Kyntronics
Innovative Actuation Solutions for Every application
Actuator speed is often evaluated as a single performance specification, but in many industrial applications, how that speed is controlled throughout the operating cycle is just as important. Acceleration, deceleration, changing loads, and transitions between motion stages all influence how effectively an actuator performs.
An application may require rapid movement during one stage of operation, followed by slower, more controlled positioning or force application. The ability to adjust speed and maintain control throughout these transitions is especially important in pressing, forming, assembly, and testing applications, where precise and repeatable motion can directly impact cycle times, product quality, and process consistency.
Maximum actuator speed is an important specification when evaluating an actuation system, but it doesn’t reflect how the actuator will perform during an actual operating cycle. Travel distance, acceleration and deceleration rates, load conditions, and the time required to complete each movement all influence overall cycle time and machine productivity.
For example, in an automated pressing application, the actuator may need to extend quickly, slow down as it approaches the pressing stage, and then operate at a controlled speed as force is applied. Once the required force or position is reached, the actuator retracts to begin the next cycle. Each stage requires a different level of speed and control to ensure consistent, repeatable operation.
Applications involving frequent starts, stops, or changes in direction introduce additional considerations, particularly when maintaining consistent motion under varying loads. How an actuator accelerates and decelerates can also influence overall machine performance. Programmable motion profiles allow engineers to manage transitions between operating speeds, helping reduce abrupt loading, vibration, and mechanical stress. Evaluating the complete motion profile helps engineers determine the appropriate actuator configuration, motor, drive, and control system to meet the application’s performance requirements.
Understanding Actuator Motion Profiles
Illustrative velocity profile showing how controlled acceleration, operating speed, and deceleration contribute to smooth, repeatable actuator motion.
Speed, force, and position requirements should be evaluated together, especially in applications where loads vary throughout the operating cycle. The ability to deliver higher force at a slower speed or maintain controlled movement under changing loads depends on the capabilities of the actuation system.
While hydraulic, electromechanical, and hybrid actuation systems generate and control motion differently, each must account for the relationship between speed, force, position, and available power. Hydraulic systems regulate actuator speed through fluid flow and generate force through pressure, while electromechanical systems use motor torque and mechanical transmission components to produce linear motion. Hybrid systems combine hydraulic force generation with electric motor control to manage speed, position, and force.
When evaluating these requirements, engineers should consider:
Understanding how speed, force, and available power interact helps engineers determine which actuation technology and system configuration can best meet the application’s performance requirements.
Closed-loop control plays an important role in applications requiring precise, repeatable motion, controlled force application, and optimized cycle times. Unlike open-loop systems, which operate without using feedback to correct the controlled output, closed-loop systems continuously monitor actual operating conditions and compare them to the commanded values. The controller uses this feedback to adjust and maintain the required performance throughout the operating cycle.
Depending on the system and its sensors, feedback can be used to control position, force, or speed. Position feedback allows the controller to monitor actuator movement and make corrections to reach a target position, while force feedback helps regulate the applied force as load conditions change. Speed can be controlled through programmed motion profiles, with feedback used where supported by the control system to maintain the desired motion.
The accuracy and repeatability of closed-loop control also depend on how and where feedback is measured. Monitoring actual actuator rod position, rather than relying solely on motor rotation, provides a more direct measurement of position and helps improve control under changing load conditions. This allows the controller to identify and correct positioning deviations, helping maintain accuracy and repeatability as load conditions change.
Similarly, accurate force control depends on how applied force is determined. While electromechanical actuators often estimate force through motor torque calculations, which can be affected by friction, mechanical losses, and changing operating conditions, hybrid linear actuators can use integrated pressure sensors to calculate and regulate applied force. This approach supports precise, repeatable force control without relying solely on motor torque estimates.
Hybrid actuation combines hydraulic force capabilities with the precision and programmability of electric control, allowing speed, position, and force to be managed throughout the operating cycle.
The Kyntronics Hybrid Linear Actuator (SHA) integrates a hydraulic cylinder, motor, gear pump, and supporting components into a sealed, self-contained system. The servo motor controls the speed and direction of the hydraulic pump, regulating fluid flow to manage actuator movement. With integrated position and force feedback, the SHA supports closed-loop control and programmable motion profiles to accommodate changing application requirements.
For applications using existing hydraulic cylinders or rotary actuators, the Kyntronics Compact Hybrid Power Unit (SPU) provides another approach. By combining a motor, gear pump, and controls into a compact power unit, the SPU allows engineers to manage speed, position, force, and pressure without relying on a traditional continuously operating hydraulic power unit. Both solutions allow engineers to program different operating speeds, transition between position and force control, and adjust motion to meet the requirements of each stage of operation.
To learn more about how these capabilities can support your equipment requirements, submit an Application Review to connect with our engineering team.
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