Pick the Right Actuator Stroke: Avoid Costly Mistakes

A common mistake in actuator selection is picking a stroke length longer than necessary. Oversizing adds cost, weight, and can reduce system stiffness. Start by measuring the exact travel your application requires—account for all moving parts, tolerances, and any misalignment. Add a small margin, typically 10-20%, to avoid hard stops.

Force and moment considerations change with stroke length. A longer stroke increases the cantilevered load on the rod, potentially leading to buckling or side loading. For rotating linkages, calculate the effective stroke at the point of force application. Use the manufacturer’s load–stroke charts to verify your actuator can handle the moment throughout its travel.

End-of-stroke cushioning is critical. If the stroke is too short, the actuator may not have room for deceleration, causing impact damage. For high-speed or heavy loads, ensure the cushioning zone is within the stroke. Also consider duty cycle—longer strokes in high-cycle applications may require oversize bearings or a different actuator type.

Finally, always check physical installation constraints. The retracted length plus stroke must fit in your assembly. Remember that a shorter stroke often means faster cycle times and lower cost. When in doubt, prototype or simulate to validate your choice. A properly sized stroke saves money and improves reliability.

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