Industrial Automation Trends Drive Ball Screw Actuator Innovation

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Traditionally, asset monitoring, the practice of collecting and analyzing data about the health of equipment, was time consuming and labor intensive when managed manually or complicated to set up when using disparate Internet of Things-enabled sensors and devices. However, a modern, simplified solution – the Asset Monitoring Gateway with SNAP ID from Banner Engineering – allows users to begin monitoring equipment in minutes so they can quickly start making informed decisions that help increase productivity, save energy and prevent unexpected maintenance issues. This blog will outline the simplified process of getting started with this user-friendly technology and highlight the benefits asset monitoring can bring to a facility.

Asset Monitoring for Beginners

Asset monitoring is the real-time observation of the performance of plant assets, such as pumps, motors and gearboxes, air compressors, HVAC units, and dust-collection equipment, with the ultimate goal of minimizing downtime and optimizing usage.

Important variables such as vibration, differential pressure, temperature, humidity, tank level and other specifications are collected via sensors that are connected to the assets. Critical data is then presented to operators and technicians, allowing them to make informed decisions about maintenance and usage in an effort to prevent unplanned downtime, increase uptime, optimize production schedules and minimize utility bills.

Asset monitoring was traditionally performed manually whereby technicians made rounds on critical assets and recorded data in Excel spreadsheets or maintenance software programs, but this practice was time consuming, prone to human error and only provided historical data, not actionable data. With the advent of the Internet of Things (IoT), connected sensors, devices and analytical software programs, the practice of asset monitoring become proactive rather than reactive, allowing users to identify abnormalities in the monitored variables in real-time and make informed decisions about when to conduct maintenance activities before failure or how best to use equipment so that downtime is avoided and productivity and uptime are maximized. While the real-time capabilities of this type of asset monitoring provide a wealth of benefits, deploying such a monitoring solution can be complex and time consuming, sometimes requiring months before it is useful.

However, Banner Engineering’s SNAP ID technology significantly reduces the complexity of this  type of IoT project by providing a no-code platform in which wired sensors are instantly recognized by compatible gateways. The new technology allows users to begin monitoring equipment in minutes thanks to automatic recognition of compatible sensors that simplify installation and setup. The touchscreen display on the solution’s Asset Monitoring Gateway with SNAP ID provides simple, local access to machine data or Banner’s Cloud Data Service platform can present the data in customizable online dashboards. Both methods provide maintenance and production personnel with instant access to data so they may evaluate overall operational performance.

Getting Started with Asset Monitoring with SNAP ID

There are three steps involved with this simplified asset monitoring solution:

1. Install and power up the Asset Monitoring Gateway.
2. Select, connect and address up to 20 compatible sensors.
3. Install sensors on equipment and commission the system.

There is no complexity when it comes to using this monitoring solution. Up to 20 condition-monitoring sensors can be plugged into the gateway, which can be used to commission the sensors, create unique names for sensors and groups and set warning and alarm thresholds. This means that within minutes of installation, critical system information can be viewed locally via the onboard touchscreen display or sent to the cloud for remote monitoring, giving operators and maintenance technicians instant, actionable insight into machine status so problems can be addressed before failure, equipment usage can be optimized to achieve higher levels of throughput and utility bills can be minimized. Machine status can also be viewed at a glance via an on-board status indicator that features a green-, yellow- and red-light system.

The Benefits of Asset Monitoring

The ability to quickly deploy the asset monitoring system and begin using it provides significant operational and financial benefits for industrial users, such as:

These and other benefits of real-time asset monitoring can be available within minutes thanks to the simplified process of deploying the Asset Monitoring Gateway with SNAP ID, allowing manufacturers to make informed and proactive decisions surrounding predictive maintenance, energy usage, equipment allocation and production schedules, maximizing plant efficiency. To learn more, please contact Sensors Incorporated, a Tavoron company.

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Industrial control panels impact safety and provide electrical supply and control to the machines and equipment that allow a business to successfully make its product, so it’s crucial to choose a control panel that meets the needs of the operation. While it can be overwhelming to consider all the available choices, the first step is usually choosing between a custom control panel or a standard electrical control panel.

This blog will compare these options so you can decide whether a custom-built or a standard model is best for your application. 

The Key to a Good Control Panel 

Before exploring the differences between a custom control panel or a standard one, it’s important to understand the attributes of a “good” control panel. 

Every control panel – whether it’s custom built or standard – should offer: 

• UL listing: UL standards exist for a reason – to ensure safety and high levels of functionality – so it is essential that any selected control panel is UL listed. UL-listed control panels have been made to rigorous standards and will meet regulatory mandates. 
• A solid layout: A properly laid out control panel provides accessible functionality, as well as adequate space to upgrade the system and perform electrical panel maintenance when needed. 
• Appropriate size: A control panel that is too small can present a major problem. Within the panel, there should be enough room around each component for expansion and heat dissipation to protect the system from damage and perform necessary electrical panel maintenance activities. 
• Logical component placement: In order to make life easier for operators and maintenance techs, it is essential that components within the control panel are arranged in logical groups so that power can be properly distributed and maintenance can be easily performed. 
• Organization: Wires and components should be well organized to simplify identification of the current path and allow users to run additional wires in the future without creating a control panel interior that looks like a “bowl of spaghetti.” 
• Proper labeling: If control panel component labeling is ignored or done haphazardly, it can create issues when it is time for maintenance or if cutting power becomes necessary. Each label should be visible and should use clear language or symbols to avoid confusion

The Pros and Cons of Standard & Custom Control Panels 

After establishing that a control panel provides safety and functionality to industrial equipment and the features that compose a good control panel, it is still often difficult to choose between purchasing a standard model or a custom-built one. To help narrow down the choice, we will explore the pros and cons of each below. 

Standard control panels are readily available through suppliers and usually arrive at the facility very quickly. They are often less expensive than having a control panel custom designed to your specifications because they are produced in bulk quantities specific to customer demand. Standard control panels are typically designed for fast and easy installation and offer a simple, universal design. 

On the flip side, standard control panels are limited to standard sizing and material options. Further, even though they are designed for easy installation, it may be necessary to add or resize holes to accommodate specific needs before use. Standard control panels are typically made from stainless steel or polycarbonate, which may not meet the unique needs of an application. 

Custom control panels offer several distinct benefits in that measurements, holes, hinges and other components can be designed to meet the exact specifications of the application. They can be made to accommodate special needs, such as operation in hazardous or outdoor locations, additional cooling systems, special locking mechanisms and unique or specialized materials. 

However, custom control panels are typically more expensive because they are made to order. This also means that the lead time is generally longer than that of standard control panels. Custom control panels tend to be a bit more complex in design; however, this complexity is often a result of being designed to accommodate unique specifications or specialized components. 

Standard vs. Custom Control Panels: Deciding Factors 

With the pros and cons of both standard and custom control panels in mind, there are a few factors that should be considered before choosing between these options. Answering the following questions should help make the decision easier: 

While standard control panels are usually the faster, less expensive option for simple installations, custom control panels can benefit applications with unique needs that require flexibility and adaptability. In either case, working with a trusted supplier, such as Tavoron, or an experienced fabricator, such as PTS, a Tavoron company, will ensure that you receive a

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As more manufacturers add automation and robotics into their production lines, the use of linear electric actuators is growing. While ball screw actuators have always been a popular style for these applications as they are robust and precise enough for industrial applications, recent innovations in ball screw linear actuators, such as higher load capacities, miniaturization and longer service life, are making them more useful than ever. 

This blog will introduce readers to ball screw linear actuator operating technology and share the latest developments in linear actuator design that encourage the use of ball screw actuators in an ever-growing list of applications. 

What is an Actuator?

Generally speaking, actuators enable physical movement by converting energy – either electric, pneumatic or hydraulic – into a mechanical force that drives and/or controls motion in the machine, device or equipment in which it is placed. 

Linear actuators, therefore, are motion control components that permit linear or straight/side-to-side motion in applications ranging from industrial robots and automated production machinery to 3D printers to delicate electronics and medical equipment. Like other actuators, linear actuators may be powered via electricity, air or fluid to achieve the desired movement. 

However, when precision, strength and efficiency are needed, linear electric actuators are often the technology of choice as they provide all of these characteristics. In an electric actuator, the actuator control system signals the electric motor to create a force, which is then applied to the component that needs to be moved. Linear electric actuators are very precise in their movements as they rely on a feedback mechanism to accurately and repeatedly achieve the correct position.

While there are several types of linear electric actuators available, electric ball screw linear actuators are known to be very reliable in critical applications. Ball screw actuators feature recirculating ball bearings that travel along a threaded shaft with very little friction, allowing the ball screw to provide precise motion and accommodate heavy loads. The assembly serves as a nut that travels along the raceway on the shaft, converting rotary motion into linear motion. 

The design of ball screw linear actuators provides robustness, rigidity, precision and high speeds. And, because there is very little friction, electric ball screw linear actuators are among the most efficient linear actuators available – typically over 90% efficient – while also providing high thrust and long service life. 

Industrial Automation Trends Drive New Linear Actuator Designs 

While ball screw linear actuators have been used in industrial machinery for quite some time, the desire to use electric ball screw actuators in applications such as smaller, more precise robotics and medical devices, as well as applications that demand higher speeds and greater efficiency, such as 3D printers and sustainability-based innovations such as wind turbines and solar panels, are driving developers to design electric ball screw linear actuators that are smaller, yet capable of carrying heavy loads with less friction, enhanced reliability and significantly longer service life. 

Actuator Advancement Push Electronification

Advancements in motors and linear actuators have driven a significant shift from hydraulic to electrical systems across various industries. Modern electric motors, like servo and stepper motors, offer precise control over position, speed, and torque, while linear actuators provide accurate movement and positioning. This precision, coupled with greater energy efficiency, makes electric systems more attractive, as they only consume power when active, unlike hydraulic systems that suffer from energy losses and require constant pump operation. Additionally, electric systems demand less maintenance, with fewer moving parts and no fluid leaks, enhancing reliability and reducing long-term costs. Their compact size and lighter weight are advantageous in space-constrained applications, and the ease of integration with digital control systems allows for advanced automation and real-time monitoring. Moreover, electric systems are quieter and have a lower environmental impact, making them cleaner and more sustainable. While hydraulic systems still have their place, especially in applications requiring very high force, the overall benefits of electric actuators and motors—precision, efficiency, reliability, and integration—are leading more industries to make the switch. 

3 Recent Advances in Ball Screw Actuators

Here, we look at three advances in ball screw actuators that allow them to find use in demanding motion control applications.

• Miniaturization: As devices and machinery continue to be housed in smaller packages, yet still require highly precise movement, linear actuator designs are rising to the challenge. For example, ball screw splines are becoming smaller, yet more rigid due to an array of spline nut, shaft, spline groove and bearing options, allowing ball screw linear actuators to become more rigid so they may drive axes on industrial equipment and robotics that demand highly accurate motion and positioning in more compact sizes. In addition, some ball screw linear actuator designs offer a variety of features, including caged balls, different end plate designs or newer circulation methods that result in a more compact package, as well as faster ball screws, to provide miniaturization, precision and higher speeds for applications such as electronics, solar panels and medical devices. 
• Higher load capacities: Meanwhile, many industrial motion control applications require higher load capacities and longer service life, so high-load ball screws with new thread designs have been developed to provide greater load capacity and enhanced robustness for applications such as in robots used in harsh food processing environments or wind turbines. Other designs optimize the ball track to offer greater load capacities than standard ball screw actuators and allowing these recently developed ball screw actuators to provide extended service in difficult industrial applications or harsh environments, such injection molding or fabrication equipment. 
• Customization: Advanced manufacturing processes and techniques are allowing customization of ball screw linear actuators so that motion control designers can pick and choose the features that are the most useful for their application requirements. Choices might include different combinations of nut and screw to increase accuracy or repeatability, different sizes to accommodate application envelope requirements or different manufacturing techniques to provide ball nuts that enhance precision.

As motion control designers continue to demand smaller and more robust ball screw actuators for applications such as 3D printers and medical devices, as well as linear electric actuators with higher load capacities and longer service life for industrial equipment and robotics – or any combination of these things – innovations in ball screw manufacturing techniques, designs and materials will continue to make it possible. To find out if an innovative ball screw linear actuator is right for your application, please contact Accu Tech USA, a Tavoron company, today. 

As more manufacturers add automation and robotics into their production lines, the use of linear electric actuators is growing. While ball screw actuators have always been a popular style for these applications as they are robust and precise enough for industrial applications, recent innovations in ball screw linear actuators, such as higher load capacities, miniaturization and longer service life, are making them more useful than ever. 

This blog will introduce readers to ball screw linear actuator operating technology and share the latest developments in linear actuator design that encourage the use of ball screw actuators in an ever-growing list of applications. 

What is an Actuator?

Generally speaking, actuators enable physical movement by converting energy – either electric, pneumatic or hydraulic – into a mechanical force that drives and/or controls motion in the machine, device or equipment in which it is placed. 

Linear actuators, therefore, are motion control components that permit linear or straight/side-to-side motion in applications ranging from industrial robots and automated production machinery to 3D printers to delicate electronics and medical equipment. Like other actuators, linear actuators may be powered via electricity, air or fluid to achieve the desired movement. 

However, when precision, strength and efficiency are needed, linear electric actuators are often the technology of choice as they provide all of these characteristics. In an electric actuator, the actuator control system signals the electric motor to create a force, which is then applied to the component that needs to be moved. Linear electric actuators are very precise in their movements as they rely on a feedback mechanism to accurately and repeatedly achieve the correct position.

While there are several types of linear electric actuators available, electric ball screw linear actuators are known to be very reliable in critical applications. Ball screw actuators feature recirculating ball bearings that travel along a threaded shaft with very little friction, allowing the ball screw to provide precise motion and accommodate heavy loads. The assembly serves as a nut that travels along the raceway on the shaft, converting rotary motion into linear motion. 

The design of ball screw linear actuators provides robustness, rigidity, precision and high speeds. And, because there is very little friction, electric ball screw linear actuators are among the most efficient linear actuators available – typically over 90% efficient – while also providing high thrust and long service life. 

Industrial Automation Trends Drive New Linear Actuator Designs 

While ball screw linear actuators have been used in industrial machinery for quite some time, the desire to use electric ball screw actuators in applications such as smaller, more precise robotics and medical devices, as well as applications that demand higher speeds and greater efficiency, such as 3D printers and sustainability-based innovations such as wind turbines and solar panels, are driving developers to design electric ball screw linear actuators that are smaller, yet capable of carrying heavy loads with less friction, enhanced reliability and significantly longer service life. 

Actuator Advancement Push Electronification

Advancements in motors and linear actuators have driven a significant shift from hydraulic to electrical systems across various industries. Modern electric motors, like servo and stepper motors, offer precise control over position, speed, and torque, while linear actuators provide accurate movement and positioning. This precision, coupled with greater energy efficiency, makes electric systems more attractive, as they only consume power when active, unlike hydraulic systems that suffer from energy losses and require constant pump operation. Additionally, electric systems demand less maintenance, with fewer moving parts and no fluid leaks, enhancing reliability and reducing long-term costs. Their compact size and lighter weight are advantageous in space-constrained applications, and the ease of integration with digital control systems allows for advanced automation and real-time monitoring. Moreover, electric systems are quieter and have a lower environmental impact, making them cleaner and more sustainable. While hydraulic systems still have their place, especially in applications requiring very high force, the overall benefits of electric actuators and motors—precision, efficiency, reliability, and integration—are leading more industries to make the switch. 

3 Recent Advances in Ball Screw Actuators

Here, we look at three advances in ball screw actuators that allow them to find use in demanding motion control applications.

• Miniaturization: As devices and machinery continue to be housed in smaller packages, yet still require highly precise movement, linear actuator designs are rising to the challenge. For example, ball screw splines are becoming smaller, yet more rigid due to an array of spline nut, shaft, spline groove and bearing options, allowing ball screw linear actuators to become more rigid so they may drive axes on industrial equipment and robotics that demand highly accurate motion and positioning in more compact sizes. In addition, some ball screw linear actuator designs offer a variety of features, including caged balls, different end plate designs or newer circulation methods that result in a more compact package, as well as faster ball screws, to provide miniaturization, precision and higher speeds for applications such as electronics, solar panels and medical devices. 
• Higher load capacities: Meanwhile, many industrial motion control applications require higher load capacities and longer service life, so high-load ball screws with new thread designs have been developed to provide greater load capacity and enhanced robustness for applications such as in robots used in harsh food processing environments or wind turbines. Other designs optimize the ball track to offer greater load capacities than standard ball screw actuators and allowing these recently developed ball screw actuators to provide extended service in difficult industrial applications or harsh environments, such injection molding or fabrication equipment. 
• Customization: Advanced manufacturing processes and techniques are allowing customization of ball screw linear actuators so that motion control designers can pick and choose the features that are the most useful for their application requirements. Choices might include different combinations of nut and screw to increase accuracy or repeatability, different sizes to accommodate application envelope requirements or different manufacturing techniques to provide ball nuts that enhance precision.

As motion control designers continue to demand smaller and more robust ball screw actuators for applications such as 3D printers and medical devices, as well as linear electric actuators with higher load capacities and longer service life for industrial equipment and robotics – or any combination of these things – innovations in ball screw manufacturing techniques, designs and materials will continue to make it possible. To find out if an innovative ball screw linear actuator is right for your application, please contact Accu Tech USA, a Tavoron company, today. 

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