In the field of industrial automation, it is very important to choose the right actuator to achieve the best results. The global actuator market is growing at a fast pace and is expected to grow at a CAGR of 12.05% from 2022 to 2029, from $44.6 billion to $98.92 billion.
When it comes to actuators, there are two major categories: pneumatic actuators and electric actuators. Each has its own benefits and is appropriate for specific uses. This article will provide more information on each type of valve actuator and assist you in choosing the most suitable one.
What Is Pneumatic Actuator?
A pneumatic actuator is a mechanical device that converts compressed air into motion. It works by utilizing the force created by air pressure to push parts such as pistons or cylinders. The most common form is the pneumatic cylinder where air is pumped into the cylinder to push a piston and hence the linear movement.
This simple motion can be used to control valves, with common applications including valve control in industries such as oil and gas production, chemical processing, water treatment, HVAC systems, and manufacturing plants.These actuators are also used in automation machinery, robotics, and transportation systems.
The principle of its functioning is based on the pressure of the air, which affects the force and the movement produced. The force generated by the actuator is proportional to the air pressure and the size of the piston, which makes these actuators suitable for applications where the movement is direct, fast, and accurate.
What Is Electric Actuator?
An electric actuator is a device that is used to convert electrical energy into mechanical energy. It employs an electric motor to drive mechanical parts such as gears or screws to produce linear or rotational movement. The motor receives electrical energy in the form of AC or DC and converts this energy into mechanical energy to operate the actuator.
In this process, the electric motor is the most important part, which converts electrical energy into mechanical energy and transmits it. This motion is controlled accurately, and therefore electric actuators are suitable for use in applications that require high accuracy and precision such as automated manufacturing.
Key Differences Between Pneumatic and Electric Actuators
Having discussed the general information about pneumatic and electric actuators, it is time to compare the two types of actuators.
| Feature | Pneumatic Actuators | Electric Actuators |
| Response Speed | Fast (0.1 seconds) | Slower (0.3 to 1 second) |
| Control Precision | Accuracy of 1-2mm | High precision (0.01mm) |
| Force & Speed | Quick large force (1000 N < 0.1s) | Moderate force (up to 500 N) with precision |
| Temperature Suitability | Operates in the range of 5°C to 60°C | Operates in the range of -20°C to 80°C |
| Humidity Suitability | Up to 80% relative humidity | Suitable for up to 95% relative humidity |
| Maintenance Requirements | Less frequent, seal replacement and filter cleaning every 6-12 months | More frequent, grease gears every 3-6 months and inspect electrical circuits |
| Component Cost (Initial Cost) | $50 – $500 | $200 – $1,500 |
| Operating Cost | Higher (requires air compressor system) | Lower (energy-efficient) |
| Design | Simple structure, typically larger in size | More compact design, suitable for space-limited applications |
Response Speed
In terms of responsiveness and response time, pneumatic actuators are generally faster than electric actuators. Pneumatic actuators are capable of performing movements in as little as 0.1 seconds because of the high rate of application of air pressure, which makes them suitable for use in industrial automation processes that involve repetitive and fast operations such as valve operations. On the other hand, electric actuators are relatively slower with response time ranging from 0.3 to 1 second, this is because motors take some time to develop the required torque.
Control Precision
In terms of control, electric actuators offer accurate control and are more precise than other types of actuators. They can be accurate to within 0.01mm, which is ideal for applications that require precision, such as in the control of valves in delicate systems. However, pneumatic actuators are very reliable but they are not as accurate as hydraulic ones; they can only achieve an accuracy of about 1-2mm because of the fluctuating air pressure.
Force and Speed
Pneumatic actuators are particularly good at producing a large force rapidly, some models can produce 1000 N of force in less than 0.1 s. This makes them suitable for use in applications where there is a need for frequent and forceful movements. However, electric actuators are more versatile in terms of force and speed when it comes to controlling the movement with precision, especially in applications where both force and precision are important. For instance, they can apply forces up to 500 N with high accuracy, and the speed is 20-30 mm/s, while also regulating voltage for optimal performance.
Environmental Suitability
As for the environmental conditions, electric actuators are generally more suitable for a variety of conditions. They can work in a temperature range of -20°C to 80°C and are not affected by moisture, thus they can be used indoors and outdoors. Electric motors are not affected much by humidity and can operate in conditions of up to 95% relative humidity.
On the other hand, pneumatic actuators are not very suitable for wet or moist environments. They become a problem when exposed to high humidity or water such as in the case of air leakage and corrosion. Pneumatic actuators are most effective in conditions that do not exceed 80% relative humidity and temperatures between 5°C and 60°C. Therefore, electric actuators are used in most cases where the environment is unforgiving or varies in terms of temperature, humidity, etc.
Maintenance Requirements
Pneumatic actuators are relatively easy to maintain because they have few parts and rely on compressed air. However, some problems like air leakage or damage to the pneumatic valve may arise, which may reduce its efficiency, it requires frequent maintenance like replacement of seals and cleaning of filters every 6-12 months depending on usage.
In contrast, electric actuators need more frequent maintenance. This involves greasing gears every 3-6 months and inspecting electrical circuits for signs of wear or failure. However, electric actuators are generally more reliable in the long run, especially in applications where the actuator is used frequently, as they do not suffer from problems such as air leakage or moisture damage like pneumatic actuators.
Cost
Pneumatic actuators are relatively cheaper than other types of actuators, and their cost may range from $50 to $500 depending on the model. They also have lower replacement costs and are easier to install, which makes them suitable for projects that are not very large or where high accuracy is not required. However, they need an air compressor system which adds 20-30% to the overall operating cost due to energy consumption and maintenance.
Electric actuators are relatively expensive and cost between $200 and $1,500 for the initial investment. While they are more expensive to purchase initially, they are cheaper to operate in the long run, especially in applications that need fine tuning. In the long run, electric actuators are usually more cost effective, especially in applications that require high precision and low maintenance.
How to Determine the Best Actuator for Your Project
Selecting the appropriate actuator for the project depends on the requirements and limitations of the project.
First, decide whether linear or rotary motion is needed and then decide on the force, speed and accuracy required. Pneumatic actuators are used where there is a need for fast and powerful movement, while electric actuators are used where there is a need for precision.
Next, evaluate the power source. In situations where electricity is not easily accessible or is unavailable or in extreme conditions, the pneumatic actuators which are operated through compressed air may be more useful. On the other hand, if you require an actuator that is more energy-efficient and can be adjusted to a certain degree, then electric actuators can provide fine motor control of an electric motor.
Take into account the environmental conditions in which the actuator will be used. For example, if the application requires the use of high temperature, high humidity or exposure to hazardous substances, electric actuators are usually preferred because of their robust construction. In these conditions, pneumatic actuators can have problems such as air leakage or corrosion.
Also, it is important to evaluate the long-term costs of running the business and the maintenance costs. Pneumatic actuators are less complex in construction and use compressed air, which means they incur ongoing costs for air compression. These costs, including energy consumption for compressors and regular maintenance, are recurrent and in the long run. On the other hand, electric actuators are relatively more costly than pneumatic ones, but they are cheaper in the long run. They are easier to manage and are more suitable for use in systems that require constant tweaking or fine tuning, which makes them cheaper to maintain in the long run.
Last but not least, assess the space limitation in terms of the size and manner of installation of the actuator. Make sure that the actuator can be installed in the given area, especially in the case of a small space or certain conditions for installation. There are some applications where the equipment may be required to be compact or designed for a specific area of use.
By considering these factors, you can select the most suitable actuator for your project.
Why Choose Vincer for Your Project?
When selecting the actuator for the project, it is also important to consider the reliability of the actuator suppliers. Vincer is a reputable manufacturer that has been in the business of providing quality electric and pneumatic actuators for various industries.
We have completed over 800 projects and have over 650 happy clients, and we offer dependable, long-lasting, and affordable actuator systems. The products we offer are of the best quality and are designed to provide the best performance and accuracy. Vincer actuators are certified with ISO9001:2015 and CE, which means that they are long-lasting and meet all the necessary requirements.
If you are interested in high-performance actuator solutions for your system, please get in touch with Vincer to learn how our solutions can help improve your business.
Conclusion
In conclusion, it is clear that pneumatic and electric actuators are two different types of actuators that have their own advantages and disadvantages, and the choice between them depends on the specific project. Pneumatic actuators are suitable for applications that require fast, powerful and lower-cost movements, while electric actuators are suitable for applications that require accurate, durable and controlled movements. Thus, considering speed, precision, environmental conditions, and long-term costs, etc, you can choose the actuator that will provide the best performance, reliability, and cost-effectiveness for your project.