Electric vs. Pneumatic Actuators: Which One is Right for You?

The choice between pneumatic and electric actuators is not always an easy one. However, the two technologies are so different that one can rarely be a replacement for the other. Many variations exist to meet the demands of the compressed air market. There are a few key points that can help you to decide between electric and pneumatic actuators. 

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This decision becomes easier by evaluating performance, productivity gains, component costs, and system costs. Whether you choose electric or pneumatic actuators will largely depend upon the applications that are required for your system. The technologies are quite different. They have their own distinct advantages and disadvantages. In best-case scenarios, both technologies are utilized by capturing the major advantages of each. 

Pneumatic Components 

Pneumatic actuators provide high force and speed in a low unit cost that has a small footprint. Force and speed are easily adjustable and independent of each other. The typical pneumatic application employs over-sized cylinders as a safety factor. This is common because pneumatic cylinders are inexpensive. Stepping up to the next larger diameter is feasible and practical. 

Advantages

• Low cost: Pneumatic actuators are less costly than electric actuators . Pneumatic systems generally have long operating lives and require little maintenance.  
• High force and speed: Due to their simple design, pneumatic actuators can provide rapid movement and high force as long as adequate compressed air pressure and flow are available 
• Simplicity of operation: Pneumatic systems are easier to design and use than their electrical counterparts in many applications. Pneumatic cylinders and actuators provide a quick path to linear motion.  
• Sophisticated transfer mechanisms are not required: Fluid power systems require air or fluid to transmit energy. Pneumatic systems use the atmosphere as the source of their fluid. 
• Tolerance to overloads, up to a full stop: Pneumatic system components do not burn or get overheated when overloaded.  
• High reliability of work: Pneumatic systems offer a long service life, reliability, and are low maintenance.  They can withstand extreme temperatures, shock and vibration. 
• Explosion and fire safety: Being pneumatically powered they can be used in hazardous environments without causing fire or explosion.  When properly configured they can withstand most damage and resist corrosion.
• Pneumatic system components are very durable: They are reliable and not easily damaged.  
• Ease of assembly: Due to its straightforward design, installation of a pneumatic actuator is a relatively quick process.

Disadvantages

• Difficult to attain mid-stroke positioning: Mid-stroke positioning requires adding hardware to hit the third position.  
• This results in positional performance that is not very accurate or repeatable. 
• Difficult to maintain uniform and constant speed: Due to compressibility, it is not always possible to have a uniform and constant speeds. 
• Difficulties in performance at slow speeds: Due to the compressibility and pressure loss of the air, the pneumatic system has less efficiency as compared to other techniques.  
• Requires clean, dry air for maximum performance and life expectancy: Minimizing costs could produce a compressed air system that is contaminated by water, oils, particulates, or micro-organisms. This can lead to higher expenses for equipment maintenance and replacement. 
• High maintenance and operating costs of the compressed air system: Approximately 25% of the cost of compressed air is due to maintenance, equipment, and installation. More than 75% is due to electricity costs. 

Electric Components 

Electric actuators provide precise control and positioning, help adapt machines to flexible processes, and have low operating costs.  They are most economical when deployed on a moderate scale.  This is especially true in processes where their performance advantages can be a benefit.  They are economical when the electronics are separate from the actuator, to segment and minimize replacement costs. 

Advantages

• Precise control: Electric actuators offer outstanding precision and repeatability. They perform fast and powerful movements with flexible positioning. 
• Multiple positioning: Electric actuators can precisely and accurately control velocity as well as acceleration and deceleration throughout the motion profile. They can be changed from one speed to another without stopping or over-running position.
• Low operating costs: An electric system is energy efficient and can provide you with cost savings. 
• They help adapt machines to flexible processes: Not only do Electric actuators provide accurate control and positioning, operation can easily be modified by making simple program changes.
• Minimal maintenance: They can offer reduced maintenance and costs of ownership since they don’t require a compressed air system and don’t suffer air leaks.
• Easy to set acceleration and deceleration: Electric actuators can precisely and accurately control velocity as well as acceleration and deceleration throughout the motion profile. They can be changed from one speed to another without stopping or over-running position. 

Disadvantages

• Higher cost: Component costs are usually higher for an electric actuator system versus a pneumatic one.
• Sensitivity to vibration: Vibration can cause part fatigue and breakage, component wear, loss of performance, and damage to accessories.
• Technology is more complex: This can lead to higher production costs than the alternatives. 
• High speeds, less thrust: Electric actuators tend to lack the speed and thrust associated with pneumatics. Thrust must be sacrificed to achieve high speeds and vice versa. 

The goal of any industry’s air compressor system is to increase process efficiency while minimizing costs. 

This can only be attained by ensuring that the appropriate equipment is integrated relative to system demands.  Pneumatic actuators have advantages in cost, size, and thrust.  On the other hand, electric actuators are best when speed, accuracy, flexibility, and control are required.  An assessment of your needs and equipment can help you to find the right balance while increasing performance and reliability. 

What if I have questions about Electric and/or Pneumatic Actuators? 

At JHFOSTER, one of our technicians would be happy to speak with you about choosing the right Actuator for your process. Our expertise is in working with our clients to help them achieve optimal efficiency in their facilities. JHFOSTER is a leading distributor of automated systems and robotics. 

Contact us to discuss your requirements of Electro Pneumatic Valve. Our experienced sales team can help you identify the options that best suit your needs.

A JHFOSTER representative is available at 651.998. or 855.688. 

• Senior Vice President of Automation Integration Group, Tavoron Tim Swedberg, a senior executive with over 30 years of experience in automation integration, is currently serving as Senior VP at Tavoron, where he leads the Automation Integration Group. Previously, he was VP of Global Operations at BW Packaging and founded PASE Group, combining technical expertise and strategic leadership to drive innovation in industries like packaging and food & beverage. Tim holds a Bachelor of Science in Mechanical Engineering with a Minor in Applied Mathematics, and a Bachelor of Science in Engineering Management from the University of North Dakota. He also earned an Associate of Science in Engineering from Minnesota North College.

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.

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.

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. 

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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