Actuator Failure: Causes and Solutions

Actuator Failure: Causes and Solutions! Actuated valves are devices that take an energy source to move or control a mechanism. These devices, which play a vital role in industrial automation systems, ensure the smooth operation of processes. However, over time, actuator failures can occur due to various factors.

In this article, we will examine the causes of actuator failures and provide detailed solution suggestions. At the same time, we will explain how these failures can be prevented, offering sustainable solutions for businesses.

What is an Actuator Failure?

An actuator failure occurs when an actuator is unable to perform as expected. These failures can result from electrical, mechanical, or software-related issues. Especially in production lines, if actuators fail to perform their tasks, it can halt the entire process and lead to significant costs.

The working principle of actuators is to move, change position, or open/close the controlled element according to the given command. Therefore, even the smallest malfunction in an actuator can affect the entire system.

Symptoms of Actuator Failure:

• The system not moving as intended or slowing down
• Valves not fully opening or closing
• Loss of power in pumps or robotic arms
• Motor overheating
• Noisy operation
• Incorrect signal detection
• Sudden stoppage or random restarting
• Providing feedback with incorrect position information

These symptoms can indicate failures occurring within the system. Ignoring them may lead to more serious problems. Therefore, early intervention is critically important.

Causes and Solutions of Actuator Failure

1.Actuator Motor Not Running:

Possible Causes:

• There may be a break in the motor control circuit.
• The motor insulation may be damaged.
• A short circuit may have occurred in the motor windings.

Preventive Measures:

• Check the wiring diagram and, if necessary, reconfigure it.
• Perform motor insulation tests to check the insulation level.
• Replace the faulty motor with a suitable spare or perform maintenance.

2. No Power Indicated on the Actuator:

Possible Causes:

• There may be no supply voltage on the line.
• A fuse may have blown, or the power may have been cut off.
• The control board may be faulty.

Preventive Measures:

• Check the supply voltage and the fuse.
• Inspect the cable connections to the power source.
• If necessary, test or replace the control board.

3. Actuator Only Opens or Closes:

Possible Causes:

• The gears may have lubrication issues.
• The valve may be experiencing a sticking issue.
• The limit switch settings may be misaligned.

Preventive Measures:

• Lubricate the gears as recommended.
• Perform regular valve maintenance and use filters in the system.
• Review the limit switch settings and recalibrate them.

4. Manual Open/Close Handle Not Working:

Possible Causes:

• The gears may be slipping.
• The manual handle shaft or valve shaft may be broken.
• The internal mechanism may be jammed.

Preventive Measures:

• Check the gears and replace them if necessary.
• Disassemble and inspect the manual handle mechanism.
• Replace the necessary parts and reassemble them.

Ways to Prevent Actuator Failure

Taking preventive measures in actuator systems before a failure occurs saves both time and costs. Below are these measures outlined as key points:

1. Regular Maintenance and Inspection

Implementing maintenance schedules periodically allows potential failures to be detected in advance. In particular, the operation of valve mechanisms, motor performance, and the condition of electrical components should be reviewed.

2. Proper Lubrication

Lubrication is crucial in actuator gear systems. Using oil with the appropriate viscosity reduces wear on the gears and enhances performance.

3. Protection Against Dirt and Dust

Actuators operating in dusty environments can accumulate debris inside their components, which over time leads to reduced performance. Protective covers or filtration systems should be used.

4. Avoiding Overloading

Actuators have maximum load limits they can handle. Exceeding these limits can cause the motor to burn out or mechanical parts to break. Proper sizing should be done, and the process load must be considered when selecting an actuator.

5.Using High-Quality Products

Low-quality or uncertified products can fail quickly. Choosing tested products from reputable brands is important for longevity and efficiency.

For Efficiency, Proper Actuator Selection and Maintenance Are Essential!

Actuators are one of the key components for efficiency in industry. Therefore, regular inspection, choosing high-quality products, and proper installation are essential to minimize failures. Early detection of failures is crucial for production continuity and safety.

At Unox, you can explore our range of actuated valves suited to your needs and access our long-lasting and reliable solutions.