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The bore size of a rotary actuator directly determines its torque output capacity – larger bore sizes generate significantly higher torque due to increased piston surface area and greater force multiplication through the actuator’s internal mechanisms.
Internal sensing integrates position feedback directly within the gripper body for compact design and protected sensors, while external sensing uses separate sensors mounted outside the gripper for easier maintenance and greater flexibility in sensor selection.
Maximizing pneumatic flow requires proper tube sizing using the 4:1 rule (tube ID 4x larger than orifice), low-restriction fittings with full-bore designs, minimized bend radii (6x tube diameter minimum), optimized routing with fewer than 4 direction changes, and strategic valve placement within 12 inches of actuators to achieve flow coefficients (Cv) that support maximum actuator speed while maintaining system efficiency.
Rotational backlash mitigation requires systematic measurement using precision encoders or laser interferometry to quantify angular play (typically 0.1-2.0°), mechanical solutions including anti-backlash gearing with spring-loaded split gears, pneumatic preloading systems that maintain constant torque bias, electronic compensation through servo control with position feedback, and design optimization using direct-drive configurations that eliminate gear trains entirely.
ISO 13849 compliant rotary actuator integration requires systematic risk assessment, proper Performance Level (PL) determination, validated safety function implementation, and comprehensive documentation—with actuator selection based on required Safety Integrity Level and fail-safe operation modes.
