Basic Guide to Electric Actuator Maintenance and Care

Basic Guide to Electric Actuator Maintenance and Care

Basic Guide to Electric Actuator Maintenance and Care

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Electric actuators play a critical role in automated control systems by precisely managing valve operations and fluid regulation. Regular maintenance is essential to ensure long-term, efficient, and stable performance. Proper upkeep helps prevent issues like wear and corrosion, extending the equipment's lifespan and reducing operational costs. Below is a detailed explanation of the objectives of maintaining electric actuators, cleaning requirements, lubrication maintenance, component inspection, and operational precautions.

Objectives of Electric Actuator Maintenance

 
The primary goal of electric actuator maintenance is to ensure the equipment remains in optimal working condition, including:

Keeping the equipment clean: Preventing the accumulation of dust, oil, or media residues that could degrade performance or cause damage.
Ensuring proper lubrication: Reducing friction and wear between mechanical components, thus extending the actuator's service life.
Verifying component integrity: Ensuring all parts are intact to prevent operational failures due to missing or damaged components.
Maintaining normal operation: Through regular inspections and repairs, potential breakdowns during critical moments can be avoided.

Cleaning Maintenance for Electric Actuators

 
The external and internal parts of electric actuators can easily accumulate dust, oil, and other contaminants, which can hinder normal operation. Keeping the equipment clean is an important aspect of maintenance. The following are the specific cleaning methods:

Cleaning external surfaces: Surfaces and moving parts, such as valve stems, trapezoidal threads, gears, and worm gears, tend to attract dust and dirt. Use a brush to sweep away debris or compressed air to blow it off.
Removing stubborn grime: For tough dirt on trapezoidal threads and gears, wipe with a cloth. If buildup is severe, steam or a copper brush may be used to clean the area until the metal surface or paint is visible.
Cleaning valve parts: Condensate traps should be cleaned regularly to prevent blockages. Designate personnel to check them at least once per shift and periodically open flushing or drain valves, and flush the bottom plug to prevent debris buildup.

Lubrication Maintenance

 
Numerous mechanical parts within electric actuators require lubrication, such as trapezoidal threads, valve stem nuts, sliding brackets, bearings, gears, and worm gears. Proper lubrication reduces friction, prevents wear, and enhances equipment longevity. Key points for lubrication maintenance include:

Regular oiling: Adjust oiling frequency based on usage and temperature. For frequently operated actuators under high temperatures, oil every one to four weeks. For less-used or lower-temperature equipment, extend the oiling intervals.
Selecting the appropriate lubricant: Different operating conditions require different lubricants. In high-temperature environments, oil and grease are not suitable as they can degrade under heat. Molybdenum disulfide or graphite powder is recommended for high temperatures as they resist dust accumulation and offer superior lubrication. For exposed gears and trapezoidal threads, molybdenum disulfide and graphite powder are more effective than grease.
Inspecting the lubrication system: Ensure the presence and integrity of oil cups or nozzles. If any are damaged or missing, repair and replace them promptly to keep the oil system functional.

Component Inspection and Repair

 
All valve parts and mounting fixtures of the electric actuator must be in proper condition. Any missing or loose components can affect operation and pose safety hazards. Focus on the following aspects:

Fastening bolts and flanges: The bolts on flanges and brackets must be intact and securely fastened, with no signs of loosening. If the handwheel's fastening nut is loose, it should be tightened immediately to avoid wear or loss of the handwheel.
Handwheel maintenance: If the handwheel is lost, it must be replaced promptly; using a wrench as a substitute is not advisable as it may compromise precision and safety during operation.
Protective measures: For electric actuators exposed to harsh environments, it is recommended to install protective covers over the valve stems to prevent contamination from dust, rain, or sand.
Condition of scales and accessories: Ensure the scale markings are intact, accurate, and legible. Seals, caps, pneumatic accessories, and insulation jackets should be complete, with no dents or cracks.

Operational Precautions

 
To ensure the safe operation of electric actuators, the following precautions must be observed during use:

Avoid external damage: Do not strike the equipment, stand on it, or place heavy objects on the actuator, especially those made of non-metal or cast iron, to avoid damage from impact.
Maintain a clean work environment: In dusty, rainy, or corrosive environments, take steps to protect the equipment. Regularly clean and inspect exposed components to prevent dirt and contaminants from entering the actuator.

Conclusion

 
Through systematic cleaning, lubrication, inspection, and maintenance, electric actuators can be kept in excellent working condition, minimizing the risk of failure. Regular maintenance not only extends the equipment's lifespan but also boosts production efficiency and reduces the economic losses from unexpected downtime. Good maintenance practices are a long-term investment that enhances the reliability and safety of electric actuators across a range of operational conditions. Therefore, establishing a thorough maintenance plan and adhering to it diligently is key to ensuring smooth operations and maintaining the efficiency of production processes.

 
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