How Machine Builders Use Integrated Motor Actuators To Optimize Machine Designs 

Today’s machine builders are challenged to simplify machine designs while optimizing performance to provide greater throughput and efficiency with less maintenance. Some builders are faced with specific challenges that make integrated servo motor actuators the best electrical linear motion choice. These challenges include component consolidation, space constraints, lightweight end-of-arm tooling, ingress protection for harsh environments or wash-down, and performance demands that are only possible with a rigid integrated design. The benefits of integrated servo motor linear actuators are key to constructing optimized machines because,  when compared to traditional electric actuators, they simplify design and offer lighter weights, higher rigidity, greater ingress protection and tremendous power density. 

Integrated linear servo actuators can be crucial to optimizing machine designs across a range of industries. We discussed the benefits of the integrated design in our previous blog post. Here, we offer real-world examples of machine builders choosing to use integrated linear actuators to elevate machine quality and performance. 

Motion Simulator Manufacturing 

In the aerospace and defense industry, actuators are used to achieve realistic motion simulation. One simulator manufacturer used hydraulic actuators to simulate disturbances with vibrations featuring frequencies ranging from 30 to 50 Hz. While the manufacturer achieved the aggressive motion necessary with the hydraulic system, the challenges of leaks, high maintenance and noise outweighed the system’s usefulness. 

To enhance its simulator design, the hydraulics were replaced with Tolomatic’s integrated IMA44 servo actuator, which met performance specifications and operated without requiring an external cooling system using water or oil. Because of the high-frequency motion requirements, the manufacturer couldn’t use a traditional rod style actuator. The IMA’s integrated design rigidly couples the integrated roller screw and servo motor into one component, making it ideal to handle the high-frequency motion required. 

Before delivering the actuator, it was tested in Tolomatic’s engineering lab to ensure its performance to customer specifications including temperature limits and lubrication intervals. Due to the IMA’s compact design, replacing the hydraulic cylinder of the previous system didn’t require any major mechanical design changes. 

Now, the manufacturer has a high-performance, highly dynamic actuator that meets the high-frequency motion requirements without leaks and with significantly less noise. This new integrated actuator system also features a longer life than traditional designs and requires minimal maintenance. 

Automotive Welding
An automotive manufacturer used a rod-style servo-electric actuator to perform resistance spot welding. However, its machine had trouble sensing the sheet metal with the electrode while using motor feedback to detect when the electrode tip contacts the metal. 

We provided a CSWX ServoWeld® Actuator, an integrated actuator that features Tolomatic’s cutting-edge skewed motor winding design. This compact, power-dense actuator was ideal for the end-of-arm tooling application. The skewed motor windings allow the CSWX to deliver superior sensitivity. Additionally, the windings minimize torque ripple and improve sensing reliability when the electrode makes initial contact. 

Because of the greater sensitivity, the CSWX provides improved, consistent weld quality as electrodes wear over time and superior performance compared to traditional servo motor actuators. These benefits also increased production throughput due to reduced downtime. 

Pharmaceutical Production
A pharmaceutical manufacturer designing a new filling and packaging machine required an actuator to operate a gate for vial indexing. Because of the highly sterile environment necessary in pharmaceutical manufacturing, the actuator had to meet stringent hygienic requirements. 

Tolomatic provided the manufacturer with an IMA-S actuator because of its suitability for hygienic environments. To ensure proper specification, the manufacturer downloaded 3D CAD files from the Tolomatic website and verified the fit and mounting in its assembly. The IMA-S actuator’s roller screw provides high accuracy and zero backlash. Thanks to its enclosed, hygienic design and 316 stainless steel construction, the actuator could withstand the manufacturing environment’s wash-down chemicals. 

Aseptic Plastic Injection Molding
A manufacturer of plastic injection molded parts used in pharmaceutical and medical industries needed to build equipment without hydraulics. While hydraulics offered the power density and force required, risk of hydraulic contamination prohibited their use in the aseptic manufacturing environment. 

Tolomatic’s IMA linear servo actuator offered a clean electric solution. Meeting the space requirements, this actuator also provided the necessary forces and speeds for the equipment specifications. The actuator is also flexible enough to operate with the existing PLC and motion control package. 

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