.
If an emergency occurs, the actuator is activated and automatically presses the brake for passenger safety. (Vaibhav, et al., 2022)
Hill Start Assist (HSA)
Hill Start Assist (HSA) is an essential feature for novice car drivers. This feature can keep the car stationary and prevent it from rolling back when you stop and go on a slope.
The HSA system can work differently for each vehicle, both automatic and manual. This system can work well thanks to the actuator embedded in it. (Vaibhav, et al., 2022)
Power Window
The actuator on the power window is a gear-connected electronic motor that generates torque to lift the window glass and can operate automatically. A switch on the door panel controls the actuator. When the switch button is activated, it signals the motor to rotate.
Electric Sunroof
According to Wikipedia, a sunroof is a movable panel on a car that can be opened to allow light and fresh air into the cabin. The sunroof found on high-end vehicles is generally operated automatically using a motor drive.
When the panel is activated, the motor will move the gear or wire to the car roof’s sunroof panel.
The car cabin can receive light and air by tilting or sliding open the panel. Electric sunroofs come with sensors or timers that automatically close them when the ignition key is off or during rainfall.
Throttle Control
Electronic Throttle Control (ETC), also known as drive-by-wire, involves a complex combination of actuators and automation systems within the car combustion system.
According to Howstuffworks, the ETC system uses sensors to detect the position of the throttle pedal. The main control unit also receives input from the steering system, brakes, and wheels slipping or still having a grip on the asphalt.
This information can help the system correct driver errors and keep the car easy to control.
Here are five examples of actuator applications in automotive products. We can explore the role of actuators further through various sources.
We will review this topic in detail on a separate occasion.
Actuator Applications in Smart Home and IoT
Today, the development of Smart Homes and Internet of Things (IoT) technology is growing rapidly.
Again, actuators play their role to perform various functions automatically and precisely, according to the preferences of customers who use them at home, hotels, or offices.
Actuator technology for Smart Homes and IoT is very complex, involving computer networks and the Internet. This ensures that the advanced features embedded in it can run well and be integrated with other automation systems.
According to Intuz, the types of actuators that can be involved in this technology are electric, hydraulic, pneumatic, thermal, magnetic, and mechanical actuators. The type of actuator used depends on the expected application aspects.
Here are some examples of actuator involvement in Smart Home and IoT:
Smart Thermostats
This device uses temperature sensors to monitor the temperature inside the house. When the temperature has deviated from the predetermined number, the actuator activates the heating or cooling system as needed.
Smart Lighting
The actuator in this system enables users to control the brightness and color of the house lights remotely. This feature adds convenience and flexibility, allowing users to effortlessly customize the ambiance of their space to suit any mood or occasion.
With this advanced technology, users can easily create the perfect lighting atmosphere from the comfort of their seats.
Smart Locks
In this advanced system, an electric actuator allows for wireless locking and unlocking of doors and gates from a convenient distance. This innovative technology offers a seamless and hassle-free experience, ensuring convenience and security for users.
Smart Blinds
Of course, some luxury homes and hotels have already implemented the “Smart Curtain” feature in their rooms. The actuator is the main key for the feature to run well.
Thanks to the collaboration of actuators and sunlight sensors around the room, smart curtains can open or close automatically.
Home Security Systems
This feature is enhanced by the actuator connected to the security system sensors. Once the signals are satisfied, the actuator promptly activates an alarm or notification to provide a timely warning.
Smart Appliances
Many smart devices, such as washing machines, refrigerators, and electric ovens, run all their features using actuators.
Regular maintenance is necessary to prevent errors and ensure the proper functioning of the actuators in Smart Home and IoT systems. Neglecting maintenance could lead to malfunctioning.
Actuator Applications in Aerospace and Aviation
The application of actuators in the Aerospace and Aviation field is very complex and requires a high level of precision in its design. There are so many technologies, developments, and innovations in the automation system in this sector.
This topic is so interesting that it would be a shame if it were not thoroughly and detailedly discussed. However, due to time constraints, we will only review it briefly on this occasion.
We have summarized it from Aviation Week and Sepac as sources that have expertise on this topic.
Actuators are involved in various tasks and types in the aerospace and aviation systems.
The aerospace automation systems are interrelated. Therefore, the sorting of actuator types is crucial, as this is directly related to life and death.
Actuators complete flight tasks and support functions such as changing the tilt of the aircraft’s fins, control levers, fuel injection, ignition, throttle, and so on.
Here are some roles and functions of actuators in the Aerospace and Aviation system:
Use in non-critical systems
The progress of actuator technology during the New Generation Aircraft Drive era has resulted in the creation of electro-mechanical actuators that replace servo control actuators in old aircraft. These actuators are implemented in non-critical controls like spoilers. Curtiss-Wright supplies this device for the central deck cargo door system of the latest Airbus A350F1.
Aerospace Actuation Systems
In the past, mechanical systems formed the backbone of aerospace actuators. Cables, gears, and shafts worked in harmony to control various components. However, as technology advanced, these traditional mechanisms gave way to more efficient alternatives.
Hydraulic Systems: Hydraulic actuators became popular due to their ability to transmit force through pressurized fluid. Levers and control panels allowed precise adjustments, making them suitable for aircraft control surfaces and landing gear.
Pneumatic Systems: Pneumatic actuators, powered by compressed air, are used in braking systems, landing gear, and cargo doors. Their simplicity and reliability make them a staple in aviation.
Electrical Technology: The advent of electrical systems revolutionized aerospace engineering. Pre-programmed electronic devices replaced manual levers and steering panels. These systems offered greater flexibility, faster response times, and reduced maintenance.
Computerized Control: Today, computerized control systems dominate. Fly-by-wire technology, where electronic signals replace direct mechanical linkages, ensures precise control. Pilots input commands via electronic interfaces, and the system translates them into appropriate actions.
Aircraft Systems
In this sector, actuators regulate aircraft and engine speed, adjust the angle of descent, and open the landing gear door.
Unmanned Aerial Vehicles (UAVs)
Unmanned Aerial Vehicles (UAV) and Micro Aerial Vehicles (MAV) involve various actuators to perform various flight functions.
Flight Control Surfaces
In this sector, the role of actuators is very critical, as it is directly related to the safety of all aircraft crew and the surrounding environment. Actuators have the vital task of regulating the position and angle of wings, rudders, elevators, and aileron functions to direct and stabilize the aircraft.
In addition to what we have mentioned above, actuators play many more roles in the rapidly growing aerospace industry.
Now, let’s roll to another industry sector: healthcare and medical equipment.
Actuator Applications in Healthcare and Medical Equipment
An interesting fact worth knowing is that actuators are essential to the healthcare sector’s transition towards Industry 4.0. As quoted from Venture MFG, actuators are used in the Medical and Healthcare Industry because they excel in accuracy and control.
Here are some real case applications of actuators for healthcare and medical devices:
Hospital Beds
Have you ever realized that you use actuators to adjust the height and position of beds in Hospitals?
Yes, that’s right.
However, is the actuator used for this task manual or mechanical?
Many types of beds also use electric actuators as their driving source.
CT Scan & MRI
Medical scanning instruments such as CT Scans and Magnetic Resonance Imaging (MRI) heavily
rely on actuators in their operations. Their function is to facilitate patient movement or image capture angles.
Laser Positioning Equipment
Another essential function of actuators in the health and medical equipment industry is in laser surgery devices. Here, the actuator controls the laser beam precisely and accurately.
The laser equipment needs to be positioned correctly for excellent and safe results. If laser beams’ position, accuracy, and stability are not well controlled, they can certainly harm humans.
This is where linear actuators can play a crucial role in helping to control the accuracy and position of laser beams on medical equipment precisely and accurately.
Hospital Lifts
At certain times, hospitals can become very crowded and busy. Meanwhile, patients need to be moved from one room to another immediately.
The presence of patient lifts in Hospitals can help medical personnel complete this task professionally and without excessive stress.
Again, actuators are involved in this aspect to speed up moving patients quickly and safely.
Dental Chair
The dental chair is an important piece of equipment in dental clinics. It has many features that are not found in other chairs in healthcare places.
The dental chair is unquestionable in terms of its ergonomic level and flexibility. Actuators in several parts, such as the headrest, legs, and support shaft, fully support this.
As a result, the dental chair can be easily and neatly adjusted according to dentists’ and medical nurses’ preferences.
Actuator Applications in the Energy and Environmental Fields
Last, actuators’ application in the energy and environmental fields contributes to efficiency, sustainability, and technological advancement.
In this sector, we refer to the real-case implementation of actuators in the energy and environmental fields. We refer to Valve Magazine and a journal titled “Functionality Analysis of Electric Actuators in Renewable Energy Systems—A Review” in MDPI.
The examples of its application are as follows:
Valve operation
This function is often used in the oil and gas industry, which operates many valves with high precision and accuracy. The actuator controls the flow through these valves so that the production process of oil, gas, or petrochemicals can run well and safely from dangerous incidents.
It should be noted that the actuators involved in this work are in demand to be highly durable and withstand extreme conditions, such as very high or very low temperatures.
Even they are required to survive in dry environments, high rainfall, arid deserts, and deep seawater.
Fail-safe systems
In fail-safe systems, actuators are often involved to prevent unexpected events that can damage equipment, materials, or personnel.
Renewable Energy Systems
Actuators can be relied upon for the oil and gas industry, health, automotive, and smart home sectors. They can also support the operation of devices that contribute to the cycle of renewable energy sources.
In this case, actuators can move solar power panels, wind, bioenergy, and geothermal energy.
For example, in implementing large-scale solar panels, actuators are integrated with light sensors to adjust the device’s position to achieve even sunlight exposure.
Actuators control the fins or fan blades that are hit by the wind on wind turbines or windmills so that the windmill can rotate continuously according to the direction of the wind.
The Future of Actuators in Automation Systems
Actuators are pivotal components in automation systems across various industrial sectors. The examples mentioned only scratch the surface of their vast capabilities, leaving much to explore.
In essence, actuators perform multiple critical functions, enhancing safety, efficiency, durability, and productivity in everyday applications and industrial processes.
Looking to the future, it’s difficult to fully grasp how extensively actuators will be integrated into automation systems, not only in industrial operations but also in day-to-day support technologies.
Technological innovations like the Internet of Things (IoT), Big Data Analytics, Blockchain, Cloud Computing, and Artificial Intelligence (AI) are accelerating advancements in this field.
As forward-thinking individuals, it’s essential that we embrace these developments and explore the new opportunities they bring in this digital era of automation. By doing so, we can boost productivity and maintain a competitive edge.
Staying informed about emerging trends and engaging in relevant digital communities is crucial in navigating this rapidly evolving landscape.
The industrial and manufacturing sectors demonstrate a strong inclination towards the adoption of actuator technology to optimize efficiency and productivity. Pneumatic and electric actuators are extensively employed in various industries to drive economies of scale and bolster profitability.
PT Bawalaksana Central Industrial is the authorized distributor for Metal Work Pneumatic, a trailblazer in pneumatic automation systems with over 50 years of industry experience.
We are also the appointed distributor for Mebra Plastik Italia, which specializes in pneumatic hoses and industrial tubing.
Backed by a proficient team and premium products, we offer comprehensive support to facilitate your industry’s seamless transition into smart manufacturing during the Industry 4.0 era.
Selecting the appropriate automation system necessitates specialized knowledge and expertise, as even minor errors in part or component selection can lead to substantial financial repercussions. We strongly advise seeking guidance from the adept and seasoned Bawalaksana team to preempt such occurrences in your business.
We are eager to help you devise and execute the optimal automation system for your industry. For precise and customized solutions, we invite you to schedule a complimentary consultation with our expert team today.
Romanta Pinrih Linuwih
Pneumatic Automation Systems Expert
This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation System, to ensure accuracy and high quality.
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Redekar, A., Deb, D., & Ozana, S. (2022). Functionality Analysis of Electric Actuators in Renewable Energy Systems—A Review. Sensors, 22, 4273. https://doi.org/10.3390/s22114273/
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