Achieving Up to 4 Million Operations: The Efficiency of Kinetrol’s Rotary Actuator

Because of their direct influence on cost, safety, and efficiency, cycle life is a vital criterion when applying pneumatic actuators on industrial quarter-turn valves.

In terms of cost, frequent replacements or repairs of actuators can lead to higher expenses over time. An actuator with a longer cycle life might have a higher initial cost, but its extended operational lifespan can minimize the need for frequent maintenance or replacement. By reducing the frequency of replacements and potential system downtimes, plants can maintain a more steady production rate and avoid unexpected costs related to equipment failure.

Safety is paramount in industrial settings, and an actuator's cycle life plays a role here, too. Actuators that don't achieve their expected cycle life can fail unexpectedly, potentially leading to uncontrolled valve movements. Such unpredictable behavior can harm personnel, the environment, and other equipment. For example, if a valve doesn't open or close as expected because of an actuator failure, it could release hazardous materials or create unsafe operating conditions in the plant.

Efficiency is another area where the cycle life of an actuator is crucial. When actuators on industrial quarter-turn valves operate consistently within their expected cycle life, they ensure the valves open and close as intended, allowing for the precise control of fluid flows. This accuracy is critical for maintaining optimal process conditions. When an actuator is nearing the end of its cycle life and begins to underperform, it can lead to inefficiencies, such as inaccurate flow rates or incomplete valve closures. These inefficiencies can affect product quality, yield, and overall system performance.

Kinetrol's claim of up to 4 million operations for its rotary actuator isn't just a mere statistic; it's a statement of endurance, reliability, and superior engineering. This impressive feat provides engineers and plant maintenance staff with undeniable advantages in terms of cost savings, enhanced safety, and operational efficiency when operating industrial valves.

In essence, Kinetrol's commitment to pushing the boundaries with their rotary actuator's impressive operational capacity isn't just an engineering achievement. It's a boon to the industries that rely on such equipment. Through cost savings, heightened safety, and enhanced efficiency, Kinetrol's rotary actuator stands as a testament to how advanced engineering can profoundly impact industrial operations.

For more information, contact:
Kinetrol USA
https://kinetrolusa.com
972-447-9443

The Role of Industrial Valve Actuators

Kinetrol pneumatic actuators installed on pipeline.
Valves are essential to industry. Valve automation refers to
the electric, pneumatic, or hydraulic systems deployed to
open, close or position the valve.

Valves are essential to industries which constitute the backbone of the modern world. The prevalence of valves in engineering, mechanics, and science demands that each individual valve performs to a certain standard. Just as the valve itself is a key component of a larger system, the valve actuator is as important to the valve as the valve is to the industry in which it functions. Actuators are powered mechanisms that position valves between open and closed states; the actuators are controllable either by manual control or as part of an automated control loop, where the actuator responds to a remote control signal. Depending on the valve and actuator combination, valves of different types can be closed, fully open, or somewhere in-between. Current actuation technology allows for remote indication of valve position, as well as other diagnostic and operational information. Regardless of its source of power, be it electric, hydraulic, pneumatic, or another, all actuators produce either linear or rotary motion under the command of a control source.

Thanks to actuators, multiple valves can be controlled in a process system in a coordinated fashion; imagine if, in a large industrial environment, engineers had to physically adjust every valve via a hand wheel or lever! While that manual arrangement may create jobs, it is, unfortunately, completely impractical from a logistical and economic perspective. Actuators enable automation to be applied to valve operation.

Pneumatic vane actuator
with spring return and positioner
on plastic body valve.

Pneumatic actuators utilize air pressure as the motive force which changes the position of a valve.
Pressurized-liquid reliant devices are known as hydraulic actuators. Electric actuators, either motor driven or solenoid operated, rely on electric power to drive the valve trim into position. With controllers constantly monitoring a process, evaluating inputs, changes in valve position can be remotely controlled to provide the needed response to maintain the desired process condition.

Manual operation and regulation of valves is becoming less prevalent as automation continues to gain traction throughout every industry. Valve actuators serve as the interface between the control intelligence and the physical movement of the valve. The timeliness and automation advantages of the valve actuators also serve as an immense help in risk mitigation, where, as long as the system is functioning correctly, critical calamities in either environmental conditions or to a facility can be pre-empted and quickly prevented. Generally speaking, manual actuators rely on hand operation of levers, gears, or wheels, but valves which are frequently changed (or which exist in remote areas) benefit from an automatic actuator with an external power source for a myriad of practical reasons, most pressingly being located in an area mostly impractical for manual operation or complicated by hazardous conditions.

Thanks to their versatility and stratified uses, actuators serve as industrial keystones to, arguably, one of the most important control elements of industries around the world. Just as industries are the backbones of societies, valves are key building blocks to industrial processes, with actuators as an invaluable device ensuring both safe and precise operation.

More Kinetrol Vane Actuators Hard at Work!

Here is a another short video of Kinetrol pneumatic vane actuators taking on some of the toughest industrial valve and damper applications.

Kinetrol engineered the first rotary vane actuators in 1958. The rotary design is based upon a single moving part which eliminates additional parts required to convert linear motion to rotary motion. This simple and innovative design provides a highly accurate and extremely reliable actuator for operating valves, drives and dampers, and is perfectly suited for the most demanding process control control applications.

For more information visit http://www.kinetrolusa.com or call 972-447-9443.

Fit and Forget, Worry-free Pneumatic Valve Actuators

Here's a short, narrated introduction to the Kinetrol vane actuator and their use on industrial valves. Kinetrol's 60 years of applying "fit & forget, worry about something else" actuators has rightfully earned their reputation for being the most durable, long-lasting valve actuator on the market today - a statement backed by a 4 million cycle warranty and documented, real-world field installations where the actuator provided upwards of 30 million maintenance-free cycles.

For more information, visit http://www.kinetrolusa.com.

What Is a Vane Actuator?

Inside view of a vane actuator showing the clam-shell
design, internal chamber layout, and double-sided vane.

Vane actuators use pneumatic or hydraulic power to open, close, or modulate quarter-turn valves, dampers, louvers, as well as for precise movement of ergonomic lifting equipment.

Linear motion gas/hydraulic cylinder or piston actuators use gears to convert linear to rotary motion. Vane actuators employ a rigid vane inside a sealed chamber that is connected directly to the drive shaft at one end with no gears. The result is much smoother rotary movement and greater cycle life.

Vane actuators operate by introducing a fluid or gas to either side of it's enclosure through inlet/outlet ports, creating the force required for movement. Advanced vane actuators utilize double sided vanes that allow for pressurization of both sides, allowing for bi-directional movement. The vane itself provides an arc movement in the far side (opposite the shaft) of the actuator, translating rotary movement back to its integrated shaft.

The vane actuator shaft is designed to connect directly to a device (valve, damper, ergo mechanism) for the transfer of movement. In advanced design vane actuators, the shaft is completely sealed from the pressurized side of the vane via “lip seals” which act to prevent the loss of air/gas/oil through shaft seals or bearings. With the help of spring steel supports, the lip seals are kept in constant contact with the inner surface of the chamber wall at all times during rotation. A side benefit of lip seals are the self-cleaning or sweeping action they provide to the inside chamber surfaces.

Since the double-sealed vane separates the vane actuator chamber in two sides, movement in either direction can be changed merely by creating a pressure differential on either side of the vane. Inlet/outlet ports allow for the pressurization and de-pressurization for either side. As gas or fluid is introduced to one side, the vane is forced away, toward the opposite side. By reversing the pressure and vent ports, and pressurizing the opposite chamber, the actuator moves in the opposite direction.

When vane actuators use only gas or fluid as their source for movement in both directions, they are referred to as “double acting”. When an optional spring is used to provide the power in one direction (open or close) they are referred to as “spring return”.

For more information on vane actuators, visit http://www.kinetrolusa.com

Vane Actuators Perform Better: Its All About the Gears (or Lack Thereof)

Why do vane actuators consistently outlast rack and pinion and scotch yoke actuators? The truth is in the gears.

Gears wear.

Surface wear, contact fatigue, scuffing and tooth bending are all real-life issues when dealing with gears. Surface wear affects gear contact in such a way that accelerates failure modes by increasing contact stresses and load distributions. This always leads to reduced accuracy and loss of smooth operation. Wear can never be completely eliminated, and over time, progresses at a more rapid rate.

Typical rack and pinion design - note gear arrangement

Types of Stress on a Gear

• Sliding stress - causes surface fatigue damage.
• Rolling stress - causes contact fatigue damage.
• Bending stress - like a cantilever beam, always deforms. 

Vane actuator - no gears

Pure simplicity - the rotary vane.

One moving part. No gears.

The rotary vane actuator design is based upon a single moving part which eliminates gears required to convert linear motion to rotary motion. This simple and innovative concept provides an extremely reliable mechanism for operating valves, drives and dampers.

More Accurate Control

Another advantage rotary vane actuators have over rack & pinion and scotch yoke actuators is in smoothness and accuracy of control. The more mechanical connections the actuator has, the greater the cumulative hysteresis, and the lower the control responsiveness and accuracy.

For long, trouble-free performance, choose a rotary vane actuator for your next valve actuation or damper drive requirement. You'll be very glad in the long run. 

Installation, Operation & Maintenance Instructions for Kinetrol Rotary Actuator: Double Acting & Spring Return Models

The Kinetrol rotary vane actuator is based upon a single moving part that converts linear motion to rotary motion. Since 1958 it has been a true workhorse solving the most demanding valve actuation applications. Millions of actuators are used around the world operating valves, drives and dampers with flawless performance.

As a matter of convenience and support, we are posting the general Kinetrol actuator IOM here for future reference.

Installation, Operation & Maintenance Instructions for Kinetrol Rotary Actuator: Double Acting & Spring Return Models from Kinetrol USA

Warehouse Palletizers Rely on Kinetrol Actuators for Trouble-free Performance

Palletizer gripper head with
Kinetrol actuator

In today’s highly automated fulfillment centers, distribution centers, and warehouse automation operations, fast, efficient and reliable packaging automation is the key to the company’s success. Complete packaging systems seamlessly connect an array of subsystems to form a cohesive, highly optimized, accurate packaging automation operation.

Palletizer with Kinetrol Actuators

One component is the palletizer subsystem. The palletizer subsystem provides automatic stacking of products on top of a pallet.

More sophisticated palletizers have complex control systems to provide the speed, accuracy and control required for large scale operation. The control systems are made up of computers, PLCs, proximity devices, and optical instruments. For product movement, transfer, and placement, palletizers rely on highly accurate pneumatic, electro-pneumatic, and electro-hydraulic motors, actuators, and drives.

Palletizer in plant.

Because of their high cycle life, smooth movement, precise control, and maintenance free operation, Kinetrol vane actuators have been very successfully used by palletizer OEMs. The actuator provides 90 degree and 180 degree rotation on the vacuum gripper head and pivot arms. During normal operation the Kinetrol actuators can see upwards of 20,000 cycle per day.

For more information on applying Kinetrol vane actuators to your packaging systems, contact:

Kinetrol USA
1085 Ohio Drive
Plano, Texas 75093
www.kinetrolusa.com
(972) 447-9443 phone
(972) 447-9720 fax

Kinetrol Vane Actuators Replace High Maintenance Pneumatic Cylinders in Water Treatment Plant

Kinetrol Rotary Vane Actuator

A Kinetrol USA Western Distributor was told by a water treatment plant operator that two 10" Pratt butterfly valves with cylinder actuators were not working reliably. The valves were okay, but the pneumatic cylinders were a maintenance nightmare. Not only did they introduce far too much hysteresis (slop) in the actuator-to-valve movement, but they also leaked air, and in the winter time had to have a heater placed next to them to keep the cylinders from sticking. The cylinder seals were so poor moisture would penetrate the cylinder and freeze, rendering the actuator unresponsive.

An experienced, application savvy Distributor came to the water treatment plant's rescue. After looking at the application the Sales Engineer specified new butterfly valves and Kinetrol Model 14 double acting actuators, manual gear overrides, AP positioners with I/P, ULS limit switches, angle retransmit, and point-of-use filters.  He knew the Kinetrol actuators would not only eliminate the constant maintenance, but also provide much tighter control.

After 1 year of continuous service, the actuators have performed flawlessly without any downtime. The maintenance crew at the water treatment plant are so pleased they plan on standardizing.

Kinetrol Actuators. Field Tested. Application Driven.

Kinetrol actuators on butterfly valves for water treatment plant.

20" High Performance Butterfly Valve Closed in Under 1/2 Second!

Fast closing Kinetrol actuator

This video demonstrates how quickly a large butterfly valve can be closed with a Kinetrol vane actuator spring return unit. In this case, it's a 20" stainless steel high performance butterfly valve (HPBV) being tested in the shop.

You'll note the valve takes about 11 seconds to open, but only 0.4 seconds to close, using the Kinetrol spring return unit.

Quick closing valves are used in emergency situations to stop the flow of fluids that may contribute to uncontrolled combustion, cause backstream contamination, or allow spillage of hazardous materials.

6 Reasons Why Pneumatic Vane Actuators are Superior to Rack and Pinion Actuators

Rotary vane actuators offer distinct design and performance advantages.

1. Rotary vane actuators do not convert linear motion to rotary motion, unlike rack and pinion actuators. No additional gearing is required and no side loading is transferred to the actuator housing.
2. Vane actuator lip seals are the key to long life. The double opposing lip seal design, with stainless steel expanders, provides unmatched service life by using air pressure to improve the actuators seal-to-enclosure contact, and provide a “self cleaning” effect on the epoxy or PTFE internal finish.
3. The elimination of pressure bearing o-ring shaft seals. Rack and pinion actuators require shaft sealing o-rings that are exposed to the full supply air pressure used to operate the actuator. These o-rings wear, causing leaks, a drop in efficiency, and wasted energy through air consumption. Vane actuators' double opposing lip seals isolate the supply air pressure from the actuator shaft, requiring only a low friction bearing on the shaft.
4. Rotary vane actuators provide superior modulating accuracy. Because of the integral vane and shaft (machine from a single casting), lost motion or hysteresis is reduced dramatically which intern provides much tighter modulation and control. The vane actuators inherent low friction also reduces hunting and sticking.
5. Direct mount, modular design for springs, positioners, switches, and solenoids reduce space requirements and lower inventory costs. Since vane actuator accessories direct mount to various size actuators, there’s no need to inventory and keep track of mounting kits. 
6. Rotary vane actuator spring return units are designed to be virtually indestructible. Using low stress, clock springs reduces spring tension loss and metal fatigue. The housing for vane a actuator springs are sealed from the atmosphere, preventing corrosion of internal parts. Most importantly, these type of spring units provide the lowest torque loss which enables the section of smaller (less expensive) actuators.

Don't Get Racked Up ... Use Kinetrol Vane Actuators

Little video "commercial" about the virtue of Kinetrol Vane actuators over pneumatic rack and pinions actuators ...

Kinetrol vane actuators provide:

• Single moving part - Simplest and most reliable mechanism for quarter-turn rotary actuation.
• Close couple control modules - Fail-safe spring returns, limit switches, positioners and solenoid valves all close couple to the actuators.
• No cranks or gearing - No power loss or backlash - allows accurate positioning.
• Durable corrosion resistant finish
• Long maintenance-free life - Up to 4 million operations guaranteed.
• Compact - space saving - efficient: Best torque/size package available, fast operating speeds, best air consumption, proven design.

The Principles of Rotary Actuators

Variation of the rotary actuator.
(Kinetrol pneumatic vane actuator.)

A rotary actuator is an output device for a fluid power system that delivers an oscillating motion over a limited range in less than one full revolution of the circle.

A true rotary actuator produces work by direct action of fluid pressure against internal vanes. Work is defined as a force applied over a distance. Rotary actuators produce a special type of rotational work called torque.

Torque occurs when a force acts on a radius. Since rotary actuators operate at low speed with high torque, torque output rather than the horsepower is used for the rating and identification purposes. Speed is a secondary consideration when choosing a rotary actuator for a particular application.

The typical units of measurement for torque are foot pounds (lb·ft). For example, if a rotary actuator with an arm length or radius of two feet were used to lift the two hundred-pound weight, then the resultant torque required to accomplish the work would be 400 lb·ft.

Understanding the relationship between the output torque required and the physical set up a fluid system enables designers to determine the appropriate rotary actuator for each unique application.

The following video does an excellent job of illustrating the mechanics and the physics behind rotary actuators.

Very High Cycle, Coal Power Plant Butterfly Valve Application

One moving part. Simply the best.

A coal fired power plant was using old Powell gate valves with dual air cylinders and volume tanks. Because of high cycle rate (the valve cycles open/closed every 30 seconds), the Powell gate valves were breaking down constantly - leaking at first, then failing. Downtime for repair was costing a fortune.

Kinetrol Model 12

A local Kinetrol Distributor was called in to recommend a better solution. After discussing the capabilities of Kinetrol, the power plant decided to replace the gate valves with 6" high performance butterfly valves actuated with Kinetrol size 12 actuators, spring returns and limit switch packages. 

The result was a robust valve/actuator package that could handle the 120 cycles per hour required - truly a difficult application. As of two years in operation, both valve and actuator have been running reliably much to the delight of the power plant maintenance crew. 

High cycle coal fired power plant Kinetrol / HPBV application.

Vane Actuator for Pneumatic Power on Roll Lifting Machine

Kinetrol vane actuator on roll lifter.

There are many examples in machine design where the need for pneumatically driven, 90 ° rotation is required. One such application is a coil/roll lifting machine used to lift heavy rolls of material.

The machine is pneumatically operated and provides an expandable shaft that grabs and holds on to the center hole of the roll. The expandable shaft also prevents spiraling while lifting.  The roller can be tilted 90 ° so that it will be retrieved horizontally and vertically. A Kinetrol pneumatic vane actuator is used for the 90 ° movement because it provides very smooth rotation and has exceptional long cycle life.

See the equipment in operation below. Note the function and use of the vane actuator.

Thanks to the equipment manufacturer, JLM Teknik.

A Cheesy Application for a Kinetrol Actuator & Positioner

Kinetrol Actuator, Positioner and Spring on
Steam Line in Cheese Making Plant

High above the cheese factory floor, mounted to a 1-1/2 steam supply pipe is a lonely V-ported ball valve with a Kinetrol 097-120 actuator, spring  unit, and positioner. The valve is controlling 180 PSIG steam at 375 Deg. F. with the ambient air surrounding the actuator, positioner and spring unit at a constant 135 deg. F.

Its a tough application, and critical to keep running. Losing steam supply is very costly because of production losses and access to the valve is difficult.

The plant maintenance people tried a few of the more well-known valve/actuator packages without success. These packages would last a few weeks (a couple months at best), before failing. Frustrated and out of answers, the maintenance crew turned to a local Kinetrol Distributor salesperson for advice.

Knowing Kinetrol actuators, spring units and positioners are designed for the toughest applications, the salesperson specified the 097-120 on top of a Triad v-ported ball valve. Hopeful, but with little optimism, the maintenance crew installed the 1-1/2 control valve on the steam line and fired the system up.

For 11 months now (without any downtime), 24 hours a day, this lonely control valve, powered by a Kinetrol positioner and vane actuator, accurately throttles the steam supply and reliably keeps the cheese process line running.

Problem solved by Kinetrol!

The Kinetrol Universal Limit Switch

The Kinetrol universal limit switch box offers a wide range of signa ling options in a zinc alloy fully enclosed corrosion resistant case available for direct mounting onto Kinetrol rotary actuators,
or discrete mounting via an industry standard VDI/VDE interface onto any make of rotary actuator. Easy to wire and set up with real industrial-quality robustness. - Internally fitted options include AS interface digital communication and a 4-20 mA 2-wire modulating angle retransmit circuit.

Kinetrol Universal Limit Switch from Kinetrol USA

Kinetrol Solves the Toughest Pneumatic Actuator Challenges

Kinetrol pneumatic vane actuators are world-renowned for their high cycle rate, durability, sealed spring unit, and precise control.

Kinetrol provides a rugged, corrosion-resistant pneumatic vane actuator with only a single moving part.

This simple and innovative design provides a highly accurate and extremely reliable actuator for operating valves, drives and dampers, and is perfectly suited for the most demanding process control control applications.

The Kinetrol vane actuator is warranted to operate trouble-free for 4,000,000 (million) cycles.

For more information, contact:

KinetrolUSA
1085 Ohio Drive
Plano, Texas 75093
(972) 447-9443 phone
(972) 447-9720 fax
sales@kinetrolusa.com

Why Kinetrol Pneumatic Vane Actuators Are Superior in Design - in 20 Sec...

It's a bold statement, but it's backed up with decades of proven performance, millions of actuators in the field, and many happy customers.

• Single moving part - Simplest and most reliable mechanism for quarter-turn rotary actuation.
• Close couple control modules - Fail-safe spring returns, limit switches, positioners and solenoid valves all close couple to the actuators.
• No cranks or gearing - No power loss or backlash - allows accurate positioning.
• Durable corrosion resistant finish
• Long maintenance-free life - Up to 4 million operations guaranteed.
• Compact - space saving - efficient - Best torque/size package available, fast operating speeds, best air consumption, proven design.
• Millions of units in trouble free service all over the world
• Choice of male or female output drive square - easy to interface to application
• Unique serial number for identification and traceability

Kinetrol USA
1085 Ohio Drive
Plano, Texas 75093
(972) 447-9443 phone
(972) 447-9720 fax
sales@kinetrolusa.com

Use Vane Actuators on the Toughest Applications

Use vane actuators on
tough applications.

The "vane type" pneumatic valve actuator is well regarded for its simplicity in design and extremely long life, even in the toughest valve actuation applications.

The heart of this simple design, and the primary reason for such long life, is the "single moving part" - a one-piece shaft and vane that moves in response to the air pressure differential on either side of the vane. A rotary vane actuator has no gears or yokes which will wear and cause problems over time. Wear, movement slop, and internal corrosion are the most typical modes of failure for rack and pinion and scotch yoke actuators.

The video below illustrate the elegance and simplicity of the rotary vane actuator and its "single moving part".