Choosing the Right Voltage for Your Linear Actuator

Understanding Voltage Selection for Electric Linear Actuators

Selecting the correct voltage for your linear actuator is one of the most fundamental decisions in any motion control project. While it might seem like a simple binary choice between 12V and 24V systems, this decision cascades through every aspect of your actuator's performance—from speed and force output to efficiency, heat generation, and system reliability.

The voltage you choose determines not just whether your actuator will work, but how well it will work. An undersized voltage may leave your actuator struggling to meet force requirements or operate at impractically slow speeds. Conversely, mismatched voltage and power supply configurations can lead to voltage drops, excessive current draw, overheating, and premature component failure. For engineers and DIYers alike, understanding the interplay between voltage, current, motor design, and operational requirements is essential to achieving optimal performance.

This comprehensive guide examines the critical factors that should inform your voltage selection—from power supply compatibility and multi-actuator configurations to the fundamental differences in motor construction between 12V and 24V units. Whether you're building a custom TV lift, automating a camper van, or designing industrial machinery, the principles outlined here will help you make informed decisions that maximize efficiency, reliability, and longevity.

Power Supply Types and Compatibility

The foundation of any electric actuator system is its power supply, and not all power supplies are created equal. Understanding the characteristics of different power supply types is crucial because they directly affect actuator performance, reliability, and lifespan.

Unregulated Power Supplies

Unregulated power supplies are the most basic and economical option, converting AC to DC without voltage regulation. While their low cost makes them attractive for budget projects, their output voltage contains significant ripple—periodic fluctuations that can cause inconsistent actuator performance. For applications requiring precise positioning or smooth motion, such as feedback actuators in automation systems, unregulated supplies are generally unsuitable. They may work adequately for simple on-off applications where speed and position consistency aren't critical.

Linear Regulated Power Supplies

Linear power supplies transform and regulate AC to produce clean, stable DC voltage with minimal ripple. They achieve this through continuous regulation, essentially dissipating excess energy as heat. While this produces excellent voltage stability—ideal for precision applications—it comes at the cost of efficiency. Linear supplies are typically 50-60% efficient, meaning nearly half the input power is wasted as heat. They're also heavier and bulkier due to large transformers. For stationary installations where space and weight aren't constraints, linear supplies offer reliable, noise-free operation.

Switching Power Supplies

Switching power supplies represent the modern standard for most actuator applications. By rapidly switching power transistors on and off at high frequencies, they achieve 85-95% efficiency while remaining compact and lightweight. They generate less heat than linear supplies, making them safer and more practical for enclosed installations. Quality switching power supplies provide stable output voltage with adequate current capacity for demanding actuator applications, making them the preferred choice for both mobile and stationary installations.

Matching Supply Specifications to Actuator Requirements

When selecting a power supply, voltage rating is just the starting point. Current capacity must meet or exceed your actuator's peak draw, typically occurring during startup and under maximum load. For example, if your actuator draws 5A at peak load, a 7-8A supply provides adequate headroom to prevent voltage sag. Additionally, consider duty cycle—actuators running continuously require supplies rated for 100% duty cycle, while intermittent use may allow for lighter-rated supplies. Always verify that your power supply's specifications align with the actuator's electrical requirements outlined in its datasheet.

Powering Multiple Actuators: Series vs. Parallel Configurations

Many projects require multiple linear actuators working together, such as synchronized TV lifts or multi-point adjustable platforms. How you wire these actuators—series or parallel—fundamentally affects system performance and reliability.

Series Wiring: Voltage Division

In a series configuration, actuators are connected end-to-end, with current flowing through each actuator sequentially. The supply voltage is divided among the actuators, meaning two 12V actuators in series each receive only 6V. This results in dramatically reduced speed and force output, as motors operate far below their rated voltage. Series wiring is rarely recommended for actuators except in highly specialized applications where voltage reduction is intentionally desired. For standard installations, series wiring should be avoided as it leads to underperformance and may prevent actuators from generating sufficient force to move their loads.

Parallel Wiring: Current Multiplication

Parallel wiring connects all actuators directly to the power supply voltage, ensuring each receives full rated voltage. The trade-off is that current draw multiplies—two actuators each drawing 3A will draw 6A total. This is the standard configuration for multi-actuator systems, as it maintains performance while only requiring a power supply with sufficient current capacity. When planning parallel installations, calculate total current draw by summing the peak current of all actuators, then select a supply rated for at least 125% of this value to provide operational margin.

Individual Power Supplies for Enhanced Reliability

For mission-critical applications or systems with diverse actuator types, individual power supplies for each actuator or actuator pair offer maximum reliability and performance consistency. This approach isolates electrical issues, preventing a fault in one actuator from affecting others. It also allows mixing of different actuator voltages or current requirements within the same system. While more expensive initially, individual supplies can simplify troubleshooting and enhance overall system robustness, particularly in industrial actuator installations where downtime is costly.

Understanding and Preventing Voltage Drops

Voltage drop is one of the most common yet preventable causes of actuator underperformance. When current flows through wire, the wire's resistance causes voltage loss proportional to both current draw and wire length. A 12V actuator receiving only 10V due to voltage drop will operate slower and with reduced force, potentially failing to complete its intended motion.

Factors Affecting Voltage Drop

Several variables determine voltage drop magnitude. Wire length is the most obvious—longer runs mean more resistance and greater voltage loss. Wire gauge (AWG) is equally critical; thinner wires have higher resistance per foot. A 20 AWG wire has four times the resistance of 14 AWG wire of the same length. Current draw directly affects voltage drop through Ohm's Law (V = I × R)—doubling current doubles voltage drop for a given wire. Finally, conductor material matters: copper's low resistivity makes it the standard choice, while aluminum requires larger gauges for equivalent performance.

Calculating Acceptable Voltage Drop

Industry standards typically recommend limiting voltage drop to 3% or less for optimal motor performance, though 5% is sometimes acceptable for less critical applications. For a 12V system, 3% equals 0.36V drop, while 24V systems can tolerate 0.72V before reaching the same percentage threshold. This is one practical advantage of 24V systems—the same percentage drop represents a larger absolute voltage, providing more tolerance for longer wire runs or higher currents.

Practical Solutions for Minimizing Voltage Drop

The most effective solution is using adequately sized wire. For runs under 10 feet with currents below 5A, 18 AWG is typically sufficient. For 10-25 foot runs or higher currents (5-10A), step up to 14 or 16 AWG. Runs exceeding 25 feet or currents above 10A may require 12 AWG or heavier. When wire routing allows, shortening the distance between power supply and actuator directly reduces voltage drop. For unavoidable long runs, consider placing the power supply closer to the actuator rather than at a central control location. Additionally, ensure all connections are clean and tight—corroded or loose terminals add resistance that compounds voltage drop issues.

12V vs. 24V Actuators: Engineering Differences and Performance Characteristics

The choice between 12V and 24V linear actuators extends far beyond simple voltage compatibility. These two voltage classes represent fundamentally different motor designs, each optimized for specific performance characteristics and application requirements.

Internal Motor Construction Differences

The DC motors inside 12V and 24V actuators are engineered differently to operate efficiently at their respective voltages. A 12V motor features fewer coil windings wound with thicker wire. This lower-resistance design allows adequate current flow at lower voltage, producing the magnetic fields necessary for motor rotation. The thicker wire handles higher current without excessive heating, as 12V systems draw roughly twice the current of equivalent 24V systems for the same power output.

Conversely, 24V motors incorporate more coil windings using thinner wire. The increased number of turns generates stronger magnetic fields at the same current level, while higher resistance limits current flow to safe levels. This design enables more efficient operation at higher voltages, with improved power density—more output from the same physical package size. The materials used in 24V motor construction are often specified for better thermal performance, as higher voltage operation can generate more heat under sustained loads.

Speed Performance Comparison

Voltage directly influences motor speed in DC systems. For identical actuator designs operating at different voltages, the 24V version typically operates 50-100% faster than its 12V counterpart. This speed advantage stems from higher voltage driving faster motor rotation, which translates through the actuator's gearbox to faster linear extension and retraction speeds.

For applications requiring rapid motion—such as automated doors, TV lifts that must complete their cycle quickly, or industrial machinery with short cycle times—24V actuators offer clear advantages. However, many applications don't require maximum speed, and 12V actuators provide perfectly adequate performance for adjustable furniture, solar tracking, vent opening, and similar moderate-speed applications.

Force Output Comparison

Force output is determined by motor torque multiplied by the mechanical advantage of the actuator's gearbox and lead screw. Because 24V motors can deliver more power (power = voltage × current), they typically provide 30-50% higher force output than mechanically similar 12V units. This increased force capability makes 24V actuators better suited for heavy-duty applications such as industrial actuators moving large loads, automotive applications, or any scenario where maximum pushing or pulling force is required.

It's important to note that force ratings are also influenced by gearbox design and gear ratio. High-force 12V actuators with appropriate gearing can match or exceed the force of lower-geared 24V units. However, when comparing actuators of similar mechanical design, the 24V version will consistently deliver higher force capability.

Efficiency and Heat Generation

From an electrical efficiency standpoint, 24V systems offer advantages in multi-actuator and long-wire-run installations. Because power (watts) equals voltage times current, achieving the same power at 24V requires half the current of a 12V system. Lower current means reduced I²R losses in wiring, less voltage drop, and the ability to use smaller gauge wire. This becomes particularly significant in mobile installations like RVs or boats, where wire routing through walls and compartments can involve substantial distances.

Heat generation within the actuator itself is primarily determined by load conditions and duty cycle rather than voltage. However, 24V motors' more efficient design and lower current draw can result in slightly cooler operation under sustained loads, potentially extending motor brush and gearbox life in continuous-duty applications.

Application-Based Voltage Selection Guide

Mobile and Automotive Applications: 12V

Twelve-volt actuators are the natural choice for mobile applications where 12V power systems already exist. Cars, trucks, RVs, boats, and campers all feature 12V electrical systems, making 12V actuators plug-and-play compatible. Common applications include sliding door automation, bed lifts, storage access systems, solar panel adjustments, and vent controls. The ubiquity of 12V power in vehicles eliminates the need for voltage conversion, simplifying installation and reducing component count. For these applications, 12V actuators offer the perfect balance of performance, efficiency, and system compatibility.

Industrial and High-Performance Applications: 24V

Twenty-four volt systems dominate industrial automation, robotics, and machinery applications. The higher voltage provides the speed and force required for demanding duty cycles and heavy loads characteristic of industrial actuators. Manufacturing equipment, automated assembly lines, material handling systems, and agricultural machinery commonly employ 24V control systems. The reduced current draw at 24V also simplifies compliance with industrial electrical standards and reduces conductor sizing requirements in large installations. For applications requiring maximum performance, reliability, and integration with industrial control systems, 24V is typically the superior choice.

Residential and DIY Projects: Application-Dependent

Home automation projects can successfully utilize either voltage depending on specific requirements. For light-duty applications like TV lifts, drawer slides, cabinet doors, or window openers, 12V actuators provide adequate performance with the advantage of compatibility with common 12V wall adapters and power supplies. Projects requiring faster operation or higher forces—such as heavy furniture, large panel movements, or standing desks—benefit from 24V actuators. Consider power supply availability, wire routing distances, and performance requirements when selecting voltage for residential applications.

Battery-Powered and Off-Grid Systems

For battery-powered installations, 12V often proves more practical due to the widespread availability of 12V battery systems, particularly lead-acid and AGM batteries common in solar and off-grid applications. While 24V battery banks can be created through series connections, 12V systems offer simpler battery management and wider component compatibility. However, if your solar or off-grid system already operates at 24V—common in larger installations—using 24V actuators eliminates the need for voltage conversion and its associated efficiency losses.

FIRGELLI Automations Voltage Options and Custom Solutions

FIRGELLI Automations offers comprehensive voltage options across our entire actuator product line. Our standard catalog includes both 12V and 24V versions of most actuator models, from compact micro linear actuators for light-duty applications to robust industrial actuators for demanding environments. Each actuator is paired with detailed specifications including voltage requirements, current draw at various loads, and recommended power supply ratings.

Our track actuators, bullet actuators, and feedback actuators are all available in standard 12V and 24V configurations, ensuring you can find the right voltage match regardless of actuator style. We also provide a complete selection of power supplies specifically matched to our actuators' electrical requirements, eliminating guesswork in system design.

For applications with unique voltage requirements—whether 48V for telecom installations, 36V for certain industrial standards, or other specialized voltages—FIRGELLI Automations offers custom actuator solutions. Our engineering team can modify motor windings and control electronics to accommodate virtually any DC voltage requirement for OEM and high-volume applications. Custom voltage actuators typically require minimum order quantities and extended lead times, but provide perfect integration with specialized power systems.

When selecting actuators for your project, we recommend using our online resources and technical datasheets to match actuator specifications with your application requirements. Our engineering guides provide detailed information on force calculations, mounting considerations, and electrical system design. For complex projects or custom requirements, our technical support team can provide application-specific guidance to ensure optimal actuator selection and system performance.

Making the Right Voltage Choice for Your Application

Selecting the appropriate voltage for your linear actuator system requires balancing multiple factors: existing power infrastructure, performance requirements, installation environment, and cost considerations. While 12V systems offer simplicity and compatibility with common mobile power sources, 24V systems deliver superior performance and efficiency in demanding applications.

The key to successful voltage selection lies in thoroughly understanding your application requirements before committing to a voltage standard. Consider not just immediate needs but future expansion—will you add more actuators? Might loads increase? Will the system need to operate faster? Answering these questions upfront helps avoid costly redesigns later.

Remember that voltage is just one element of a complete motion control system. Proper wire sizing, adequate power supply capacity, correct mounting brackets, and appropriate control systems all contribute to reliable, long-lasting actuator performance. By carefully considering each element and how they interact, you can design systems that meet performance requirements while maximizing efficiency and reliability.

Frequently Asked Questions

Can I run a 12V actuator on 24V or vice versa?

No, you should never operate an actuator at a voltage significantly different from its rating. Running a 12V actuator on 24V will cause excessive current flow, rapid overheating, and immediate damage to the motor windings and control electronics. The actuator may fail within seconds to minutes of operation. Conversely, running a 24V actuator on 12V results in severely reduced performance—the actuator will operate at roughly half speed with significantly reduced force output, and may not generate sufficient torque to move its load at all. Always operate actuators at their rated voltage for proper performance and longevity. Small variations (±10%) are typically tolerable, but doubling or halving voltage is destructive or ineffective.

What wire gauge should I use for my actuator installation?

Wire gauge selection depends on three factors: current draw, wire length, and acceptable voltage drop. For typical actuator installations, follow these general guidelines: For runs under 10 feet with currents up to 5A, 18 AWG wire is usually sufficient. For 10-25 foot runs or currents between 5-10A, use 14-16 AWG wire. For runs exceeding 25 feet or currents above 10A, step up to 12 AWG or heavier. Always calculate voltage drop for your specific installation—aim to keep drop under 3% of supply voltage for optimal performance. Use our voltage drop calculator or standard voltage drop tables to verify your wire selection. When in doubt, oversizing wire is inexpensive insurance against performance problems.

How many actuators can I run from a single power supply?

The number of actuators a single power supply can drive depends on the supply's current capacity and the actuators' combined current draw. Add the peak current draw of all actuators (found in their specifications), then select a power supply rated for at least 125% of this total. For example, if you have three actuators each drawing 4A at peak load, total draw is 12A, so you need a supply rated for at least 15A. Consider that actuators draw peak current during startup and under maximum load—if your application runs actuators sequentially rather than simultaneously, you can size the supply based on the maximum number running concurrently. For systems with many actuators or diverse voltage requirements, multiple power supplies may be more practical and provide better isolation against electrical faults.

Are 24V actuators more energy-efficient than 12V actuators?

At the actuator level, 12V and 24V units of similar design have comparable efficiency when operating at their rated voltages—both typically convert 50-70% of electrical input to mechanical work, with losses to friction, heat, and motor inefficiency. However, 24V systems offer system-level efficiency advantages, particularly in installations with multiple actuators or long wire runs. Because 24V systems operate at half the current of 12V systems for the same power, they experience lower I²R losses in wiring and connections. This translates to less wasted energy, reduced voltage drop, and the ability to use smaller gauge wire. For compact, single-actuator installations, efficiency differences are negligible. For larger systems, especially those with wire runs exceeding 15-20 feet, 24V systems provide measurable efficiency improvements.

Do I need a special power supply for linear actuators?

Linear actuators don't require specialized power supplies, but they do need supplies with appropriate specifications. The power supply must match the actuator's voltage rating (12V or 24V) and provide sufficient current capacity for the actuator's peak draw plus a safety margin. Most importantly, the supply must be rated for continuous duty if the actuator will operate for extended periods—some power supplies are rated for intermittent use only and will overheat under continuous load. Switching power supplies are generally preferred over linear supplies due to their higher efficiency, lighter weight, and better thermal performance. Look for supplies with overcurrent protection to prevent damage if an actuator stalls or becomes mechanically bound. FIRGELLI Automations offers power supplies specifically matched to our actuators' requirements, simplifying system design and ensuring compatibility.

Can I use a voltage converter to change from 12V to 24V or vice versa?

Yes, DC-DC converters can convert between voltages, allowing you to run 24V actuators from 12V sources or vice versa. However, this approach has important limitations. Converting 12V to 24V requires a boost converter capable of handling the actuator's full current draw—remember that power is conserved, so drawing 5A at 24V (120W) requires drawing at least 10A from a 12V source (plus converter inefficiency losses). This means your 12V power source must supply double the current, potentially requiring battery upgrades in mobile installations. Converting 24V to 12V uses a buck converter and is more efficient, but you sacrifice the performance advantages of 24V operation. Voltage conversion adds cost, complexity, and potential failure points. When possible, match actuator voltage to your available power source rather than adding conversion hardware.