Kyntronics
Innovative Actuation Solutions for Every application
Military ground vehicles are continuously evolving as electrification, autonomy, and growing demands on vehicle power and space change the way platforms are designed. At the same time, requirements around size, weight, and power (SWaP), reliability, maintainability, and field serviceability continue to influence system design and components selection.
For prime contractors, defense OEMs, and system integrators, actuation is an important part of this equation. The actuation technology can influence more than just the motion requirements of the application, affecting vehicle weight and space claim, power consumption, thermal management, maintenance requirements, system complexity, and ease of field serviceability. As current and next-gen military platforms become more electrified, hydraulic, electro-mechanical, and hybrid actuation technologies each offer different advantages and tradeoffs.
Size and weight are critical considerations for military ground vehicles, but comparing actuation technologies based on dimensions or weight alone provides an incomplete picture. Traditional hydraulic actuation systems require a centralized hydraulic power unit, reservoir, filtration, valving, hoses, tubing, fittings, hydraulic cylinders / actuators, and various other supporting components. The entire hydraulic system requires valuable space throughout the vehicle and contributes to the overall system weight.
Electro-mechanical actuation solutions, on the other hand, can eliminate this hydraulic infrastructure but introduces different considerations on the force, speed, stroke, shock loading, and duty cycle required by the application.
Hybrid actuation provides another approach by combining electric control with hydraulic power. Self-contained hybrid actuators integrate the motor, pump, manifold, and hydraulic cylinder into a single line replaceable unit (LRU) assembly, eliminating the need for a centralized hydraulic power unit, external hydraulic plumbing, and associated supporting components.
Reliability is critical for military equipment, but how quickly a system can be maintained, repaired, and returned to service can be equally important. Traditional hydraulics incorporate extensive hoses, piping, fittings, and fluid connections throughout the vehicle. This added infrastructure requires routine inspection and maintenance over the life of the platform and introduces many leak points. Troubleshooting and diagnosing issues can also require specially trained personnel, adding to maintenance challenges and downtime. In military and defense applications, specialized hoses and fittings can also be expensive to maintain and replace. Reducing external hydraulic components can simplify the actuation architecture while reducing potential leak and maintenance points.
Maintainability should also be considered. Modular actuation architectures can allow components or complete actuator assemblies to function as line-replaceable units. Rather than requiring extensive troubleshooting or repair in the field, maintenance personnel can replace the affected module and return the vehicle to operation more quickly. For military ground vehicles operating in the field, reducing downtime is critical. Simplifying how actuation systems are diagnosed, serviced, and replaced can help minimize time out of service and get equipment back into operation faster.
As military ground vehicles become more electrified, available power and thermal management become increasingly important design considerations. Conventional hydraulic systems consume energy and generate heat even when the actuators are idle because the hydraulic power unit continues operating to maintain system pressure. Power-on-demand systems operate differently, using energy only when required, reducing unnecessary power consumption and heat generation.
For military vehicles, reducing heat is about more than energy efficiency. Excess heat adds to the vehicle’s thermal management requirements and can contribute to its thermal signature. As more systems compete for available power and cooling capacity, the energy and thermal demands of the actuation system become an important part of the overall vehicle.
Defense ground vehicles operate in demanding environments where actuation systems are exposed to shock loads, vibration, contamination, and temperature extremes. These conditions make durability and load tolerance critical factors in actuator selection.
Electro-mechanical screw-type actuators transfer power through a series of mechanical interfaces, including the screw, nut, bearings, and depending on the design, additional couplings, gears, or belts. Each interface introduces contact points where loads are transferred, alignment must be maintained, and wear can occur over time. Repeated shock and side loading place additional stress on these mechanical interfaces, potentially accelerating wear and affecting actuator performance and life.
Hydraulic actuation, by comparison, is well suited for high loads, shock, and side loading, but traditional systems require additional supporting hydraulic infrastructure. Hoses, fittings, and fluid connections throughout the vehicle are also exposed to vibration and shock, which can contribute to wear, loosened connections, leaks, and reliability issues over time. Hybrid actuation retains the high load, shock, and side-load tolerance of hydraulic actuation in a rugged, self-contained, durable design, while eliminating the supporting infrastructure required by traditional hydraulic systems and adding programmable electric control.
As military vehicle designs evolve, actuation technology must evolve with them. Traditional hydraulic systems have long provided the force density and durability required for heavy-duty military applications, but centralized hydraulic infrastructure can present challenges as ground vehicles evolve. At the same time, moving to an all-electric actuator is not necessarily the right solution for every application, particularly where high forces, shock loading, or other demanding operating conditions are involved.
Hybrid actuation provides an innovative alternative by combining hydraulic power with electric control. Designed to integrate with electric, diesel-electric, and hybrid-powered platforms, hybrid actuation can support the transition toward more efficient, software-controlled motion while maintaining the force and load-handling capabilities traditionally associated with hydraulics. Closed-loop control, integrated sensing, diagnostics, and communication with higher-level vehicle controls further support integration into current and next-generation military systems.
Technical performance is only one consideration when selecting an actuation solution for a military vehicle program. Prime contractors, defense OEMs, and system integrators must also consider development schedules, prototype availability, supplier responsiveness, manufacturing capabilities, and long-term support.
Actuation requirements can evolve as a vehicle moves through development and testing. Force, stroke, speed, mounting, controls, packaging, and environmental requirements may all change as the platform matures.
Working with an actuation supplier that has design-build capabilities can allow the system to evolve with the application rather than requiring the vehicle architecture to accommodate a fixed solution. Domestic engineering, manufacturing, prototyping, and testing capabilities can also help support shorter development cycles and long-term lifecycle requirements.
Kyntronics works with prime contractors, defense OEMs, and system integrators to develop actuation solutions for demanding military and defense applications. Our approach extends beyond supplying an actuator. Kyntronics can support the complete actuation system from initial application engineering through delivery, including sizing and configuration, motor and drive selection, controls and software development, system integration, and testing.
That support continues after installation. Kyntronics engineers can provide ongoing technical assistance to help resolve issues and support the system throughout its operating life. With U.S.-based engineering and manufacturing, Kyntronics can support military and defense programs from early development and prototyping through production and long-term lifecycle support.
Learn more about Kyntronics’ hybrid actuation capabilities for military and defense applications on our Military & Defense Solutions page.
GET EXPERT ACTUATION SUPPORT: Not sure which actuation technology is right for your application? Tell us a little about your application. Once submitted, a Kyntronics engineer will review your information and follow up with recommendations tailored to your specific requirements.
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