Kyntronics
Innovative Actuation Solutions for Every application
In hazardous environments where gases, vapors, or dust may be present, actuation system design must prioritize safety without sacrificing performance. Any potential ignition source, whether from electrical components, heat, or mechanical friction, must be carefully controlled/eliminated.
Because of this, traditional hydraulic actuation systems have long been used in these conditions. As non-electrical devices, hydraulics can operate safely in hazardous areas when pressures are properly managed. However, as applications demand more precise control, higher reliability, lower maintenance, data feedback, and system flexibility, engineers are increasingly evaluating electric actuation solutions that introduce new challenges around explosion-proof actuator design.
Hydraulic Systems
Hydraulic actuation is inherently well-suited for hazardous environments due to its non-electrical nature. These systems can deliver high force while minimizing ignition risks within the application zone. However, traditional hydraulic systems often rely on centralized power units, long hose runs, and continuous operation. This can introduce challenges related to maintenance and fluid leaks (environmental challenges), energy inefficiency due to constant pump operation and downtime.
Electromechanical Actuators (EMAs)
Electromechanical actuators offer precise, programmable motion and are widely used in automation. However, their use in hazardous environments introduces important considerations. EMAs rely on mechanical components such as screws, gears, and bearings to generate motion. These metal-to-metal contact points create friction, which can generate heat over time. In certain conditions, this friction presents a potential ignition risk, making explosion-proof implementation more complex and often more costly. Additionally, EMAs are sensitive to side loading and mechanical wear, which can further increase the likelihood of failure in demanding environments.
A Hybrid Approach to Explosion-Proof Design
Hybrid actuation systems combine the advantages of hydraulic power with the precision of electric servo control, providing the best of both worlds for hazardous environments.
Hybrid solutions enable:
This approach allows engineers to implement advanced control strategies while minimizing the risks associated with purely electromechanical systems.
Remote Electronics and Safe Zone Design
One effective strategy for meeting explosion-proof requirements is to locate sensitive electrical components outside of the hazardous area. In this configuration, electrical devices such as drives and controllers are housed in a safe zone, while motion is transmitted with smooth, controlled flow into the risk area via hydraulic hose lines, thus meeting explosion proof requirements.
Intrinsically Safe and Explosion-Proof Configurations
Hybrid systems can be configured to meet both intrinsically safe and explosion-proof requirements depending on the application.
These configurations can support:
This flexibility enables engineers to tailor the system to both performance and safety requirements without sacrificing reliability.
Hybrid actuation can be implemented in different ways depending on the application, offering flexibility in system design.
Servo-Controlled Power with Compact Servo Power Units (SPU)
The Compact Servo Power Unit (SPU) delivers servo-controlled hydraulic power in a compact, power-on-demand system, fundamentally different from traditional hydraulic power units (HPU).
Rather than operating continuously like a centralized HPU, the SPU generates power only when motion is required. This eliminates the need for large reservoirs, constant pump operation, and extensive infrastructure, while enabling precise, closed-loop control.
This approach enables:
The SPU is particularly well-suited for applications such as oil & gas valve control or systems requiring coordinated multi-axis motion.
Self-Contained Actuation with Hybrid Linear Actuators (SHA)
Hybrid Linear Actuators (SHA) offer a fully self-contained solution without the need for external hoses. SHAs can be equipped with upgraded certified rated sensors and certified explosion-proof motors.
This design provides:
Self-contained hybrid actuators are ideal for applications such as pressing, particularly in environments such as munitions manufacturing, where both precision and safety are critical.
While explosion-proof EMAs are available, they often require additional design considerations, protective enclosures, and increased costs to mitigate the risks associated with mechanical friction and heat generation.
Hybrid actuation systems provide an alternative approach by:
As a result, hybrid solutions can offer a cost-effective and reliable option for engineers seeking explosion-proof actuation without compromising performance.
Learn More About SPU & SHA Solutions for Hazardous Environments Explore how hybrid actuation can support your explosion-proof application. View Kyntronics Hybrid Actuators & Servo Power Units
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