7/12/23, 2:55 PM Eight selection criteria for actuation components | Plant Engineering

Home / Eight selection criteria for actuation components

Eight selection criteria

for actuation
components
Electromechanical systems offer
advantages over hydraulic and pneumatic
actuators
BY CHAD CARLBERG AND CHRIS DIAK
NOVEMBER 12, 2019

When deciding between fluid-driven and

electromechanical linear actuators, close
consideration of long-term benefits to the
intended end user can help original equipment
manufacturer (OEM) system designers maximize
both product value and return on investment
(ROI).

Fluid-driven actuators translate electric energy

motion through a column of air, gas, oil or other
media. While the motion they provide is simpler
than with other type actuators, the infrastructure
required to support them is not. Hydraulic
actuators require an external system of pumps
and valves; Pneumatic actuators require complex
air delivery systems. For both, stroke length is
defined by a mechanical hard stop.

Electromechanical systems can handle more

complex operations with a much simpler design.
An electric motor — through a belt gear, a worm
gear, a planetary gear or via a direct coupling —
rotates a ball screw, which translates the torque

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into axial force through an extension tube. All key

motion components are, or can be, self-
contained. Motion is controlled by a
programmable electronic signal.

System designers should consider the following

eight criteria when choosing between fluid-driven
and electromechanical actuators.

1. Motion profile control

As business volatility and complexity increase,
users of actuator-driven machinery and
equipment demand greater control over position,
velocity or force throughout the range of motion.
Fluid-driven actuators cannot provide this easily.
It is difficult for them to achieve the slow,
controlled speeds that may be needed in many
applications. To some extent, fluid-based
actuators can gain control using external
systems such as proportional regulators, valves
and encoders, but this adds cost and further
complexity.

Because electromechanical motion is controlled

electronically, the device can be programmed to
stop at any point along the stroke. Force and
motion profiles can be changed in software
without having to shut down and reconfigure the
machine. The increased controllability of
electromechanical actuators often can eliminate
the need for changeover when switching from
one product to another. In applications such as
packaging lines, where numerous package sizes
may run in a single shift, this can result in
significant savings (see Figure 1).
Electromechanical actuators also can be
networked, enabling functionality such as
synchronization, making it easier for end users to
work with unbalanced loads.

2. Impact on cleanliness and

safety
In addition to limiting control over the motion
profile, fluids make for a grimier, potentially
dangerous work environment. For example,
hydraulic fluids must be transported and stored.

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Ever-present leaks must be cleaned and can

contribute to slip-and-fall accidents on the plant
floor. Various filtration methods must be used to
reduce contaminants. When the fluid has fully
degraded, it must be changed and disposed of
carefully. Pneumatic actuators present similar
issues due to the presence of oil and other
impurities in compressed air supplies. The
exhausted air must be filtered to remove
impurities before it is released into the
environment.

Electromechanical actuators have no such

issues. Motion is in precision-fit metal parts,
which require only routine lubrication — or in
some cases no lubrication at all. Given that,
electromechanical actuators are especially
appropriate for use in sanitary applications that
require ultraclean operation such as in the food,
beverage, packaging, medical and electronics
manufacturing industries (see Figure 2).

Because all components are contained in sealed

modules with high ingress protection,
electromechanical actuators also are more
suitable for environments with higher
contamination risk: chemical plants, paper mills,
welding operations and outdoor applications.

3. Durability and maintenance

Just avoiding the grime and contamination of
fluids reduces pressure on maintenance
resources, but the greatest contributor to the
maintenance workload is the complexity of fluid-
based systems.

Routine, break/fix-style maintenance is essential

for fluid-based systems. Oil loses efficacy and
must be checked. Gaskets and seals are subject
to damage and wear. Infrastructure components
must be monitored and replaced as needed.
However, electromechanical actuators run longer
with no maintenance intervention, providing
consistent performance for the entire actuator
lifetime.

4. Ambient noise

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Noise is a significant issue with both hydraulic

and pneumatic actuators. A hydraulic system
consists of an electric motor, bearings,
rotor/stator assembly and a fan. The motor
drives a pump, which pressurizes hydraulic fluid
in the cylinder via a valve. The fluid is transmitted
through a system of tubing, hoses and fittings.

To maintain the pressure, this system must be

kept idling continually, which produces additional
baseline noise that often can be heard
throughout the plant, adding to ambient
environmental noise levels. This is such a
concern that products offering noise mitigation
on hydraulic systems are an industry in itself.

With pneumatic actuators, noise is mostly the

result of air leaks, which are frequently present.
Pressure losses and impurities found in
compressed air supplies impact pneumatic
actuators, causing increased energy usage and
noise levels.

By contrast, the design of electromechanical

actuators makes their operation quiet. This
technology is continuously advancing to achieve
quieter operation for use in applications not
possible for the other media actuators. For
example, there is an electromechanical actuator
on the market that operates with a sound level of
less than 45 dB — about the same as a typical
library.

5. Energy efficiency
Fluid actuators use energy very inefficiently
because they go through a two-step energy
conversion process. Hydraulic systems have the
advantage of being able to hold constant
pressure without having to apply additional
amounts of energy, but this requires keeping a
pump running continuously, even when the
actuator is not performing any work. With
pneumatic actuators, escaping air through leaks
increases energy usage and ambient noise levels.

In contrast, electromechanical technology uses

energy only when doing work, and does so with
high efficiency. More than 90% of the energy
applied to an electromechanical ball-and-roller
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screw assembly is converted to work. An

electromechanical device also can hold a load in
place without expending additional energy or
complex system assemblies.

6. Space efficiency
The fact that everything in an electromechanical
actuator can be self-contained in a compact unit
means that OEMs can make smaller machines.
This size reduction helps end users add
automation to smaller spaces, improving
efficiencies for both operation and space
utilization (see Figure 3). Certain manufacturers
have gone one step further in making actuators
with a single-mount capability, making it easier
for OEMs to deliver smaller systems.

7. Integration with other

applications
As industrial systems become smarter and more
connected, opportunities to optimize production
to new levels of quality, efficiency and cost
control are emerging. Many of these involve
exchanging operational data across workplaces
via the cloud. Fluid actuators are not as equipped
to play in those applications, as additional
hardware often is required to provide what is
integrated in electric actuators. This additional
technology requirement makes integrating fluid
actuators into process optimization or
modernization strategies more costly and
difficult at times.

Electromechanical actuators connect to

networks with only a few wires, making it easier
for them to exchange performance information
among actuation devices as well as with
optimization software.

8. Total cost of operations

While each selection criteria discussed thus far
translates into end user value to some degree, an
electromechanical actuator’s greatest
contribution is most likely its role in reducing total

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cost of operations. Greater control over the

motion profile means there is no need to buy
complex add-on components, servo valves or
other components to control operations.

Cleaner operation and reduced maintenance

contribute to the bottom line by reducing the
labor otherwise needed to monitor and repair
systems. Using electromechanical actuators
eliminates the expense of hydraulic oil
associated with traditional hydraulic systems.

Because electromechanical actuators run longer

without needed maintenance, manufacturers
save on replacement purchases and inventory
management. The ability for electromechanical
actuators to convert 90% of energy to work
allows a plant to save thousands in energy costs.
In energy intensive industries, energy cost
savings can justify upgrades to
electromechanical actuators with system
paybacks as quickly as one year.

More efficient space utilization can have a

significant financial benefit, especially in areas
where real estate values are high or on offshore
and remote operations. Going forward, it may be
that the greatest financial benefit of using
electromechanical actuators is in their readiness
for integration into the digital age. Companies are
making gains by pulling device data into asset
management software, enabling greater
predictive management of processes and assets.

A key aspect for system designers is ensuring

that the right components are selected and
integrated to deliver accuracy, efficiency,
precision, noise level and other performance
characteristics. Many companies manufacturing
electromechanical actuators offer online self-
service sizing and selection tools that enable
designers to accurately size and select linear
motion systems and other components.

Sharing the benefit

Most of the same features that make
electromechanical actuators more valuable than
fluid-based systems to end users also make it
easier for OEM system designers to deliver that
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value. Pneumatic or hydraulic technology

requires working with complex, space-consuming
infrastructures.

Electromechanical actuators are simpler and

easier to size. In a few steps, designers can
determine the required load and duty cycle, and
specify stroke and retraction length. Modern
configuration tools make this process even
easier. Once an actuator is determined, the end
user determines a location, mounts and wires it
with a few wires and the actuator is up and
running. Designers of fluid-based systems do
similar calculations but must consider the
additional system requirements of how to locate
and sustain the fluid supply to the actuator.

Because they deliver so many benefits to end

users, electromechanical actuators can help
OEMs field a more competitive offering. As they
are easier to work with and more versatile,
electromechanical actuators also can reduce
design and development costs.

Maximizing value and ROI

In addition to providing system designers with an
easier and more versatile motion component
than fluid actuators, electromechanical linear
actuators provide significant advantages to both
end users and OEMs. They are cleaner, easier to
integrate, control and maintain, quieter and more
energy efficient. In addition, they take up less
space — all of which contribute to a lower total
cost of operation and last longer without
maintenance. Hydraulic and pneumatic
alternatives have their place, but best practice is
to consider all alternatives when deciding which
actuation technology would be best for the
application.

Selecting motion control

components
As industrial technology advances, and
electromechanical actuators and other motion
control components expand in capabilities for
heavy duty applications, system designers are

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faced with a wide variety of options for their

projects.

Application and selection tools make it easier for

design engineers to select the right product for
their specific application needs, providing an
effortless navigation experience to help identify
the ideal actuator solution quickly.

To ensure the best fit, they should take into

account a handful of end-user considerations
when making their selections:

How much control will the end user have over

motion profiles?
How clean is the operating environment? What
are the potential hazards?
What is the stated life cycle? How much
maintenance is required?
How quiet is the system?
How energy-efficient is it?
How much space is required for operation?
How easy is it to integrate with other
applications?
What is the impact on total cost of operating?

Do you have experience and expertise with the

topics mentioned in this content? You should
consider contributing to our CFE Media editorial
team and getting the recognition you and your
company deserve. Click here to start this process.

Chad Carlberg and Chris Diak

Author Bio: Chad Carlberg is product line
manager, Linear Actuators-Americas with
Thomson Industries. He is responsible for all
aspects of the short- and long-term strategies of
the linear actuator business, including product
road maps and product development. He earned
his Bachelor of Science in Marketing at Butler
University and has been with Thomson for 15
years. Chris Diak is the Automation Product sales
manager at Motion Industries and has worked in
the electrical/automation field for 24 years, with

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the last 22 at Motion Industries. He earned a

BSEE from Clemson University.

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