I have intermediate skills with Arduino hardware and electronics. A friend of mine and I are building a linear actuator concept prototype that we hope to eventually take to market and distribute throughout the US. Our current linear actuator setup relies on external limit switches to govern the bounds of travel. The NEMA 23 (bigger actuator prototype uses 34) motor direction is controlled by a remote button setup. The primary requirement of the system, aside from ensuring safety, is to carry a load of 150+ lbs load (w/ safety factor).
Our problem statement:
We decided several weeks ago to integrate a second set of external limit switches just a short distance beyond each in the first set. Instead of using a signal line (via Arduino), as the first set of limit switches uses to bound the actuator travel, we run the voltage line of the motor through these second switches before it reaches the motor. We mean for this to shut off the motor if the traveling component goes beyond the intended first switch set positions.
For a number of reasons, this extra set of switches will not work in the final design of our product. Is there a better choice or all-in-one component that would work better for limiting travel and ensuring safety with a high torque motor? How can we guarantee the motor will stop when it hits the switch or component, even if there is a hardware failure or software error? I cannot seem to find other viable solutions for other similar commercial products that ensure safety on top of accomplishing the desired behavior.
Thank you for taking the time to read through my post. Have a blessed day!