Electric linear actuators can automate secondary conveyor movements such as guide rails, chutes, gates and height adjustments, but not the belt drive itself. Choose by force, stroke, loaded speed, duty cycle, IP rating and control method. Upgrading conveyor and factory equipment doesn't always require replacing an entire machine. In many cases, adding an electric linear actuator can automate an existing adjustment, reduce repetitive manual work, or make equipment easier to configure for different production requirements.
Linear actuators are useful for moving conveyor guide rails, adjusting transfer mechanisms, positioning gates, and operating selected lifting or material-handling components. They can also support automation upgrades to packaging equipment, manufacturing fixtures, and mobile machinery.
For these applications, the right actuator depends on the required force, travel distance, operating speed, duty cycle, environmental conditions, and control system.
This guide explains how to select linear actuators for conveyor retrofits and factory equipment upgrades, compares suitable Progressive Automations models, and outlines the limitations that should be considered before installation.
Selection Criteria and Constraints
The first step is identifying exactly what movement needs to be automated.
Conveyor systems often contain mechanisms that are adjusted manually during changeovers or operated intermittently during production. These are potential candidates for electric linear actuators.
For example, an actuator can move an adjustable guide rail between two positions or reposition a chute to direct materials toward another conveyor.
However, a linear actuator is not normally used to provide the continuous rotational motion that drives a conveyor belt. That function requires an appropriately designed conveyor drive system.
Where Linear Actuators Fit in Conveyor Automation
| Application | Actuator Function | Main Selection Priority |
|---|---|---|
| Adjustable conveyor guide rails | Change guide width for different products | Stroke, positioning, mounting |
| Transfer chute adjustment | Move a chute between positions | Force, stroke, duty cycle |
| Intermittent diverter gate | Extend or retract a gate | Loaded speed, cycle frequency, controls |
| Conveyor height adjustment | Position a supported conveyor section | Load, stability, synchronized movement |
| Packaging equipment adjustment | Reposition stops, guides or fixtures | Repeatability, feedback, mounting |
| Material-handling platforms | Adjust a supported mechanism | Force, precision movement, environmental protection |
These applications have different requirements. A guide rail that moves twice during a production changeover does not need the same duty cycle or response time as a diverter operating for every passing product.
How to Size a Linear Actuator for Factory Equipment
A linear actuator sizing guide should begin with the actual forces and movements of the mechanism, not the overall weight of the machine.
1. Determine the required force
Identify the maximum push or pull force the actuator must produce.
For conveyor guide adjustments, this may include friction in the sliding mechanism, acceleration, product contact forces and resistance from existing components.
For a lifting or angled mechanism, gravity and mounting geometry also affect the required actuator force.
The selected actuator should have sufficient dynamic force capacity for the maximum expected operating load, with suitable allowance for the application's uncertainties and mechanical conditions.
If force is difficult to determine, use our Linear Actuator Force Calculation Guide.
2. Determine the required stroke
Stroke length is the distance the actuator extends or retracts.
Measure the movement required by the mechanism, then confirm that the selected actuator's retracted and extended mounting dimensions fit within the available space.
For example, a conveyor guide that must move 4 inches needs a mechanism capable of providing that travel. However, the actuator's overall length and mounting geometry must also be checked.
3. Calculate the required movement speed
Speed determines how quickly the actuator completes its travel.
For a simple direct linear movement:
Travel time ≈ Required stroke ÷ Loaded actuator speed
Use the manufacturer's full-load speed as a conservative starting point when estimating travel under load. Actual movement time depends on the applied force, power supply, controller and acceleration characteristics.
A higher-speed actuator may be useful for frequent adjustments, but faster models often have lower available force than slower, high-force configurations.
4. Check the duty cycle
Duty cycle is especially important in manufacturing applications.
It describes how much of an operating period the actuator can spend moving.
Duty cycle (%) = Motor running time ÷ Total operating time × 100
For example, an actuator operating for 4 minutes and resting for 16 minutes during a 20-minute period has a 20% duty cycle.
Many standard Progressive Automations electric linear actuators are rated for 20% or 25% duty cycles. They are intended for intermittent movement within their published limits, not unrestricted continuous operation.
In a factory retrofit, calculate the duty cycle during the busiest expected production period, including both extension and retraction.
Learn more in our Understanding Duty Cycle guide.
5. Review mounting and environmental conditions
Confirm the mounting-hole dimensions, available clearance, cable routing, and alignment throughout the full motion range.
Linear actuators should not be used as substitutes for the guides and structural supports needed to resist side loads.
For dusty or wet environments, choose an appropriate IP rating and confirm the manufacturer's operating temperature range.
IP protection does not automatically mean that an actuator is resistant to every cleaning chemical, coolant, oil or industrial contaminant.
Comparing 12V and 24V Linear Actuators for Factory and Mobile Equipment
Both 12VDC and 24VDC actuators can be used in industrial automation when properly matched to the available power source and control system.
| Consideration | 12VDC Actuators | 24VDC Actuators |
|---|---|---|
| Typical power source | 12V batteries or DC supplies | 24V industrial DC supplies or compatible mobile systems |
| Current requirements | Can be higher for comparable power | Can be lower for comparable power |
| Wiring | Must support operating and startup current | May reduce current demand in comparable configurations |
| Common applications | Mobile equipment, retrofits with existing 12V power | Factory equipment and 24V control environments |
| Speed | Depends on the particular actuator design | Not automatically faster than a 12V model |
| Compatibility | Requires 12V-rated components | Requires 24V-rated components |
For example, the 100 lb PA-04 configuration lists a full-load current of 12A at 12VDC and 6A at 24VDC, with the same published full-load speed of 2.16 inches per second.
This illustrates why a 24V configuration may be practical when lower operating current is desirable and a suitable 24V supply is available.
However, a 24V actuator cannot simply be substituted into an unchanged 12V system. The actuator, power supply, control electronics and wiring must all be compatible.
Choosing Motion Control for Automated Conveyors
The control system determines when and how an actuator moves.
For simple adjustments, a compatible switch or control box may be sufficient. More complex manufacturing equipment may require communication with sensors, a programmable logic controller (PLC), or an existing machine controller.
| Control Requirement | Approach to Consider |
|---|---|
| Manual extend/retract | Compatible switch or control box |
| Independent operation of multiple actuators | Multi-channel controller supporting independent movement |
| Two actuators moving together | Compatible feedback-equipped actuators and synchronization controller |
| Repeatable position settings | Appropriate feedback and position-control system |
| Integration with factory automation | PLC or machine controller with a properly rated actuator-drive interface |
For automated conveyor integration, a typical control arrangement includes the machine controller, an appropriately rated motor-drive or switching interface, the actuator, and any required position sensors.
The PLC should not be assumed capable of directly powering the actuator motor from its control outputs.
Additionally, a controller providing normal actuator operation should not automatically be treated as a certified emergency-stop or personnel-safety device.
Explore Linear Actuator Control Systems and Controllers and Relays for available options.
Which PA Actuators Fit Conveyor Retrofits?
Progressive Automations offers several electric linear actuator families that may be suitable for conveyor adjustments, industrial machinery and factory equipment retrofits.
The correct model depends on whether the application prioritizes speed, compact size, high force or position feedback.
Compare Linear Actuators for Conveyor and Factory Applications
| PA Model | Dynamic Force | Full-Load Speed | Duty Cycle | IP Rating | Potential Retrofit Use |
|---|---|---|---|---|---|
| PA-04 | 100 or 400 lbs | 2.16"/sec at 100 lbs; 0.78"/sec at 400 lbs | 20% | IP66 | Faster, intermittent guide or chute adjustments |
| PA-09 | 330 lbs | 0.27"/sec | 25% | IP66 | Compact industrial positioning mechanisms |
| PA-04-HALL | 400 or 900 lbs | 0.35"/sec at 400 lbs; 0.16"/sec at 900 lbs | 20% | IP66 | Feedback-based positioning and synchronized movement |
| PA-HD2 | 450–2,023 lbs | 1.50"/sec at 450 lbs; 0.24"/sec at 2,023 lbs | 20% | IP67 | High-force positioning of heavy mechanisms |
| PA-HD3B | 3,822 lbs | 0.20"/sec | 20% | IP67 | Very high-force, low-speed industrial movement |
IP67 submersion protection for PA-HD2 and PA-HD3B applies while the actuator is static. Force, speed and electrical characteristics vary by configuration. Verify the selected voltage, stroke, force option and datasheet before ordering.
PA-04: High-Speed Option for Intermittent Conveyor Adjustments
The PA-04 Linear Actuator is an option for applications where relatively fast movement and moderate force are needed.
Its 100 lbs configuration reaches a published no-load speed of 2.80 inches per second and a full-load speed of 2.16 inches per second.
It also features IP66 protection and is available in 12VDC and 24VDC configurations.
The 400 lbs option provides greater force at a lower speed and is offered in a 12VDC configuration.
For a conveyor retrofit, the PA-04 may be worth considering for intermittent guide adjustments, transfer mechanisms, or other supported positioning tasks.
Before selecting it, confirm the required operating force and cycle frequency. A high travel speed does not mean the actuator is suitable for continuous or extremely high-frequency movement.
Compatible mounting brackets include the BRK-01 and BRK-02, subject to their specified load ratings and installation requirements.
PA-09: Compact Industrial Actuator for Limited Spaces
The PA-09 Mini Industrial Actuator provides 330 lbs of dynamic force in a compact industrial design.
It is available in 12VDC and 24VDC configurations, with IP66 protection, a stainless steel stroke rod, and a published 25% duty cycle.
Its full-load speed is 0.27 inches per second.
For factory upgrades, the PA-09 may be appropriate when mounting space is limited but the mechanism requires more force than a small, lightweight actuator can provide.
It is better suited to relatively slow positioning adjustments than rapid conveyor diversion.
PA-04-HALL: Feedback for Positioning and Synchronization
Some conveyor retrofits require more than basic extend/retract operation.
For example, two sides of a wide adjustment mechanism may need coordinated movement, or a controller may need position information.
The PA-04-HALL includes Hall effect feedback and offers 400 lbs and 900 lbs force configurations.
With compatible controls, its feedback supports functions such as synchronization and position monitoring.
The PA-04-HALL can be paired with specified Hall effect control systems, including compatible PA-CB40 configurations.
However, synchronization capability depends on the complete system. Verify the selected actuator variants, controller, wiring and mechanical arrangement before installation.
PA-HD2 and PA-HD3B: Heavy-Duty Industrial Actuators
For larger material-handling mechanisms, industrial machinery adjustments and high-force retrofits, the PA-HD2 and PA-HD3B offer higher dynamic force ratings.
The PA-HD2 provides force options up to 2,023 lbs, with a stainless steel shaft, metal gearing, IP67 protection while static, and optional Hall effect feedback.
Its performance depends on the selected force configuration. The 450 lbs option is considerably faster than the 2,023 lbs option.
The PA-HD3B uses a ball screw design and offers up to 3,822 lbs of dynamic force. Its full-load speed is 0.20 inches per second.
These are potential candidates for demanding, slower-moving mechanisms rather than high-speed conveyor product rejection.
Neither model is rated for shock or pulse loads. Applications involving impacts, sudden stops or repeated mechanical shocks require special attention before selection.
Controllers and Supporting Hardware
The actuator is only one component of a working retrofit.
Depending on the installation, additional equipment may include mounting brackets, power supplies, wiring harnesses, controllers, relays and feedback components.
Two commonly used PA controllers:
PA-CB31 single-channel controller
The PA-CB31 supports 12VDC and 24VDC operation, with published ratings of 25A at 12VDC and 12.5A at 24VDC.
It is intended for compatible single-actuator systems and requires the correct wiring harness, which is sold separately.
PA-CB40 dual Hall effect controller
The PA-CB40 supports synchronized control of two compatible Hall effect actuators.
Its published output ratings are 12.5A per channel at 12VDC and 6.25A per channel at 24VDC.
Neither controller should be assumed to provide a complete PLC interface or machine-safety system without reviewing the exact integration requirements.
For more hardware options, explore Power Supplies and Mounting Brackets.
Worked Example: Retrofitting Adjustable Conveyor Guide Rails
Consider a small manufacturing facility that uses a conveyor for different package sizes.
The guide rails are currently adjusted manually whenever the product dimensions change.
The facility wants to automate the rail adjustment while retaining the existing conveyor structure.
Example Application Requirements
| Requirement | Example |
|---|---|
| Mechanism | Sliding conveyor guide rail |
| Required travel | 4 inches |
| Maximum measured operating force | 60 lbs |
| Available power | 24VDC |
| Operating frequency | One complete adjustment cycle every 2 minutes |
| Environment | Dusty indoor manufacturing area |
| Control | Operator-initiated end-to-end movement |
This is an illustrative design example, not a tested or approved application.
Step 1: Select a Candidate Actuator
The 24VDC, 100 lbs PA-04 is a potential starting point because it provides:
-
A dynamic force rating of 100 lbs.
-
A 4-inch stroke option.
-
A full-load speed of 2.16 inches per second.
-
A full-load current of 6A.
-
IP66 ingress protection.
-
A 20% duty cycle.
A 60 lbs measured requirement is below the actuator's nominal 100 lbs dynamic rating. The final design must still account for load variation, friction, binding, geometry and an appropriate engineering margin.
Step 2: Estimate Movement Time
Using the published full-load speed:
4 inches ÷ 2.16 inches/second ≈ 1.85 seconds
A full extension-and-retraction cycle covers approximately 8 inches.
8 inches ÷ 2.16 inches/second ≈ 3.7 seconds
This is an approximate full-load travel estimate. Actual movement time may differ due to operating load, acceleration and controller behavior.
Step 3: Check Duty Cycle
If the actuator completes one full extension-and-retraction cycle every 2 minutes, estimated motor running time is:
3.7 seconds ÷ 120 seconds × 100 ≈ 3.1%
This is below the PA-04's published 20% duty cycle for the assumed cycle.
However, production schedules can change. The facility must also check the busiest operating period, consecutive movement duration and real-world thermal conditions.
If the mechanism needs to move several times per minute, the duty-cycle requirement could increase enough to make this actuator unsuitable.
Step 4: Verify Electrical and Mechanical Compatibility
The final system requires a 24VDC power supply and control components rated for the selected actuator's operating and startup currents.
The installation also needs suitable mounting brackets and independent guidance for the sliding rail.
The rail should move freely without forcing the actuator to resist excessive side loads.
If the adjustment is initiated through the conveyor's existing PLC, the electrical integration must be designed using a compatible switching or motor-drive interface.
Step 5: Test Before Production Use
After installation, test the actuator through its complete travel range with the conveyor unloaded and under representative operating conditions.
Verify that movement does not interfere with the conveyor belt, product path, guards or surrounding machine components.
Record operating current, travel time and any unexpected mechanical resistance.
Before returning the equipment to production, confirm that required safeguards, stops and control interlocks operate as intended.
For mounting recommendations, see Linear Actuator Installation Tips.
Limitations and Unsuitable-Use Cases
Electric linear actuators can simplify many factory equipment adjustments, but they are not suitable for every motion requirement.
Continuous Conveyor Belt Drive
A conventional rod-style electric linear actuator is not a substitute for a conveyor's continuously rotating drive motor.
For belt movement, use a suitably rated conveyor motor and drive arrangement.
Linear actuators are better suited to secondary movements such as guide adjustments, positioning and intermittent transfer functions.
High-Frequency Product Rejection
Production lines that require a gate or diverter to move rapidly for every passing item often exceed the speed or duty-cycle capabilities of a standard electric linear actuator.
Depending on the required response time and operating frequency, pneumatic, servo-driven or other purpose-built industrial mechanisms can be more appropriate.
A high no-load speed rating alone does not establish suitability for high-frequency rejection.
Impact and Side Loading
Linear actuators are not designed to absorb uncontrolled mechanical impacts or carry significant unsupported side loads.
Use appropriate guides, supports and mechanical stops.
The PA-HD2 and PA-HD3B are specifically identified by Progressive Automations as unsuitable for shock or pulse loads.
Continuous Operation
Most of the PA actuator configurations discussed in this article are rated for 20% or 25% duty cycles.
They should not be selected for 100% continuous-motion operation without a product specifically rated and validated for that requirement.
Harsh or Specialized Environments
An IP66 or IP67 rating addresses particular dust and water exposure conditions. It does not establish suitability for corrosive chemical washdowns, hazardous atmospheres, food-contact zones or every industrial environment.
Review material compatibility, cleaning procedures, operating temperature, corrosion resistance requirements and applicable approvals before installation.
Machine Safety and Integration
Factory equipment retrofits benefit from having guarding, emergency-stop functions, interlocks, overload protection and validation of the modified machine's safety system.
These requirements should be evaluated by qualified personnel.
A standard actuator controller or internal limit switch should not be relied on as the sole safeguard against hazardous machine movement.
For an industrial installation, proper mechanical design and safety integration are just as important as actuator performance.
Frequently Asked Questions
What linear actuator should I use for conveyor adjustments?
Start with the movement type, force, stroke, speed and duty cycle. For relatively fast, intermittent adjustments, the PA-04 may be a candidate. Compact mechanisms may benefit from the PA-09, while higher-force movements may require a heavy-duty industrial model.
What is the best high-speed linear actuator for conveyor applications?
There is no single best actuator for every conveyor. The PA-04's 100 lbs configuration offers a published full-load speed of 2.16 inches per second and no-load speed of 2.80 inches per second. It is worth considering for intermittent, relatively light-force adjustments when its 20% duty cycle meets the application.
Can linear actuators be used on existing manufacturing equipment?
Yes. Electric linear actuators can be integrated into suitably designed existing equipment to automate selected movements. The retrofit must be checked for mechanical fit, electrical compatibility, force requirements, control integration and safety.
Are 24V actuators better than 12V actuators for factory automation?
Not necessarily. A 24V actuator can offer lower current demand in comparable configurations and may fit an existing 24V control environment. A 12V actuator may be more practical for equipment already using a 12V power system. Choose based on the actual specifications and available electrical infrastructure.
Can a linear actuator be controlled by a PLC?
Yes, with a properly designed control interface. The PLC generally sends commands to a suitable relay, motor driver or controller rather than powering the actuator directly. Feedback, stop positions and safety functions must also be considered.
Do industrial conveyor actuators need position feedback?
Not always. Simple end-to-end movement may use a suitable control arrangement without continuous position feedback. Applications requiring intermediate positions, position monitoring or synchronized motion may benefit from compatible Hall effect or other feedback-equipped actuators.
Can one actuator synchronize two conveyor guide rails?
A single actuator can move mechanically linked rails when the linkage and guides are properly designed.
For mechanisms requiring multiple actuators, use compatible feedback-equipped models and a controller designed for synchronized operation. Two independently powered actuators should not automatically be assumed to move at exactly the same speed.
What automation products should a small manufacturer consider for a conveyor retrofit?
A basic retrofit may require an electric linear actuator, mounting brackets, a DC power supply, wiring, and a compatible control or switching system.
More advanced projects may also require position sensors, PLC integration, independent guiding mechanisms, and additional machine safeguards.
Start with the specific task being automated before selecting components.
Can a heavy-duty linear actuator replace a hydraulic cylinder?
Sometimes, but it is not always a direct replacement.
The electric actuator must meet the required force, travel, speed, duty cycle, load-holding, mounting and environmental requirements. Applications involving shock loads or continuous heavy-duty movement may need a different solution.
How do I maintain linear actuators in factory equipment?
Follow the manufacturer's maintenance instructions and regularly inspect mounting hardware, cables, connectors, alignment and the surrounding mechanism.
Keep the actuator within its published operating limits. Investigate unusual noise, binding, unexpected current draw or inconsistent travel before continuing production.
Do not open sealed actuator housings or apply lubricants unless the product documentation specifically allows it.
Find the Right Actuator for Your Factory Retrofit
A successful conveyor or factory equipment retrofit begins with identifying the movement that needs to be automated.
For fast, intermittent adjustments, prioritize loaded speed and duty cycle. For compact mechanisms, consider installation dimensions and required force. For heavier equipment, review industrial actuator force ratings, mounting arrangements and electrical requirements.
Progressive Automations offers electric linear actuators, control systems, mounting hardware and technical resources for a range of manufacturing and material-handling applications.
If your existing machine has unusual mounting dimensions, specialized operating conditions or integration requirements, our team can help review the available options.