KYNTRONICS ACTUATOR COMPARISON GUIDE: CHOOSING THE RIGHT TECHNOLOGY FOR YOUR APPLICATION

This comprehensive comparison article outlines the differences between Kyntronics' Hybrid actuator (SHA) technology vs. traditional hydraulic actuation systems and electro-mechanical screw-type actuators (EMAs).
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Education, Electro-Mechanical Replacement, Hydraulic Replacement, Insights, Technology

WHAT IS THE HYBRID ACTUATOR (SHA)?

Kyntronics’ Hybrid actuator (SHA) incorporates a motor, pump, valving, sensors, and integral hydraulic cylinder in a single sealed unit. It eliminates the hoses, fluid reservoirs, and external hydraulic power units (HPUs) found in traditional hydraulic actuation systems while delivering high force (up to 150,000 lbs), servo precision, IoT readiness, and ultra-low fluid usage. It is designed for energy efficiency reliability, precision, and low maintenance.

 

Kyntronics’ Hybrid actuator (SHA) Diagram

 

HYBRID SHA VS. TRADITIONAL HYDRAULIC ACTUATOR SYSTEMS

Traditional hydraulic actuators (cylinders) rely on a separate hydraulic power unit (HPU) that connects via hoses to hydraulic cylinders that perform the work. The HPU generally includes a number of components including: a large fluid storage tank, accumulation system, filtration system, motor / pump assembly and valves to control fluid flow and fluid routing. The pump runs continuously so pressurized fluid is available at any time to perform work. Unfortunately, these systems will inevitably leak and exposure to the environment require regular fluid and filter replacements to maintain reliable operation. Additionally, HPUs and their associated components have a large footprint, are noisy and generate a lot of heat.

 

Hybrid SHA – Key Advantages:

  • The SHA uses power only when performing work, dramatically reducing energy usage.
  • Its totally sealed system eliminates contamination risks and never requires fluid changes.
  • The compact design of the SHA saves space and is easily integrated into machines.
  • Integral position and force sensors in the SHA provide precision control capability.

  VS. 

HYBRID SHA VS. ELECTRO-MECHANICAL SCREW-TYPE ACTUATORS (EMAs)

Electro-mechanical actuators incorporate a motor that drives a screw through a series of gears, belts or other means of mechanical power transmission. There are various types of screw mechanisms used in EMAs including acme screw, ball screw or roller screw. EMAs are often used in applications requiring precise control and unlike traditional hydraulics, they consume energy only when performing work. Unfortunately, EMAs have a significant shortcoming in that they are fragile and susceptible to damage from shock loads, side loading and concentrated wear. They also require regular lubrication to prevent pre-mature failure from metal-to-metal wear with the power transmission components. EMAs can be relatively expensive at higher force ratings (above 5,000 Lbs.) and with longer stroke lengths (over 36 in.).

Hybrid SHA – Key Advantages:

  • Shock-load tolerant design with no metal-to-metal wear parts. No lubrication required.
  • Up to 50 million inches of rod travel before preventative maintenance.
  • Available in forces ranging from 100 Lbs. to 150,000 Lbs and stroke length in any increment up to 120 in.
  • Operates with power-on-demand saving energy
  • Integrated pressure and position feedback sensors for precise control.

         

 

KYNTRONICS’ HYBRID ACTUATORS – THE BEST OF BOTH WORLDS

Hybrid actuators are an all-electric actuation solution that integrates high-precision servo control with an integral pump and cylinder. It combines the best features of traditional hydraulic actuation and electro-mechanical actuation while eliminating their respective shortcomings as illustrated in the chart below:

 

 

 

FEATURE COMPARISON SUMMARY

 

FEATURE KYNTRONICS HYBRID SHA TRADITIONAL HYDRAULIC ACTUATION SYSTEMS ELECTRO-MECHANICAL ACTUATORS (EMAs)
Energy Efficiency Power-on-demand; up to 90% energy savings compared with hydraulics Continuous pump operation; high energy usage Metal-to-metal friction reduces efficiency
Force Capability Up to 150,000 lbs (665 kN) Very high Limited force range, very expensive over 5,000 lbs. rated force
Maintenance Requirements Minimal maintenance; rod seal change after 50M inches of travel Frequent oil changes, filter replacements, and hose maintenance Requires regular lubrication. Very expensive to repair
Environmental Impact Clean operation with a sealed system eliminates leaks and fluid disposal Highly prone to leaks; risk of environmental contamination, old fluid must be carefully disposed of Clean operation but susceptible to wear-related failures
Precision Control Integrated sensors for real-time position and force feedback; IoT-compatible Difficult and costly to achieve precise control; limited IoT integration Position uses motor feedback, less accurate. Requires expensive load cells for accurate force measurement
Reliability & Durability No metal-to-metal wear points; robust design for heavy-duty applications Robust but noisy and prone to leaks, unplanned downtime Highly susceptible to shock load damage and metal-to-metal contact leads to mechanical failures
Complete Solution vs. Components The Hybrid SHA is available as a “Total Solution” that includes the actuator, motor, drive/control, cables and software, fully factory tested Hydraulic systems contain many components from multiple suppliers that must be selected, purchased, assembled and tested Generally sold as an actuator only. The  motor, drive, cables and software are supplied by others who must integrate them into a functioning system 
Integration & Space Efficiency Compact all-in-one design; high force density, easy installation with minimal footprint HPU has a large footprint with hoses, pipes, and other components, cylinders have high force density Force density is less than hydraulics, higher force units (>5,000 lbs) are quite large
Total Cost of Ownership Slightly higher upfront cost compared with simple hydraulic systems but significantly lower total cost due to reduced energy usage, much  lower maintenance, less downtime and product spoilage risk Slightly lower upfront cost for simple systems but significantly higher operating costs due to high energy consumption, fluid maintenance expenses and uplanned dowtime make hydraulic actuation the highest total cost option over time  High upfront costs for higher force actuators,  maintenance costs for regular lubrication, very high repair costs
Skilled Trade Requirements Generally serviced by Electrical Maintenance personnel Generally serviced by Hydraulic Maintenance personnel, who are  becoming more scarce Generally serviced by Electrical Maintenance personnel

 

WHY CHOOSE KYNTRONICS SHA

If your operation struggles with:

  • Leaky hydraulics
  • High energy usage
  • Costly downtime or maintenance
  • Reliability issues with screw actuators
  • Integration complexity

 

Then the Hybrid SHA is your solution. Kyntronics offers:

  • “Total Solution” actuator systems
  • Fully tested solutions with complete documentation
  • Engineering support for selection and sizing
  • Customization tailored to your application needs

 

 

From pressing, material handling, metal forming, lifting, and clamping to test equipment—if your project demands force, precision, efficiency, and low maintenance, Kyntronics Hybrid actuators and Servo Power Units are the answer. It’s not just a better actuator—it’s a better approach to motion control.