Request a quote

Kyntronics’ Hybrid Electro-Hydraulic Actuators Compared to Traditional Hydraulic Actuation Systems

Kyntronics Hybrid Electro-Hydraulic Actuators (SHA) Compared to Traditional Hydraulic Actuation Systems (HPU)

Traditional hydraulic power units (HPUs) and cylinders have long been a mainstay in industrial actuation, but they still present a range of challenges associated with outdated technology. Kyntronics Hybrid Electro-Hydraulic Linear Actuators (SHA) offer a durable and efficient electric alternative to conventional hydraulic systems—often serving as a compact hydraulic power unit replacement for applications seeking higher efficiency and lower maintenance. The following comparison highlights the features and advantages of both actuation technologies.

Traditional Hydraulic Actuators / HPUs

Hydraulic Actuators connected to Hydraulic Power Units (HPUs) are a commonly used motion control solution. These systems are used in high- force applications where robust performance is required. However, hydraulic actuators are complex, high-maintenance, expensive to operate, and have a large footprint. In many cases, users seeking a compact hydraulic power unit replacement explore alternatives that reduce system size and simplify integration.

Hydraulic actuators / HPUs require many components

Hydraulic actuators / HPUs require many components, including:

  • Pumps and motors
  • Cylinders, hydraulic lines, and fittings. Fluid reservoir, accumulators and filters, servo control valves
  • Electrical components / controls
  • Pressure transducers and position sensors
  • A significant volume of hydraulic fluid

Hydraulic Actuators (HPU) Issues

Kyntronics Hybrid Electro-Hydraulic Actuator (SHA)

The SHA combines the best features of screw-type EMAs and hydraulic actuators while eliminating their shortcomings. The SHA is an electrically powered, totally sealed, linear actuator consisting of a cylinder, pump, manifold, and servo motor, with an optional drive/control system. For applications needing a compact hydraulic power unit replacement, the SHA provides a streamlined all-in-one solution. There are no hoses or leak points on the SHA compared to a traditional hydraulic cylinder/HPU system, and the SHA contains minimal fluid (generally measured in ounces).

 

Read Kyntronics’ Insights: THE SMART ALTERNATIVE TO HYDRAULIC ACTUATION SYSTEMS (HPUS)

 

Comparison of Features and Benefits – Kyntronics Hybrid Electro-Hydraulic Actuator (SHA) vs. Hydraulic Cylinder / HPU

Comparison Category Kyntronics SHA Hydraulic Cylinder / HPU
Environmental Waste The SHA is a totally sealed system. Does not require fluid changes or replenishment.
SHA Fluid volume measured in ounces for most applications.		 HPUs require regular fluid changes and fluid replenishment, which is expensive and creates environmental impact.
Energy Usage SHA uses power-on-demand to save energy. The All-In-One SHA design is more efficient by eliminating energy losses associated with hoses, connections, and other components. HPUs run constantly, consuming significant amounts of energy. Hydraulic systems, on average, are 22% efficient due to energy losses from hoses, connections, and other components.
Maintenance Cost SHA does not require regular maintenance other than a rod seal change (field replacement) after 50,000,000 inches of rod travel. Hydraulic systems require regular maintenance, including repair of fluid leaks, changing fluid, replacing filters, and other components.
Ergonomics / Safety
The totally sealed design of the SHA eliminates leaks.
SHA operates quietly and generates far less heat waste compared with HPUs.		 Hydraulic system leaks create safety hazards that can result in lost-time accidents.
Hydraulic systems are noisy and generate excessive heat due to inefficient operation.
Unplanned Downtime / Product Spoilage The sealed design of the SHA eliminates fluid contamination, often the cause of unplanned downtime, and eliminates the risk of fluid leaks that can spoil product and create scrap. Fluid contamination is often the root cause of unplanned downtime. Leaky hydraulics can contaminate products, resulting in scrap and spoilage.

 

Annual Operating Cost Comparison – Kyntronics Hybrid Electro-Hydraulic Actuator (SHA) vs. Hydraulic Cylinder / HPU

Comparison Category SHA HPU Assumptions / Cost Basis (April 2023)
Environmental Waste $0
$0		 $33,600
$16,000		 200 Gallon HPU Tank Hydraulic Fluid Index (HFI) = 4.1
SHA is sealed – no fluid replacement or disposal is required
$42/gal x 800 gallons (4:1 HFI) $20/gal x 800 gallons (4:1 HFI)
Energy Usage $1,642 $16,429 SHA Uses Power on Demand SHA is 70% efficient (Kyntronics testing)
30 HP Hydraulic Power Unit that runs continuously HPU is 22% efficient
(based on IFPE paper) Using $0.17 per KWh (average US rate – Fed 2023)
Floor Space Utilization / Maintenance $0
$1,760		 $2,000
$5,250		 SHA is All-in-One, no floor space required
HPU requires space of 10’x10′ = 100 Sq-ft @ $20 per sq-ft.
SHA @ 1hr/week @ Labor $35/hr HPU @ 3hrs/week @ Labor $35/hr
Ergonomics / Safety $0 $2,000 HPU oil leaks create hazardous conditions and safety risk
SHA is totally sealed, no oil leak risk
Lost days + Medical costs + Legal costs
Unplanned Downtime / Product Spoilage $0
$0		 $10,000
$10,000		 SHA is totally sealed, no oil leak risk, minimal downtime risk $4k-$6k
average downtime cost per incident. Assuming two downtime events.
1% scrap from product contamination due to leaky connections
Annual Operating Costs $3,392 $95,279 A $91,887 Annual Savings Opportunity!

References – The basis for several of the assumptions used in the annual operating cost table originates from the Fluid Power Industry trade journal, published statistics, and sources noted below:

Discuss your application with an Engineer and learn how the all-electric, Hybrid Electro-Hydraulic Actuator (SHA) can eliminate hydraulics from your business—especially when seeking a compact hydraulic power unit replacement that reduces complexity, cost, and environmental impact. Contact Kyntronics.

Contact an Engineer Size an Actuator The Kyntronics Difference
Related Resources
Video
SAVE ENERGY, IMPROVE SAFETY & REDUCE OPERATING COSTS WITH HYBRID SHA PRECISION ACTUATION SOLUTION
Video thumbnail
Webinar
REPLACING HPUs AND HYDRAULIC CYLINDERS… AVOID THE RISKS, EXPERIENCE THE BENEFITS
Video thumbnail
Hybrid Actuator Total Solution
THE SMART ALTERNATIVE TO HYDRAULIC ACTUATION SYSTEMS (HPUS)

Hydraulic power units (HPUs) and cylinders have served industrial automation for years, yet they remain costly to maintain, waste energy, and pose env...

read more

Pressing
GLULAM BEAM PRESS: 55 HYBRID LINEAR ACTUATORS WITH PROGRAMMABLE POSITION, FORCE AND DWELL HOLD TIME

A fabricated lumber products manufacturer had a project to build large presses to produce glulam and LVL structural lumber components. Traditionally, ...

read more

faqs
We Have the Answers to Your Questions!

We have compiled information about our Hybrid Electro-Hydraulic Actuators and Servo Power Units.
Read FAQs