How to Choose Between Linear Actuators and Air Motors for Your Production Application

When designing or upgrading a production line, a key decision is choosing the right actuation method to drive movement and automation. Two popular options are electric linear actuators or pneumatic air motors. This guide will compare the pros and cons of each to help you select the best solution for your specific application.

What are Linear Actuators and Air Motors?

A linear actuator converts rotary motion into linear motion in a straight line. Most industrial linear actuators use an electric motor to extend and retract a piston rod. Models using hydraulics are also available but less common in factory settings.  

In contrast, an air motor utilizes compressed air to generate rotational kinetic energy through vanes, turbines, or pistons. It transforms pressure into continuous rotary force at high torque levels.

Comparing Motor Types

Several key factors differ between electric linear actuators and pneumatic air motors:

• Power Source – Linear actuators run on electricity. This allows for precise position and speed control with servo motors. Air motors require an external compressed air supply and regulator components.
• Force Output – Linear actuators can produce pushing/pulling thrust up to 75,000 lbs. Air motors output high torque rotational power instead of linear thrust.
• Speed – Linear actuators typically operate at slower feeds than high RPM pneumatic air motors. But linear speeds can reach up to 240”/second on some ball screw models.
• Accuracy and Repeatability – Electric actuators generally offer better precision down to ±0.001” tolerance levels. They also repeatedly return to the exact desired position.
• Environmental Resistance – Certain waterproof and explosion proof linear actuators withstand harsh conditions. Air motors perform better than electrical options in flammable settings though.
• Upfront Costs vs. Lifecycle Costs – Top quality linear actuators using ball screws have a higher initial price tag. But their long service life counterbalances replacement and energy costs over time. Compressed air expense is the largest operating cost for pneumatic motors.

Selecting the Right Actuation Method

So which technology works best for your automation project? Here is how to evaluate your key requirements and operating conditions to determine if a linear actuator or air motor fits best:

• Load Capacity Needs – Consider the continuous and peak external force loads that must be reliably overcome for smooth cyclical motion. High-capacity roller screw actuators accommodate up to 120,000 lbs dynamically.
• Speed & Precision Requirements – Applications demanding precise millimeter-scale increments at low speeds often point toward electromechanical linear alternatives. Rotational air vane motors provide rapid rotational output exceeding 10,000 rpm instead.  
• Duty Cycle Frequency – Components expected to operate at fast repeating cycles lasting sub-minutes make pneumatic or hydraulic fluid power appropriate. Linear electric actuators tolerate lower, less demanding duty cycles better.
• Positioning Accuracy & Repeatability Mandates – Precision automated processes like product placement, material handling or CNC applications need absolute positioning down to ±0.004” deviation. This favors linear actuators over air motors
• Available Access to Electricity & Compressed Air – Assess whether circuits can deliver adequate amperage for possibly multiple large linear actuators running concurrently near your cold formed parts handling station. Or verify sufficient airflow capacity at required PSI levels for air preparation across an entire end-of-line packaging zone.   
• Harsh Environmental Conditions – Ensure the selected actuator withstands any dampness, extreme temperatures or explosive gas risks present. Washdown linear electric actuators handle wet sanitary settings. Certain air motors suit volatile solvent atmospheres poorly ventilated outdoor spaces prohibit electrical enclosures safely.

Why Choose Flexible Automation?

Flexible Assembly specializes in recommending the ideal motion components customized to your exact specifications, operational landscape and budgetary requirements. Our application engineers assess each unique customer situation individually across industries like aerospace production, clean conveying processes demanding precision or specialty machine OEMs building new automated equipment. We carry hundreds of linear actuator, track roller and pneumatic air motor stock keeping units (SKUs) ready for configuration or modification if necessary. Everything from form-fit direct replacements for existing drives or fixtures to newly engineered platforms for cutting-edge motion control demands, Flexible Assembly makes sizing everything right hassle-free. Compared to large industrial distributors, our smaller factory-direct supply partner network allows special requests at purchaser quantities as low as one-offs while keeping costs reasonable on large orders.

In summary choosing the best actuator comes down to aligning technical capabilities against realistic operational needs while considering lifecycle value. Mounting back pressure requirements also factor in. Connect with our staff anytime to evaluate options hands-on.

Keep an eye for more latest news & updates on Visit Blog!