Hydraulic vs Pneumatic vs Electric Actuators: Pros and Cons

Linear actuators can be powered by electricity, pressurized fluid, or air. In this post, we will break down the key advantages and disadvantages (pros and cons) of hydraulic, pneumatic, and electric linear actuators. Additionally, you will be able to see the key differences of an electric over hydraulic linear actuator or a pneumatic over electric linear actuator, for example.

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Pros and Cons of Hydraulic Linear Actuators

Hydraulic linear actuators utilize a piston-cylinder configuration. An incompressible liquid from a pump fills the cylinder and forces the piston to move. With increased pressure, the piston moves linearly inside the cylinder, and the speed can be adjusted by changing the flow rate of the fluid. A high-speed hydraulic actuator is not only fast, but can supply a significant force. The piston returns to its retracted position by either a spring-back force or fluid being supplied to the opposite side.

Advantages of Hydraulic Linear Actuators

• Hydraulic actuators can hold a constant force without the pump supplying more fluid due to the use of an incompressible fluid.

• They can produce very high forces and speeds.

• It can produce high speeds.

Disadvantages of Hydraulic Linear Actuators

• Hydraulic fluid can leak, which leads to a loss in efficiency. This can also lead to cleanliness issues.

• Require many accompanying components including a fluid reservoir, pumps, motors, release valves, heat exchangers, and noise reduction equipment.

• High maintenance systems with numerous components to monitor constantly.

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Pros and Cons of Pneumatic Linear Actuators

Pneumatic actuators function in a similar way to hydraulic actuators with the difference being the driving fluid is air rather than hydraulic fluid. The gas is compressed in a piston-cylinder setup which creates a linear force.

Advantages of Pneumatic Linear Actuators

• A pneumatic linear actuator is very simple. Most aluminium cylinders have optimal maximum pressure ratings which allows for a range of forces.

• A pneumatic linear actuator is often used in areas of extreme temperatures due to the safety of using air rather than hazardous chemicals or electricity.

• It is a low-cost option.

Disadvantages of Pneumatic Linear Actuators

• Pressure losses and the compressibility of air make pneumatic devices less capable than other linear motion methods. A compressor must run continuously to maintain the operating pressure even if there is no movement needed.

• Pneumatic actuators must be sized for a specific job in order to be efficient. This requires proportional sized valves, regulators, and compressors which raises the cost and complexity.

• The air can be contaminated by oil or lubrication, leading to downtime and maintenance.

 

Pros and Cons of Electric Linear Actuators

Electric linear actuators convert rotational motion into linear motion. Rotational motion is first generated by the electric motor. This high-speed rotational motion is then reduced by a gearbox to increase the torque that will be used to turn the lead screw. The turning of the lead screw results in linear motion of the acme drive nut. Think of it like driving a screw into a piece of wood, but rather than the screw moving towards the wood, the wood will be moving towards or away from the screw depending on the direction of rotation. 

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Advantages of Electric Linear Actuators

• Electric actuators offer the highest precision.

• Scalable for any purpose or force requirement.

• They can be easily networked and programmed quickly. Immediate feedback for diagnostics and maintenance is available.

• They provide complete control of motion, offering custom speeds, stroke lengths, and applied forces.

• They are quieter than pneumatic and hydraulic actuators.

Disadvantages of Electric Linear Actuators

• The initial cost is greater than that of pneumatic and hydraulic actuators.

• They are not suitable for all conditions, whereas a pneumatic actuator is safe in hazardous and flammable areas.

• The electric motors can be large.

 

Final Word

All three technologies have their place in the industry, but the flexibility of electric linear actuators, coupled with the fact that the price of electric components has been steadily decreasing over the years, makes them a more popular choice than they once were. Knowing what actuator is best for your application depends on your working environment.

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Introduction

 

The need for actuators has grown exponentially. Nearly everywhere you look, you can see one of the three types of actuator motion systems at work in an endless variety of applications. There are many misconceptions involving pneumatic, hydraulic, and electric actuators. While some of these ideas may be true, many of the notions we have associated with these motion components are outdated and need to be revisited. Whereas you may think that your application&#;s need for actuation rests on one specific type of actuator, technological advances have allowed us to reexamine the specifics of each, which could mean more than one option for your project. It is essential first to identify the primary way each type of actuator completes its job. 

 

 

What Are The Three Types Of Actuators?

 

Pneumatic Linear Actuators 

Pneumatic linear actuators are composed of a simple piston inside of a hollow cylinder. A manual pump or external compressor will move the piston within the cylinder housing. As this pressure increases, the cylinder will move along the piston's axis, creating the linear force needed. It returns to its original retracted length by either a spring-back force or providing fluid to the piston's opposite side.

 

Hydraulic Linear Actuators 

Hydraulic linear actuators are quite similar to pneumatic actuators, except for the use of an incompressible liquid supplied by a pump instead of pressurized air moving the cylinder in a linear motion. This hydraulic actuator comprises two essential parts: a control device, such as variable throttles (nozzles with slide gates or paired slide valves with an initial axial gap), and an actuation component, such as a piston or controlling valve slide. 

 

Electric Linear Actuators

Electric linear actuators &#; also called an electric cylinder, an electric cylinder actuator, or an electric lift cylinder &#; take the rotational force of a motor (electrical energy) and convert it into linear movement (torque). By rotating the actuator&#;s screw via the motor, the nut will move in a lineup and down, creating the load's push/pull effect. 

 

 

 

 

Each type of these actuators is essential to their appropriate application, but as mentioned before, significant advances in the manufacturing world have allowed for these motion devices to be interchangeable. Each has its advantages and disadvantages, so be sure to weigh the options before deciding on the right actuator for your project.

 

 

Advantages And Drawbacks Of Pneumatic, Hydraulic, And Electric Linear Actuators

 

Characteristics

Pneumatic

Hydraulic 

Electric 

Complexity

Simple system composition

Moderately complex system composition 

Control systems and motion components can work together in multiple complex configurations

Peak Power

High

Very high 

High 

Control 

Simple valves

User must

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Flexibility of motion control capabilities with electronic controller 

Position

Accuracy

Very difficult to achieve position accuracy

Mid-stroke positioning requires additional components and user support 

Positioning capabilities and velocity control allow for synchronization

Speed

Very high

Moderate

Moderate

Load Ratings

High

Very high

Can be high depending on the speed and positioning desired 

Lifetime

Moderate

Long

Long

Acceleration

Very high

Very high

Moderate 

Shock Loads

Able to handle shock loads

Explosion-proof, shock-proof, and spark-proof 

Limited ability to handle shock loads

Environmental

High noise levels

Hydraulic fluid leaks and disposal 

Minimal 

Utilities

Compressor. power, pipes

Pump, power, pipes 

Power only option 

Efficiency

Low 

Low 

High 

Reliability

Excellent

Good

Good

Maintenance

 

High user-maintenance

High user-maintenance

Little to no maintenance

Purchase

Cost

Low

 

High

 

High

 

Operating

Cost

Moderate 

High

Low 

Maintenance

Cost

Low

High

Low

 

Although advances in the manufacturing world have come quite a long way, there are still specific applications in which electric lift cylinders cannot compete with the load ratings, force, or speed necessary. Some environments are unsuitable for electric actuation and have a maximum velocity that cannot be exceeded. Although it is rare, electric actuators can overheat if there are extreme changes in the duty cycle or used outside of their warranty.

 

Shock loads on an electromechanical actuator affect its lead screw or bearing, resulting in the possibility of it affecting the entire system&#;s performance. Some electric actuators can have difficulty holding a locked position or have issues with backlash, usually dependent on the screw pitch. Although the electric motion system's initial cost may be more expensive than other actuators, the whole operation's increased efficiency coupled with the little to no maintenance required over its life span makes the total cost lower than different types of actuators. 

 

 

Summary

 

Each actuator type exhibits both good and bad characteristics that one must weigh when determining their application project's best solution. By deciding what features are non-negotiable from the start, you will begin to rule out particular actuators based on these needs. Suppose it comes down to two specific actuators, both able to do the necessary job efficiently. In that case, you may want to consider the entire cost of the system: this includes the initial investment, maintenance, and repair fees, as well as the cost of potential risks you could take with each motion component system. 

 

It is also essential to choose the right company to purchase your product for optimum results. TiMOTION is an industry-leading provider of electric linear actuators, capitalizing on a global team specializing in innovative solutions to manufacture the best products for industrial, furniture, medical, and ergo markets worldwide. We understand that the right technology can solve nearly any problem and that drop-in replacement, customizable electric linear actuators are used increasingly in applications that have outgrown pneumatics and hydraulics. TiMOTION strives to provide the highest quality, customizable components at competitive pricing. For more information, visit us online today at TiMOTION.

 

 

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