Maintenance and Safety*
Maintenance, Safety and Diagnostics
The electric actuators offer great reliability and reduced maintenance compared to hydraulic or pneumatic systems.
However, like any electromechanical component, their long-term proper functioning depends on regular maintenance, adherence to safety instructions, and the ability to diagnose anomalies quickly.
Maintenance
Even though electric actuators are designed for heavy use and require little attention, certain checks must be performed periodically to ensure their reliability and lifespan:
Periodic visual inspection:
Check the condition of the fastenings, clevises, cables, connectors, and protective bellows. Look for any signs of wear, mechanical play, or deterioration of sealing.
Lubrication:
Follow the manufacturer's recommendations regarding the lubrication of screws and internal bearings. Use only compatible greases with the actuator's internal materials.
Cleaning must be done dry, without aggressive solvents or high-pressure jets to prevent moisture ingress.
Torque checks:
After commissioning, and then at regular intervals, check the tightening of fastenings (clevises, rods, terminals, cables), especially on machines subject to vibrations.
Loosening can lead to misalignment or mechanical stress on the rod.
Simple but regular preventive maintenance helps avoid breakdowns, excessive play, and performance loss.
Safety
Electric actuators generally operate at very low safety voltage (TBTS ≤ 60 V DC), but their stored energy remains significant, especially under heavy loads.
Precautions must therefore be systematically applied:
Emergency stop:
Always provide an emergency stop device or an energy cut-off switch accessible near the actuator's operating area.
Crush protection:
Integrate mechanical stops, interlocks, or restricted access areas to prevent any risk of pinching or crushing during actuator movement.
Electrical precautions:
Even at low voltage, a short circuit can cause significant heating or an electric arc.
During interventions:
Wear appropriate PPE (insulating gloves, safety glasses).
Cut the power source before any disconnection.
Ensure the complete discharge of the circuit before handling.
These simple measures ensure operator safety and equipment preservation.
Diagnostics and Control
Regular diagnostics allow for the quick detection of deviations or operational anomalies:
Electrical measurements:
Check the battery pack voltage and the current consumed under load using a DC clamp meter.
Check the voltage stability during load phases: a significant drop may indicate a weak battery or undersized wiring.
Monitor the motor temperature and integrated electronics.
Actuators with integrated controller:
Utilise the integrated diagnostic tools:
Reading of fault codes (overvoltage, overcurrent, overheating, sensor error).
Real-time monitoring of position, motor current, and internal temperature.
These data help prevent unexpected shutdowns and adapt the control strategy.
Common anomalies and possible causes:
| Observed symptom | Probable cause | Recommended action |
| Jerky or irregular stroke | Guidance defect, insufficient lubrication | Check alignment and lubrication |
| Excessive electrical consumption | Excessive friction, bent rod, or too heavy load | Check alignment and applied load |
| Motor thermal cut-off | Usage cycle too high (duty cycle exceeded) | Reduce actuation frequency or size up |
| Mechanical play or vibrations | Loose fastenings, joint wear | Tighten and replace parts if necessary |
Methodical monitoring of these parameters extends the actuator's lifespan and enhances the system's reliability.
In summary
| Domain | Best practices |
| Maintenance | Visual inspections, appropriate lubrication, regularly rechecked torques |
| Safety | Accessible emergency stop, crush protections, PPE and isolation before intervention |
| Diagnostics | Voltage/current/temperature measurement, fault code reading, usage cycle monitoring |
Conclusion
A well-maintained and monitored electric actuator offers exceptional longevity and consistent reliability, even in demanding environments.
Strict adherence to safety and preventive diagnostics rules ensures not only operator protection but also equipment longevity and control of maintenance costs.
*: The technical information presented in this article is provided for guidance only. It does not replace the official manufacturer instructions. Before any installation, handling, or use, please consult the product documentation and follow the safety instructions. Torque.works cannot be held responsible for inappropriate use or incorrect interpretation of the information provided.