WHY DIFFERENT CLAMPING REQUIREMENTS EXPOSE THE LIMITS OF TRADITIONAL ACTUATION TECHNOLOGIES

Explore how clamping applications reveal the limitations of traditional actuators and why hybrid actuation delivers precise, reliable clamping performance.

WHY CLAMPING APPLICATIONS REVEAL THE LIMITS OF TRADITIONAL ACTUATORS

Clamping and workholding applications are often underestimated. What seems like a simple sequence of motion and force quickly becomes a demanding actuation challenge once accuracy, cycle life, shock loading, and consistency are considered.

Clamping applications require precise, repeatable force, often over high cycle counts, while tolerating shock loads and side loads. Because of this, clamping applications tend to expose the limitations of traditional actuator technologies quicker than other use cases.

Understanding why this happens can help engineers make better clamping actuator selection decisions and avoid long-term performance and maintenance issues.

CLAMPING APPLICATIONS ARE NOT ONE-SIZE-FITS-ALL

Clamping requirements vary widely across industries and machines. Some applications are simple and low force, while others demand high force, tight control, and long hold times. Common clamping actuation requirements include:

  • Low to high force capability
  • Accurate and repeatable force control
  • High cycle life with minimal wear and low maintenance
  • Shock and side-load tolerance
  • Ability to hold and monitor force for extended periods
  • Efficient operation across different speeds and loads
  • Match workholding requirements to the manufacturing process

WHERE TRADITIONAL CLAMPING ACTUATION TECHNOLOGIES STRUGGLE

Pneumatic Actuators:
Simple and Fast, but Limited

Pneumatic actuators are widely used for low-force, simple clamping due to their speed, low upfront cost, and ease of use.

However, clamping applications quickly reveal their limitations:

  • Force accuracy is limited and difficult to control precisely
  • Force consistency can vary from cycle to cycle
  • Air quality and component wear increase maintenance demands
  • Limited force capability
PNEUMATIC Actuator

Electro-Mechanical Actuators (EMAs):
Torque Control Isn’t Force Control

Screw-driven actuators are commonly used for low to medium force clamping, especially where cleanliness and positioning accuracy are important.

In clamping applications, several challenges emerge:

  • Repeated clamping at the same position accelerates screw and nut wear
  • Shock loads damage mechanical components
  • As wear increases, force accuracy degrades over time
  • Lubrication and maintenance becomes more frequent in high-cycle applications
SCREW-TYPE ACTUATOR

Hydraulic Actuators:
High Force with Tradeoffs

Hydraulic cylinders remain a common choice for medium to high force clamping applications, offering pressure-based force control and the ability to actuate quickly using large pumps and motors.

However, clamping applications highlight several inherent drawbacks:

  • Environmental concerns related to leaks and contamination
  • Lower energy efficiency due to constantly running pumps
  • Increased system complexity and safety considerations
  • Added costs to perform precise force and position control
hydraulic actuator

SOLVING CLAMPING CHALLENGES WITH HYBRID ACTUATION

Kyntronics’ Hybrid Linear Actuators (SHA) combine the strengths of electro-mechanical and hydraulic technologies while minimizing their weaknesses — making it uniquely adaptable to the full range of clamping requirements.

In clamping applications, hybrid actuation systems offer several key advantages:

  • Energy efficiency with power-on-demand
  • Accurate, closed-loop control of both position and force, improving consistency and part quality
  • High-speed motion at low force and high force at low speed using a smaller motor
  • Ability to handle simple or complex clamping profiles
  • Force locking and monitoring over extended hold periods
  • High tolerance to shock loading and side loads common clamping applications
  • Ability to handle high cycle life with minimal wear and low maintenance
  • Multiple clamps powered from a single power source using a compact servo power unit (SPU)
Collage of SHA SPU and panel

WHAT CLAMPING AND HOLDING APPLICATIONS TEACH US ABOUT ACTUATOR SELECTION

Clamping applications require engineers to look beyond peak force ratings and ask deeper questions:

  • How accurately can force be controlled and repeated over time?
  • How does the actuator handle wear and shock loads during the clamping process?
  • What is the long-term maintenance impact of the technology?
  • How efficiently does the system operate across different speeds and loads?
  • How does actuation choice affect process and product quality and machine life?

By answering these questions, engineers can better select a reliable actuation solution for their application.

Ready to explore smarter actuation for clamping applications?
Check out our hybrid actuation solutions for clamping and holding applications and learn how precise control, efficiency, and durability can support long-term machine performance.