To fully harness the potential of electric linear actuators, it is essential to understand and pair them with the right source of power. By choosing suitable power supplies for electric linear actuators, applications can experience benefits such as greater reliability, ease of use, and performance optimization.
This power supply guide is dedicated to understanding the different types of power supplies for electric linear actuators, how they work, the benefits they offer, and how to choose the best one for your specific application needs.
Introduction to How Actuators Work
Actuators are fundamental components in various mechanical systems, playing a crucial role in energy conversion into motion. Essentially, an actuator takes an energy source and converts it into a physical movement. This capability is integral to countless applications, from industrial machinery to consumer electronics, and even in advanced robotics. The basic concept behind actuators involves the conversion of energy, typically electrical, hydraulic, or pneumatic into mechanical motion. This is achieved through different components and mechanisms depending on the type of actuator. For instance, electric actuators may use brushed DC motors, while hydraulic actuators utilize fluid-filled pistons to generate movement.
In electric linear actuators, electric current from a source such as a power supply or controller is used to produce rotational motion in an electric motor that’s mechanically linked to a gearbox and utilizes a lead screw to cycle the actuator’s shaft attached to an ACME drill nut for linear motion. Electric linear actuators are indispensable in today's automation landscape—from industrial equipment and home automation to robotics, automotive systems, and medical devices. Electric actuators can be controlled in various ways:
- Manual wired switches (DPDT rocker switches, Joysticks, etc)
- Remote wireless control boxes
- Control systems with built-in relays, programmed features, timers, or logic
- Smart systems using Wi-Fi/Bluetooth or PLCs
Importance of Pairing Actuators with The Right Power Source
The performance of an electric actuator is only as good as the power source it’s connected to. These systems require consistent and appropriately rated electrical power, making the power supply a key integration component in systems with electric linear actuators. Whether you're a design engineer, integrator, or advanced DIY builder, selecting the appropriate power supply is critical to:
- Maximize performance
- Prevent damage to components
- Enable efficient, safe, and smooth motion
- Ensure long-term system reliability
Components Inside A Power Supply
Before choosing a power supply, having a basic understanding of the fundamental key components inside a power supply and how they work together can help give more clarity on how it operates and be later used with actuators. A power supply is designed to convert high-voltage AC (alternating current) ranging from 110 VAC to 230 VAC from a wall outlet into low-voltage DC (direct current) suitable for actuators (commonly 12 VDC or 24 VDC). Below are common components found inside a power supply:
- Input Voltage Selector: Sliding switch that allows users to configure the power supply to accept either 110 VAC or 220 VAC input, depending on the region or system requirements. Certain models of power supplies have this switch inside the case and can be accessed by placing a screwdriver through the casing’s holes, while others may have the switch outside the case.
- AC Input Voltage: Screw terminals used for connecting high-voltage AC power from a wall outlet or main line. Check labels for the correct polarity during installation.
- DC Output Voltage: Screw terminals that provide a regulated DC output voltage to downstream devices such as actuators or control boxes. Check labels for the correct polarity during installation.
- DC Voltage Adjustment Knob Potentiometer: Variable resistor that allows manual fine-tuning of the output DC voltage, typically within ±10% of the rated value, to match the needs of sensitive components.
- Light Indicator: Displays the operational status of the power supply—usually lit when powered on and output voltage is stable.
- Fuse: Protects the power supply circuitry by breaking the connection in the event of a short circuit or a significant spike in electrical current flow.
- Input Common Mode Choke: An inductor that acts as an input filter to reduce the high-frequency noise and electromagnetic interference (EMI) that may enter or exit through the AC power lines.
- Rectifier: Converts the incoming AC input voltage from the Input Common Mode Choke to a pulsating DC voltage using a bridge configuration of diodes, where each diode allows unidirectional flow of current.
- Capacitor (Input Side): Helps smooth out the pulsating DC electrical waveform coming from the rectifier by charging during voltage peaks and discharging during dips, thereby reducing voltage ripple before the regulation stage.
- MOSFET & Heat Sink: The metal–oxide–semiconductor field-effect transistor (MOSFET) acts as a high-speed switching element to control energy delivery to the downstream inductor while the heat sink in physical contact dissipates the heat generated during operation.
- Inductor: Temporarily stores energy in a magnetic field during the switching operation, helping to smooth the current and reduce voltage ripple. It works in tandem with the MOSFET to regulate power flow and stabilize the output.
- Diode & Heat Sink: The diode allows current to flow in only one direction, preventing reverse energy flow from the inductor’s output, while the heat sink dissipates heat generated during power delivery to maintain safe operating temperatures.
- Powder Iron Core Inductor: A specialized inductor made with iron powder cores, designed to handle high-frequency switching with minimal core loss. It acts as a means of further filtering the DC output while maintaining thermal stability and reducing electromagnetic interference (EMI).
- DC Filtering Capacitors: Located near the output stage, these capacitors further smooth the DC voltage to ensure a stable, clean supply for connected devices.
- Bleed Resistors: Located throughout the power supply, these bleed resistors are often used to discharge the stored voltage of capacitors after shutdown for safety and to avoid sparking.
Together, these components form a comprehensive power supply unit, each serving a specific function that contributes to the overall effectiveness and efficiency of the electrical power output. This system not only allows for an AC-to-DC step-down voltage conversion but also enhances the safety for operators through the built-in safety mechanisms and redundancies integrated into the design.
Choosing the Right Power Supply for Your Linear Actuator
Standalone DC power supplies provide fixed 12 VDC or 24 VDC outputs and are often used in basic human-operated systems to power actuators that are controlled directly through relays, rocker switches or joysticks., They are also used as external power supplies for many control boxes that require an external AC-to-DC power supply since the control box may only accept 12 VDC or 24 VDC. When choosing a power supply for your system of electric linear actuators and controllers, there are a few parameters and features to consider, such as:
- Input & output voltage ratings
- Current draw ratings
- Ingress protection
- Size & weight considerations
- Safety features
- Feedback control requirements
Input & Output Voltage Ratings
The input voltage ratings of the power supply you choose must be within a similar value to the AC voltage of your wall outlet, while the output voltage ratings should match the requirements of your load components to ensure proper operation. The loads in your system would include your actuators, relays, controllers, and any other device that draws power from the power source. Check the control boxes and/or actuator voltage requirements in the datasheet specifications to ensure the power supply outputs a voltage that matches or is within a tolerable range of their operational compatibility. In some use cases that do not require high precision and have built tolerance that can accept slight changes in force and speed, a voltage tolerance of ±10% can be acceptable.
Example: 12 VDC × ±10% = ±1.2 VDC
12 VDC non-precision applications could accept a 10.8 VDC to 13.2 VDC supply
Current Draw Ratings
The power supply you use must be able to output at least the actuator’s maximum current draw. Even if the actuator has a low continuous current draw, there is still an inrush current draw at motor start-up that can spike and reach similar requirements to the full-load current draw ratings of the actuator. Other devices, such as controllers and relays, may have low current draw requirements relative to the actuators, but still have a current draw that needs to be added and taken into consideration when choosing a power supply. Current draw (Amps) and voltage (VDC) are used to calculate electrical power requirements (Watts), useful for comparing the electrical power efficiency of different models of electrical equipment with similar output performance.
Watts = Voltage × Current
Add margin for safety (typically 30% is ideal)
Ingress Protection
Standard power supplies, often with a low ingress protection rating (or no rating), can be rated IP20 or IP30 and are better suited for dry indoor applications. For outdoor applications, adding protective waterproof enclosure boxes and covers can help prevent water damage or debris from compromising the power supply operation. Ideally, a power supply should have at least an IP65 rating or higher for outdoor use. The PS-20-12-67 (100-120 VAC input, 12 VDC output) and PS-10-24-67 (100-120 VAC input, 24 VDC output) are both rated IP67 and can handle periods of water submersions.
Size & Weight Considerations
When space is limited, choosing a power supply with a compact form factor becomes essential, especially for integration into tight enclosures, mobile platforms, or embedded systems. Miniaturized or DIN-rail mountable power supplies are ideal for control panels where every inch counts.
Weight is another factor to evaluate, particularly for modular setups or portable systems, such as mobile standing desks or equipment with mobility constraints. The Portable FLT Battery Pack, for example, is designed specifically to be light and compact for mobile standing desks. Lighter power supplies reduce strain on mounting structures and support ease of transport and installation. Be sure to review the dimensions and weight specifications when selecting a power supply for confined or dynamic environments.
Safety Features
Power supplies should include essential built-in safety mechanisms to protect both the supply itself and the devices it powers. From the perspective of linear actuators, look for the following features:
- Overcurrent protection: Prevents damage from excessive current draw or short circuits.
- Overvoltage protection: Shuts down or limits output if voltage exceeds safe thresholds.
- Overheat protection: Activates cooling or shuts down the unit in case of thermal overload. For high-current applications, active cooling (e.g., built-in fans or heat sinks) is also recommended to maintain thermal stability.
- Inrush current limiting: Prevents spikes during power-on that could trip breakers or damage components.
- EMI filtering and surge protection: Guards against electrical noise and voltage transients from the AC mains.
Feedback Control Requirements
Certain control boxes may also have built-in power supplies that can convert AC input voltage into DC output voltage that then cycle the actuators. In this case, an additional external power supply may not be required. For actuator systems that operate with hall sensors or other positional feedback devices, control boxes/systems with more advanced programming logic are required to allow for capabilities such as:
- Synchronous motion of multiple actuators
- Memory preset positions
- Positional display functions
- Higher accuracy and precision movements
Our control boxes comparison chart highlights the compatible power supplies we carry for each of our control boxes under the AC Power Option section. To see which of our control boxes and actuators are compatible with each other, check out our control box compatibility chart and control box comparison chart for more information.
Installation and Maintenance Best Practices
Proper installation and ongoing maintenance are key to ensuring safe, efficient, and long-lasting operation of your power supply and electric linear actuator system. Below are essential tips and techniques to follow throughout the lifecycle of your setup.
Regular Maintenance Tips
Ongoing maintenance is crucial for preventing issues and maximizing system lifespan. Schedule routine checks that include the following:
- Secure Mounting Points: Regularly inspect the power supply’s physical mounting to ensure it remains securely fastened to the frame or enclosure. Retighten any loose fasteners to prevent mechanical vibration or shock damage.
- Check Ventilation: Ensure that the power supply has adequate airflow to prevent overheating by cleaning the vents and keeping them clear of dust and obstructions.
- Evaluate Load Components: Observe actuator and controller behavior for signs of trouble, such as erratic movement, excessive heat, or inconsistent operation. These may indicate a failing component or an excessive load on the power supply.
- Clean Terminals/Contact Points: Remove debris, dust, and oxidation from connectors to maintain good electrical conductivity.
- Inspect Wiring & Connectors: Look for signs of wear, corrosion, fraying, or loose terminals. Replace damaged connectors or compromised wiring immediately to prevent electrical faults and ensure reliable performance.
- Monitor Electrical Output: Periodically measure voltage and current while the system is under load to confirm it stays within specified limits.
Proper Wiring Techniques
Following proper wiring techniques is critical for system reliability and protection. Follow these best practices to avoid voltage drops, interference, or damage:
- Choose the Right Wiring Gauge (AWG): Select wire sizes that can safely carry the current required by your actuators, especially over longer distances. Undersized wires can overheat or cause a voltage drop, affecting actuator performance.
- Use High-Quality Connections: Secure all wiring with soldered joints or heat-shrink connectors to prevent disconnections or shorts over time.
- Maintain Polarity: Reversed polarity can damage actuators and power supplies. Always double-check wiring diagrams and labels.
- Add Overcurrent Protection: Install inline fuses or circuit breakers to protect against electrical faults and short circuits.
- Reduce EMI (Electromagnetic Interference): Use shielded cables and keep wire runs as short as possible to minimize noise in applications that have sensitive noise requirements.
- Backup Power Considerations: For critical applications, integrate a backup power source such as a battery system or generator to maintain functionality in the event of an electrical power outage.
In Summary
Power supplies are the backbone of any electric actuator system. Over the years, technology advancements have developed power supplies to become more compact, efficient, and reliable. Understanding their function and choosing the right type ensures optimal actuator performance, longer service life, and seamless integration across a wide range of automation applications.
We hope you found this power supply guide as informative and interesting as we did, especially if you were looking for guidance in choosing suitable power supplies for your electric linear actuators and control boxes. If you have any queries about our products or have trouble picking out the right power supplies and electric linear actuators to suit your needs, feel free to reach out to us! We are experts in what we do and will be happy to help with any questions you may have!