Converting From Pneumatic to Electric Actuators
- 3 days ago
- 3 min read
Exlar® Electric Actuators
Modern electric actuators can deliver the force manufacturers need while reducing energy use, maintenance, leaks and downtime.
Why Convert From Pneumatic to Electric Actuators?
Pneumatic actuators have long been a standard for many applications in manufacturing. They provide cost-effective actuation under certain conditions - including an underlying compressed air infrastructure..
But, pneumatic systems carry significant downsides and risks that are eliminated and/or mitigated by electric actuation.
Electric vs Pneumatic
Efficiency
Electric actuators only require power when moving. Pneumatic systems invariably leak and these leaks cost energy. This, and other efficiencies leave them operating with a significant overall energy consumption advantage and reduced utility consumption.
Maintenance Ease
Electric actuators require very little maintenance through their lifecycle and repair/replacement is simple. This leads to less downtime and a more predictable and profitable production cycle.
Workplace Noise and Cleanliness
Pneumatic actuators are loud and pneumatic systems often have noisy leaks. Compressed air forms condensate water that must be dealt with as well. Electric systems are clean and quiet and supportive of a pleasant, productive work environment.
Performance and Stability
Modern electric actuators provide the thrust and force necessary for many applications that have traditionally used pneumatic actuation. Electric actuators can also perform more complex work and can be programmed for multiple stop positions.
Environmental Impact
Electric actuation completely eliminates the contamination risks and costs associated with pneumatics. Pneumatic systems create water condensation and leaks with multifaceted costs - including environmental issues, lost production time and worker safety - for manufacturers and production teams.
Data and Automation
Electric actuators integrate with servo systems designed and built for modern automation and diagnostic processes, including IIOT. Easy to plan and execute machine maintenance and reduce downtime.
Bottom Line: Electric actuators offer significant advantages vs. pneumatic actuation systems and can significantly reduce costs and improve bottom line for manufacturers and OEMs.
Comparing Pneumatic and Electric Actuators
Category | Electric System | Pneumatic System |
Efficiency & Emissions | ||
Energy Usage | Low | High |
Green-house Emissions | Zero-Emissions | High |
Cost | ||
Actuator Price | Higher | Lower |
Installation Labor Price | Lower | Higher |
Performance | ||
Time to Open/Close | As little as a second; speed does not affect actuator life | As fast as several seconds, quick speeds negatively affect system life |
Controllable Thrust/Speed | Programmable speed, position, thrust | Very limited |
E-Stop Mid-Stroke | Easy | Requires external brake |
System Construction | Robust design | Limited life |
Maintenance | ||
Repair & Replace | Easy, just replace the actuator (or servo motor) | Easy to replace, complicated to diagnose |
Ongoing Maintenance | Minimum system components for minimum maintenance | Maintain fittings, hoses, compressor, supporting air components, mechanical wear |
Converting to Electric from Pneumatic Actuators, Do's and Dont's
An important part of getting accurate estimates in the initial cost equation when switching from pneumatic to electric actuators is making sure that the electric actuator is properly sized for the actual application. Pneumatic actuators are often over-sized and matching force specifications with electric actuators leads to needlessly inflated costs for the new electric actuators.
Don't:
✗ Use current rated system pressure
✗ Use piston area plus measured system pressure
Do:
✓ Get a realistic work force estimate (we can help!)
✓ Work with your Young Mechatronics rep to test actuators in your machine or system!
USING SYSTEM PRESSURE AND PISTON AREA CAN OVER-ESTIMATE FORCE REQUIREMENTS OVER 60%
We’re Here to Help!
Young Mechatronics has worked with many clients to reap the benefits of electric actuation. Call or email to discuss your project. We are are trained engineers and will work with you from concept to completion to make your electric actuator conversion an ROI success story.
Reach out to us using the form below!
