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Automation equipment has fundamentally changed how manufacturing floors operate. Repetitive processes that used to require a worker’s direct involvement are now handled by a variety of equipment and robots, improving productivity while also making work quality more consistent.
As production processes have become more advanced in recent years, the role equipment plays has expanded as well. Beyond simple repetitive tasks, equipment now handles assembly, transport, inspection, and other varied processes, which makes the ability to maintain consistent performance over long hours of operation an essential requirement.
As these changes continue, a natural question comes up. How can automation equipment keep repeating the same motion for long stretches of time and still operate reliably in environments where it has to handle heavy loads?
The Actuator, The Muscle Behind Automation Equipment
For automation machinery to actually move, it needs a drive component that converts control signals into physical motion, and that’s exactly the role the actuator plays. Actuators are classified by their power source into pneumatic, hydraulic, and electric types, and the right type is chosen based on the application environment and required performance.
Among these, the electric actuator generates movement using electrical energy. Since it doesn’t require separate equipment like hydraulic pumps or piping, the overall system is relatively simple to configure, and it allows for precise control of position and speed, which is why it’s widely used in automation machinery and industrial robots.
An electric actuator typically combines a motor with a reducer. The reducer converts the rotational force generated by the motor into the torque needed, helping automation equipment achieve the exact movement it requires.
To make this structure easier to picture, it helps to compare it to the human body. Muscles generate force, and joints convert that force into movement in different directions. The actuator can be thought of as the part that plays both of these roles, muscle and joint, together.
Electric actuators are typically applied to a robot’s joints, and equipment that needs to move in several directions is often built with multiple actuators working together. This lets equipment carry out complex actions, such as transferring parts to the next process or picking up objects.
How to Choose the Right Actuator for Automation Equipment
Asking a person to repeat the same motion all day without a break simply isn’t realistic. Automation machinery, however, is designed from the outset to run for long hours. That’s because the goal of an automated system is to keep processes running without direct human involvement, letting people focus on managing and overseeing the system as a whole.
In this context, durability is the single most important factor for electric actuators used in automation equipment. They need to repeat the same motion for long periods without accumulating error, and they need to deliver stable torque even in working environments where the load keeps changing.
Depending on the nature of the task, the operating environment for automation machinery can also include processes that handle heavy objects. Since the load or impact generated in these processes is transmitted directly to the drive unit, the internal drive components are more likely to experience wear or damage.
If equipment goes down, it doesn’t just hurt productivity; it can also require an emergency response team to step in, which ends up as a direct loss for the factory’s operations. That’s why actuators used in automation equipment need to operate reliably even under repetitive drive conditions, while also having a structural design that can distribute load effectively.
The BCSA V4, A Cycloidal Actuator Built for Durability
Bonsystems has focused on exactly these requirements, and we develop and manufacture the BCSA actuator series based on our own cycloidal technology.
The BCSA electric actuator delivers strong torque output even with a slim structure, so it’s designed to make more efficient use of equipment’s limited internal space. The space this frees up can be used for additional components such as a battery, which can also have a positive effect on equipment operating time. It also uses a hollow structure that lets cables be routed inside the actuator, reducing interference with other parts. This adds wiring flexibility when designing automation machinery with tight internal space.
Inside the actuator, we apply a cycloidal reduction structure. The cycloidal tooth profile is designed based on the path traced by a point on a circle as that circle rolls. This tooth profile keeps the load from concentrating in one spot and spreads it across the entire gear instead, enabling stable operation in automation equipment that handles heavy loads or needs to repeat the same motion.
On top of that, we’ve applied a pinless structure to improve the gear’s efficiency and rigidity. The pinless design simplifies the structure, and having fewer parts improves ease of assembly and productivity. Fewer components also mean fewer potential points of failure, which is an advantage when it comes to maintenance as well.
With these characteristics, the BCSA series is a drive solution well suited to equipment such as automation systems and robots that need to operate reliably over long periods. As equipment takes on an even wider range of processes going forward, the performance expected from the electric actuators that drive them is likely to rise as well.
Bonsystems is a Korean company specializing in drive solutions for automation and robotics, and we continue our research and development on core drive components such as reducers and actuators. Building on the technical expertise we’ve accumulated through this work, we can propose a solution tailored to each piece of equipment’s requirements. If you’re weighing drive-component choices while building out factory automation equipment, or if you’re considering the BCSA actuator for your application, please reach out to us through our website.
FAQ
Q. Why does the actuator matter so much in automation machinery?
Automation machinery carries out a range of tasks, including transferring parts, assembling products, and inspection. Moving objects, picking them up, and repeatedly moving to a set position are all actions carried out through the actuator. The actuator outputs the speed and torque each task requires, helping equipment perform its work reliably. Because actuator performance has a direct effect on the quality and stability of equipment’s movement, it’s a core component that needs careful consideration when designing automation equipment.
Q. What matters most for electric actuators used in automation machinery that runs for long hours?
Durability, the ability to maintain stable performance even under high-load, repetitive drive conditions, is the key factor. Output characteristics and positioning accuracy need to stay consistent even when the same motion is performed continuously, and the structure needs to distribute the load and wear that build up in internal components so they don’t concentrate in one spot. Because equipment failure is directly tied to a factory’s overall productivity and operating efficiency, it’s a good idea to review drive components like actuators closely from the early design stage.
Q. What advantages does the cycloidal structure offer for automation machinery?
This structure spreads the load evenly across multiple contact surfaces, reducing the concentration of force at any one spot, which helps deliver high durability and stable power transmission. This helps reduce component wear and allows the equipment to respond reliably even when external impact or load changes occur. That’s why the cycloidal structure is well suited to maintaining consistent drive performance even in working environments with a heavy load burden.
Q. Why is the BCSA a good fit for automation equipment and industrial robots?
The BCSA actuator is built on a slim, hollow structure, which allows for a configuration that takes internal space efficiency into account. The slim structure reduces the footprint the drive unit takes up and allows for flexible component layout, while the hole running through its center lets cables and wiring be routed inside, reducing outside interference. It also applies a cycloidal tooth profile inside the actuator, giving it a structure that spreads the load across the entire gear. This allows for stable operation even in automation environments with repetitive motion or a heavy load burden.
References
1. Why Choose an Electric Actuator? (DCL)
2. Pneumatic Actuators vs. Electric Actuators: Pros, Cons, and Use Cases (XINGCHEN)
