It’s quite a puzzle to select the best actuator for your needs, especially when you are trying to make a selection between electric and pneumatic options. Both have unique uses and benefits, but how do you determine the suitable one for your specific requirements?
But, have a seat, this blog will differentiate both actuators regarding precision, speed, force, cost, and more. It will enable you to make a well-informed choice while ensuring that your system runs smoothly and efficiently. Let’s start!
1) Understanding an Actuator?
An actuator is a machine component which is capable of producing motion. The actuator is used in controlling a mechanism, transforming the energy into rotational or linear movement. For example, the actuator will assist in the shifting of gears in a mechanism.
You can find actuators in almost all sectors, such as in factories, robots, automotive and even common household appliances. The primary function is to operate a control mechanism, such as opening and closing valves, the arms of the robot or shifting heavy containers. Moreover, the actuators can be divided into several groups. Electric and pneumatic are the most widely used.
Both have their unique benefits and can be used according to the situation. The actuator’s primary function is to perform a task based on a signal. As an illustration, if a control system sends a prompt, the actuator responds with a movement of a part. It is due to these reasons that the term “muscles” is frequently associated with the word actuator.
An actuator is the element that achieves this, thus making it the fundamental fragment needed for the independent functionality and automation of the parts.
2) Electric Actuators
In electric actuators, motion is achieved by electric energy. They apply to systems that need efficient and precise motion. Let’s take a look at their operation.
How They Work
For motion, electric actuators utilise an electric motor. The motor rotates when power is supplied, and this rotation is either converted into movement, depending on the configuration.
Manual Electric Actuators operate through the use of gears, screws, or belts within the actuator. Apart from this, some electric actuators also come with sensors that aid in the control of positional, speed, and force more finely. With the Aid of control systems, you can execute commands automatically.
In addition, electric actuators have no need for air or fluid. All that is required is a power source and a signal from a controller to commence movement. These attributes make electric actuators easy to maintain and implement in various environments. So, electric actuators are well-suited for applications requiring smooth, crisp, and clean movements.
Advantages of Electric Actuators
+ High Precision: Electric actuators’ willingness to accept inputs demonstrates their lack of restriction. You can tune their motion, speed, and position, proving crucial for work needing care, such as surgical equipment.
+ Simple to Use: The process is very straightforward. No need for pumps, air compressors, or additional valves. You just have to plug them into a power source and attach a controller.
+ Quiet Operation: Running electric actuators quietly is their strong suit. These would be ideal if there’s a need for a quiet environment, such as a lab, hospital, or office.
+ Energy Efficient: Power is consumed only while moving, and even then, the electric actuator doesn’t draw excess power. Well, it automatically saves electricity and running costs.
+ Clean and Safe: No fluid leaks or air release can happen. This is the reason why electric actuators are best suited in clean environments, for example, food production lines or medical areas.
Disadvantages of Electric Actuators
Irrespective of the many benefits electric actuators come with, electric actuators also have some drawbacks that you should keep in mind.
– Higher Initial Cost: Any type of electric actuator is more costly than the other types, and this cost will be even higher if extra features are involved. Yes, you’re right, this can be an issue if you’re on a limited budget.
– Insufficient Electric Power for Heavy Loads: If your application requires high torque or rapid relocation of heavy components, electric actuators may be underpowered. Obtaining the correct unit may mean purchasing an additional, larger and more expensive piece.
– Insensitive to Rough Environment: As is always the case, they are not designed for use in harsh conditions. Performance may be affected by water, dust, and extreme heat or cold. So, extra care might need to be taken with standard equipment, or a specially sealed version will have to be selected.
– Electrical Short Circuit Feasibility Problems: Because of their use of electricity, wiring needs to be handled carefully, as well as power surges. Apart from this, they need proper shielding to protect against short circuits or electrical disruptions.
3) Pneumatic Actuators
Pneumatic Actuators are one of the most common types found in almost every machine and automation system. They use compressed air as a force to move the rod. Their speed and strength, coupled with ease of use make them very desirable. Now, let’s take a look how do they work.
How They Work
What happens is that the air is compressed to a higher pressure. This air is allowed to enter the actuator, which then pushes a piston or a diaphragm, which moves the rod. In turn, the movement of the rod moves a component of the machine. Depending on the design, the motion can be either linear or rotating.
Once the air is let out, the actuator is positioned back to its starting place with the help of a spring or by applying air pressure on the opposing side. Well, an air compressor linked to a valve system provides these actuators with an uninterrupted supply of compressed air.
The speed and reliability of the working process make pneumatic actuators ideal for quick repetitive tasks and operations that require high speed.
Advantages of Pneumatic Actuators
Pneumatic actuators provide many strong advantages where basic motion tasks are concerned. So, if you are looking for a dependable actuator, these are optimal for many automated systems and adapt effortlessly to harsh conditions.
+ High Speed and Quick Response: From lifting to sorting, pneumatic actuators perform an array of functions at high speeds. Yes, these actuators are quick to respond to control signals and are ideal for tasks that require fast movement.
+ Strong Force Output: Pneumatic actuators do not need to be large to have high force output. Even small pneumatic actuators are capable of effortlessly moving hefty parts, which makes them invaluable in heavy-duty tasks. Great! Their high power-to-size ratio also aids in space conservation while still performing tough tasks.
+ Simple Design: The inside of these actuators is simple. Manufacturing, servicing, and part substitution become easy with reduced moving components. Moreover, the chance of major breakdowns is minimised, and repair time is low because of simple construction.
+ Cost-Effective: The first outlay incurred in buying pneumatic actuators is generally low. So, they are best suited when a large number of actuators are required simultaneously and the budget is tight.
+ Safe for Explosive Environments: Because they are non-electric, pneumatic actuators can be used safely in areas with flammable gases or dust where sparks might ignite an explosion. This feature makes them popular for mining, oil, and chemical industries.
Disadvantages of Pneumatic Actuators
As much as pneumatic actuators have benefits, it is important to have pneumatic actuators limitations in mind to make an informed decision for your project. Well, knowing the limits helps avoid problems and find the right fit for your system.
– Lower Precision: Compared to electric actuators, pneumatic ones are less precise. Highly specific and delicate tasks will not be performed well using these actuators. Due to this, they are best suited for PV cycles that require simplistic on/off actions instead of elaborate sequences.
– Uninterrupted Air Supply Required: An air compressor is a requisite, and a steady supply of air is compulsory for them to function. This adds to the running and set-up costs, more so in smaller systems. In case the air pressure is low, the entire process may get hampered.
– Very Noisy: During exhaustion of air, pneumatic actuators tend to be very noisy. This can pose a challenge for quiet work environments. So, noise-cancelling equipment might be required, which increases cost and consumes space.
– Risk of Air Leakage: With time, small air leaks may arise due to ageing hoses and worn-out seals. So, this is a loss in efficiency and can lead to higher costs in energy. Yes, if not properly maintained, these leaks slow down operations, leading to bigger problems.
– Less Energy Efficient: Pneumatic actuators fall behind electric ones due to being less overall efficient. Air compressors consume high amounts of energy, and with heat losses and leaks over time, this only adds up.
4) Key Comparison Criteria
Deciding if you want an electric actuator or a pneumatic one depends on what is more significant for your requirement. Below are four pointers which explain how you can make a rational decision.
i) Precision & Control
Electric Actuators: When compared to other options, electric actuators offer exceptional precision. They permit speed, position, and force settings to be finely controlled and adjusted. So, they are best suited for processes needing precise movement, such as robotics or medical devices.
Pneumatic Actuators: Less precise than electric ones, pneumatic actuators suit basic requirements best. They offer adequate control for basic tasks like handling materials or packaging.
ii) Speed & Force
Electric Actuators: Need controlled, smooth, and consistent movement? Electric ones are slower but suit such applications best. They are more appropriate for work with lighter loads.
Pneumatic Actuators: The best performers when it comes to speed, briskness & high force. These are perfect for high-speed operations and tasks involving lifting or motion repetition.
iii) Cost & Maintenance
Electric Actuators: These might prove to be a costly investment in the beginning but, offer a set it and forget it maintenance schedule as an energy saver. Electric actuators have considered issues making them not need maintenance, running into errors over time.
Pneumatic Actuators: More affordable at first, the long-term air drill core parts and the components suffer from being too high, compared to needing to be repaired more often.
iv) Safety & Environmental Considerations
Electric Actuators: They are the best suited for clean and quiet environments. So, these are best for indoor uses, but caution needs to be taken in wet or explosive settings because of the electrical danger.
Pneumatic Actuators: These actuators are best suited for explosive or harsh environments. Since they do not use electricity, they are much safer in these areas, though they are noisier and not as energy efficient.
5) Industry Applications
Both electric and pneumatic actuators are common in different fields of work. The difference comes into play based on speed, force, precision, and environmental conditions.
Electric Actuators Applications
Electric actuators shine in areas where accuracy and smooth control are paramount. Some of the industries that make use of electric actuators are:
- Robotics: Electric actuators are found in robotic arms and in automated assembly lines to control the speed and position because they can be controlled with high precision.
- Medical Equipment: For devices such as infusion pumps and diagnostic appliances, electric actuators ensure motion with precision and reliability.
- CNC Machines: Tasks that require fine control and steady motion, electric actuators are commonplace in CNC (Computer Numerical Control) machines.
- Electric vehicles: Electric vehicles (EVs) utilise electric actuators for steering, braking, and throttle control. Their importance in EVs is clear.
Pneumatic Actuators Applications
Applications that require high speed and force draw on pneumatic actuators, which are seen in the following industries:
- Manufacturing and Automation: In packaging systems, material transport, and conveyor belts, pneumatic actuators provide rapid and powerful movement.
- Food and Beverage: Machines that package, fill, and sort food use pneumatic actuators to provide swift movement.
- Oil and Gas: Offshore and hazardous environments utilise pneumatic actuators because of their safety in explosive atmospheres.
- Construction: Jackhammer and pneumatic drill operators rely on pneumatic actuators for heavy-duty tools.
6) Selection Guide: How to Choose
The actuator most suited to you will entirely depend on your requirements. With that in consideration, these are the six factors you should think about:
- Value of Precision: Electric actuators are better if you need fine control over speed, position and force. They execute movements well and are particularly desirable in the case of robotics or medical equipment.
- Speed and Force: For fast, heavy-duty tasks like lifting or material handling, pneumatic actuators tend to work better. They are fast and generate high force even in small sizes. Electric actuators, while being precise, are slower and more suitable for gentle, controlled movements.
- Energy Efficiency: Pneumatic actuators drive electric actuators because they require no compressed air, making them more energy efficient. If you don’t have an existing air compressor system, pneumatic actuators can become less efficient.
- Maintenance and Upkeep: Electric actuators tend to have fewer moving parts and therefore require less maintenance, while always keeping them in operating condition. Pneumatic actuators, however, require more upkeep for air leaks or wear and tear of hoses and seals.
- Pricing Factors: While pneumatic actuators might have a lesser initial investment, the energy payments can worsen the situation. Electric actuators are pricier to purchase, however, their low energy usage and maintenance make them cheaper in the long run.
7) BLCH Pneumatic Cylinders
BLCH Pneumatic Cylinders are designed specifically to turn compressed air into linear or rotary motion, enabling automation in many industries. They are made from cylindrical elements and construction parts uniquely designed to function efficiently in harsh conditions.
- Key Features
- Cylinders: Standard, compact, mini and double-acting cylinders are all part of the range, giving customers multiple options to choose from.
- Constructed Using High Quality Materials: The BLCH Pneumatic Cylinders are made of aluminium and stainless steel, enhancing their operational life.
- Compliance With ISO: A multitude of models do not comply with international standards such as ISO 6431, which is a barrier for trust, flexibility, compatibility and assurance.
- Rotary Mounting Styles: The BLCH Pneumatic Cylinders offer several mounting styles, with flange, foot and trunnion, which provide installation flexibility.
- Actuation: The requirements for extensive servicing make the BLCH Pneumatic Cylinders the go-to choice for maintenance-free operation.
- Uses
BLCH Pneumatic Cylinders are commonly utilised in:
- Manufacturing: Efficient in use in assembly and material handling systems.
- Packaging: Equipment for automated packaging and sorting.
- Robotics: Automation of systems and robotic arms.
- Food & Pharma: Clean surrounding areas requiring no contamination.
- Why BLCH?
- Quality Assurance: Extensive tests to confirm trust and effectiveness are conducted on all procedures.
- Customisation: Specific needs and requirements of an application can be customised.
- Global Reach: Available all over the world with full back support.
8) Conclusion
Electric and pneumatic actuators both have unique advantages for varying applications. Electric actuators are preferable for accurate and low-maintenance tasks due to their precise control and energy efficiency. Pneumatic actuators are best for demanding high-speed and high-force applications and industries that need fast and powerful action. The decision made will depend on the system requirements.
For dependable, high-performance pneumatic cylinders, we recommend BLCH Pneumatic. Our broad scope and durable construction, along with ISO certification, serve as a valid reason for their application in industrial automation, wherein smooth and efficient motion is required. You can contact us right now!
9) FAQs
1. Which actuator type is more energy efficient?
Out of all the options available, electric actuators have the best energy efficiency and savings features. They do not incur the extra cost of requiring compressed air, and since electric power is used for accurate control, less energy is spent.
2. Can pneumatic actuators deliver high precision?
While pneumatic actuators can deliver a reasonable degree of accuracy, their inability to control air pressure makes them significantly less accurate than electric actuators.
3. How do maintenance costs compare?
Due to fewer moving mechanical components, electric actuators have lower maintenance costs. However, the upkeep required for pneumatic actuators, tends to be more expensive.
