May. 13, 2024
Automation in recent years has significantly increased the use of electric linear actuators in smart homes, aerospace, defense, and industrial applications. The global linear actuator market, driven largely by electric options, is projected to surpass $52.67 billion this year and continue growing through 2030, according to Grand View Research.
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We recently interviewed industry experts about the markets driving this adoption. Their responses varied, indicating increased use of electric actuators in North American and European off-highway equipment and aircraft as replacements for hydraulics and pneumatics. The proliferation of smart actuators integrating encoders and other feedback with onboard electronics for controls, featuring enhanced connectivity for streamlined commissioning, automated optimization, and predictive-maintenance functions, was also highlighted as key to new DX designs.
Pre-engineered and integrated linear-motion variations are becoming standard in many industries, especially where advanced subassemblies such as stages, gantries, and XY tables are required for specific applications or captive use.
Rice: Machine builders save time and money by outsourcing the design of motion subassemblies, such as linear axes and multi-axis gantries. Whether to design and build an in-house linear solution or to specify and buy a made-to-order subassembly depends largely on available design time and the number of machines built using that design.
For longer design cycles where many repeat machines will be built, machine builders benefit from designing and building their own linear-motion solution. This process entails specifying individual components—linear bearings, drive technology, support rails, carriage materials—to optimize each for performance and cost. Complexity increases with multi-axis solutions, requiring attention to combining axes, cable management, and multi-directional moment loads.
For shorter design cycles or fewer machines, made-to-order subassemblies are more practical. Due to limited time to optimize each component, such subassemblies offer the quickest path to successful design, ensuring high-quality components built by manufacturers guaranteeing performance characteristics.
Manufacturers design the mechanical interfaces between axes, provide robust cable management solutions, and use sizing software to ensure high-performing and cost-effective solutions.
Laiewski: More companies are losing experienced engineering talent and struggling to find new talent for growth. As a result, companies increasingly outsource the design and manufacturing of single or multi-axis subassemblies to specialists. Linear and rod-style actuators are examples of such subassemblies.
White: In-house engineering design and calculation services are in demand. Component suppliers create specialized analysis tools for more accurate results and product life assurance.
Electric and pneumatic linear actuators are essential in automotive and electronics manufacturing, enhancing workpiece handling and positioning accuracy.
O’Driscoll: Many industry segments use compact actuators, especially in packaging, light assembly, and electronics industries, where smaller machinery and high-density components are valued.
To optimize space while meeting ISO 6432 or ISO 21287 standards, Festo developed new space-optimized actuator versions—DSNU-S round cylinders and ADN-S ultra-compact short-stroke cylinders.
The DSNU-S cylinder is up to 40% more slender and 3.5 cm shorter than DSNU ISO types of the same bore size, while the ADN-S is up to 45% shorter and lighter than comparable Festo ADN ISO cylinders.
O’Driscoll: Optimizing machine footprints is increasingly important, as is reducing setup time and effort for commissioning machines.
Delicate applications are adopting leadscrew-based linear actuation; position-intensive applications requiring high power density are driving the use of roller screw-based designs.
Beckstoffer: Biologics emerging as therapy options for patients are driving the development of new drug-delivery devices, often using leadscrews for precise syringe drive systems.
Mayr: Roller-screw use growth is driven by humanoid robotics markets needing high power density for compact, weight-constrained designs, often utilizing integrated force and torque sensors for accurate positioning feedback.
Rice: The demand for higher forces from linear axes is pushing roller screws' growth. They bridge the force gap better than traditional ballscrews, helping machine builders avoid costs and maintenance associated with hydraulics and pneumatic systems.
Despite increased electric linear motion migration, pneumatics remain essential.
O’Driscoll: Precision and compactness are critical in end user and machine builder applications. Festo's DGST, the most compact slide on the market, offers precision, end-position accuracy, and high feed force, combining cost-effectiveness with compact design.
Precision and accuracy in pneumatics have improved with mini-slide development, meeting the growing electronic component demand for compact, precise, high-speed automation.
Guided Actuators
Guided actuators are widely used in lifting, pressing, pushing, clamping, stopping, holding, cutting, and other applications. They offer various sizes and variants, deliver stroke lengths up to 400 mm, and apply significant force when needed.
Robustness is key to guided actuators. Festo’s DFM offers industry-leading rigidity with plain bearing or recirculating ball bearing guide solutions.
Linear motion components often surpass six-axis arrangements for roboticizing industrial workcells. Experts indicated an increased shift to Cartesian assemblies for consumer, laboratory automation, and medical applications, urging engineers to compare specifications.
Palmer: The market for linear stages and motion systems is highly competitive, offering many options with seemingly minor details significantly impacting product performance and life. Engineers should consider polymer-bearing materials, linear unit sealing solutions, and customizability.
Mayr: Linear actuation kits enhance robot versatility and utilization rates.
Korkowski: Linear-motion-based pick-and-place robots are customizable with force sensors, MagSpring-based load compensation, cleanroom certification, and optional holding brakes. These robots reduce installation costs and maintenance.
Giunta: Gantry assemblies offer cost-efficient solutions with larger motion ranges and payload capacities compared to six-axis robots for most pick-and-place applications.
Ikeuchi: IKO and AutomationWare offer electric cylinders for longer travel and heavy loads with customizable robotic joint modules. Low-profile miniature positioning stages, NT-V linear-motor, and servo or stepper-driven TM15 have seen increased optical project usage.
Linear bearings remain indispensable in linear-motion applications due to their load capacity, speed, and material flexibility.
Isaac: Linear ball bushing bearings and plain bearings continue to offer cost-efficient solutions for various industries, maintaining strong demand despite new technologies.
Marques: Interest in HepcoMotion GFX featuring Beckhoff linear motors has grown, providing variable speeds and optimizing throughput in high-precision applications.
O'Driscoll: The market for guided drives is expanding as engineers realize the benefits of integrated linear movement and guidance, such as Festo’s DFM product.
Guided actuators are versatile across industries including light assembly, automotive, and food and beverage, demonstrating robust, reliable solutions for various applications.
There is no substitute for the linear bearings that accompany linear drives, ensuring reliable motion control systems.
Marek: The linear motion market's surge in demand is driven by the need for energy-efficient motion control in industries such as material handling, factory automation, transportation, robotics, and medical.
Thomson has developed smart electric linear actuators rapidly replacing hydraulic, pneumatic, and manually operated axes, providing optimum machine performance and supporting predictive maintenance.
Meet the experts
Eric Rice | Product Market Manager – Electric Automation • Festo
Burnett Laiewski | Product Manager – Industrial Automation • Schaeffler Americas
Carl White | Engineering Manager – Industrial Automation • Schaeffler Americas
Darren O’Driscoll | Product Market Manager – Core Products • Festo
Dave Beckstoffer | Industry Manager • Portescap
Ulrich Mayr | VP – Industrial Automation • Schaeffler Americas
Matt Palmer | Product Line Manager – Linear Units • Thomson Industries Inc.
Mike Korkowski | Operations Manager • LinMot USA
Michael Giunta | VP of Sales and Marketing • Macron Dynamics Inc.
Yugi Ikeuchi | General Manager – Engineering and App Development • IKO Intl.
Charles Isaac | Product Line Manager – Linear Bearings and Guides | Thomson Industries Inc.
Alex Marques | Product Manager • Bishop-Wisecarver Corp.
Jim Marek | Senior Director of Engineering | Thomson Industries Inc.
Are you considering replacing a compressor and 200 pneumatic cylinders with electric actuators to save money on compressed air? Or, perhaps you’re building a new machine with pneumatics because 30 electric actuators cost $34,000. Either way, you might be making the wrong decision and wasting tens of thousands of dollars annually. The choice between pneumatic or electric actuators involves evaluating performance, cost, and productivity gains.
Pneumatic actuators offer high force and speed at a low unit cost with easy force and speed adjustments. They are typically employed with oversized cylinders for safety. Prices for rod-type cylinders range from $15 to $250, depending on specifications.
Pneumatics are economical when the scale of deployment matches compressor capacity. However, maintenance and operating costs can be high, including replacement cylinders, air line maintenance, and compressor electricity costs. According to the Department of Energy, 76% of the annual compressed air cost is due to electricity for the compressor.
Compressor efficiency decreases with partial loads, and idle compressors waste electricity. Oversized compressors and cylinders increase operational costs. The cost per pneumatic device rises significantly when fewer devices use the compressor.
Electric actuators provide precise control and positioning, adapting machines to flexible processes with low operating costs. They consist of a ball, acme, or roller screw connected to an electric motor. Performance varies based on materials and motor types, with steppers and servos commonly used.
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Step motors are economical for accurate positioning at lower speeds, while servos offer superior high-speed performance at a higher cost. Electric actuators require an amplifier and controller, with costs ranging from $800 to $3,000 and up.
Operating costs for electric actuators mainly come from motor power draw. While component costs are high, operating costs are low. Electric actuators can reduce manual changeover costs, thus potentially saving significant amounts annually.
To compare electric and pneumatic actuators accurately, consider the following example:
A plant uses a 100 hp compressor for 20 pneumatic actuators, costing $41,506 annually, including replacement costs. Electric actuators cost $9,648 annually, including savings from eliminated changeover labor and lost production, making the electric system more cost-effective.
Another plant with a 200 hp compressor powers 150 pneumatic actuators, costing $44,737 annually. Replacing with electric actuators would cost $69,360 annually due to high replacement costs, making pneumatic actuators the more economical choice.
The choice between pneumatic and electric actuators depends on factors like deployment scale, component costs, and replacement frequency. Accurate assessments can produce significant long-term cost savings and ensure machinery efficiency.
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