Kyntronics SMART Electro-Hydraulic Actuators (SHA) Compared to Hydraulic Actuation Systems (HPU)
Kyntronics SMART Electro-Hydraulic Linear Actuators (SHA) are an alternative to traditional hydraulic cylinders. The features and benefits of these two actuation technologies are compared below.
Hydraulic Actuators / HPUs
Hydraulic Actuators connected to Hydraulic Power Units (HPUs) are a commonly-used motion control solution. These systems are used in high force applications where robust performance is required.
Hydraulic actuators / HPUs require many components including:
- Pumps and motors
- Cylinders, hydraulic lines and fittings Fluid reservoir, accumulators and filters Servo control valves
- Electrical components / controls
- Pressure transducers and position sensors
- A significant volume of hydraulic fluid
Hydraulic Actuators are complex, high maintenance, expensive to operate and have a large footprint.
SMART Electro-Hydraulic Actuator (SHA)
The SHA is an all electric, all-in-one, totally sealed, self-contained linear actuator consisting of a cylinder, pump, manifold and servo motor with optional drive/control system.
There are no hoses or leak points on the SHA vs. a traditional hydraulic cylinder / HPU system and the SHA contains minimal fluid (generally measured in ounces).
The SHA combines the Best Features of Screw-Type EMAs and Hydraulic Actuators while Eliminating their Shortcomings.
Feature and Benefit Comparison
Kyntronics SMART Electro-Hydraulic Actuator (SHA) vs. Hydraulic Cylinder / HPU
Comparison Category | Kyntronics SHA | Hydraulic Cylinder / HPU | |
Environmental Waste | ![]() |
The SHA is a totally-sealed system. Does not require fluid changes or replenishment. SHA Fluid volume measured in ounces for most applications. |
HPUs require regular fluid changes and fluid replenishment which is expensive and creates environmental impact. |
Energy Usage | ![]() |
SHA uses power-on-demand to save energy. The All-In-One SHA design is more efficient by eliminating energy losses associated with hoses, connections and other components. | HPUs run constantly consuming significant amounts of energy. Hydraulic systems on average are 22% efficient due to energy losses from hoses, connections and other components. |
Maintenance Cost | ![]() |
SHA does not require regular maintenance other than a rod seal change (field replacement) after 50,000,000 inches of rod travel. | Hydraulic systems require regular maintenance including repair of fluid leaks, changing fluid, replacing filters and other components. |
Ergonomics / Safety | ![]() ![]() |
The totally-sealed design of the SHA eliminates leaks. SHA operates quietly and generates far less heat waste compared with HPUs. |
Hydraulic system leaks create safety hazards that can result in lost-time accidents. Hydraulic systems are noisy and generate excessive heat due to inefficient operation. |
Unplanned Downtime / Product Spoilage | ![]() |
The sealed design of the SHA eliminates fluid contamination, often the cause of unplanned downtime, and eliminates the risk of fluid leaks that can spoil product and create scrap. | Fluid contamination is often the root cause of unplanned downtime. leaky hydraulics can contaminate products resulting in scrap and spoilage. |
Annual Operating Cost Comparison
Kyntronics SMART Electro-Hydraulic Actuator (SHA) vs. Hydraulic Cylinder / HPU
Comparison Category | SHA | HPU | Assumptions / Cost Basis (April 2023) | |
Environmental Waste | ![]() |
$0 $0 |
$33,600 $16,000 |
200 Gallon HPU Tank Hydraulic Fluid Index (HFI) = 4.1 SHA is sealed - no fluid replacement or disposal is required $42/gal x 800 gallons (4:1 HFI) $20/gal x 800 gallons (4:1 HFI) |
Energy Usage | ![]() |
$1,642 | $16,429 | SHA Uses Power on Demand SHA is 70% efficient (Kyntronics testing) 30 HP Hydraulic Power Unit that runs continuously HPU 22% is efficient (based on IFPE paper) Using $0.17 per KWh (average US rate - Fed 2023) |
Floor Space Utilization / Maintenance | ![]() |
$0 $1,760 |
$2,000 $5,250 |
SHA is All-in-One, no floor space required HPU requires space of 10'x10' = 100 Sq-ft @ $20 per sq-ft. SHA @ 1hr/week @ Labor $35/hr HPU @ 3hrs/week @ Labor $35/hr |
Ergonomics / Safety | ![]() ![]() |
$0 | $2,000 | HPU oil leaks create hazardous conditions and safety risk SHA is totally sealed, no oil leak risk Lost days + Medical costs + Legal costs |
Unplanned Downtime / Product Spoilage | ![]() |
$0 $0 |
$10,000 $10,000 |
SHA is totally sealed, no oil leak risk, minimal downtime risk $4k-$6k average downtime cost per incident. Assuming two downtime events. 1% scrap from product contamination due to leaky connections |
Annual Operating Costs | $3,392 | $95,279 | A $91,887 Annual Savings Opportunity! |
References
The basis for several of the assumptions used in the annual operating cost table originate from Fluid Power Industry published statistics and sources noted below:
- Hydraulic Oil Consumption – Measure to Manage
- Assessing Industrial Hydraulic System Efficiency
- Hydraulic System Leakage - The Destructive Drip
- Calculating the Cost of Downtime
To discuss your application with an Engineer and learn how the SMART Electro-Hydraulic Actuator (SHA) can help to eliminate hydraulics from your business, contact Kyntronics.