Debunking “Conventional Wisdom” in Actuator Selection and Deployment

Understanding all the factors and costs in both pneumatic and electric actuators as well as their unique abilities can save you lots of money!

Pneumatic or Electric - How Do You Decide?

Manufacturing in the US today requires money-saving products upfront to keep the final cost of product down to the consumer. Costs in pneumatic and electric actuators vary and recognizing their very different and unique capabilities can be the first part of SMART manufacturing.

Here are some “HOW TO” tips on getting started.

1.  Consider what you are replacing

Sometimes switching from pneumatic to electric could be pricey and sometimes not worth the overall costs. For example, is the cost to run two smaller compressors less expensive to run than one larger compressor?

2.  Take an analysis of cost components for both pneumatic and electric actuators AND get a cost   estimation

If you are interested in cost calculations, The Knotts Company can provide one for those who wish to evaluate costs for their machines or facilities.

The choice of pneumatic or electric actuators involves an evaluation of performance, component costs, system costs, and productivity gains. These two technologies are very different - one IS NOT a drop-in replacement for the other.  Each has both advantages and disadvantages.

4.  What are you powering?

Pneumatic actuators provide high force and speed at low unit cost in a small footprint. Force and speed are easily adjustable and independent of each other. Typical pneumatic applications employ over-sized cylinders as a safety factor.

Pneumatic cylinders are inexpensive - stepping up to the next larger diameter is doable and practical. Depending on body diameter, stroke and options, the average cost for a non-repairable rod type cylinder can range from a few bucks to less than $300. With more force and speed per unit size than any other technology (except hydraulic), pneumatic cylinders can provide exactly what you need.

At the end of the day, pneumatics are most economical when the scale of deployment matches the capacity of the compressor. Unused compressor capacity is very costly. Time that a compressor sits idling at no load is also costly.

While pneumatic component costs are low, maintenance and operating costs can be high, especially if a serious effort has not been made to quantify and minimize the costs. Maintenance and operating costs include replacement cylinder costs, air line installation and maintenance, and electricity for the compressor.

Typically, compressor efficiency is lower when the compressor is partially loaded. Furthermore, if during the work week the compressors are left powered on at no load, a substantial amount of electricity is wasted. Waste is increased by inadequate maintenance (air leaks) and non-essential use of the compressor. Over-sized compressors and cylinders, common today, are costly to operate.

Debunking the conventional wisdom in actuator selection and deployment requires an understanding of the specific requirements of each application, the operating environment, and the long-term maintenance and cost considerations.

SMART manufacturing lies in implementing a careful analysis and tailored solutions to result in better performance, efficiency, and cost-effectiveness than simply following “best practices” that may not apply universally.

If you're looking to transform an existing process, our Knotts Company Team is ready to help!  We can spec in the appropriate IMI Bimba or IMI Norgren solution for your application needs.

Book a meeting with our Knotts Sales Team TODAY to explore proper actuator selection and deployment!