Electric Actuator vs Pneumatic Cylinder: The Complete Engineer's Guide

Industrial automation engineers face this decision every day: pneumatic cylinder or electric actuator?
The answer is no longer obvious. Rising energy costs, tighter precision requirements, and sustainability mandates are shifting the balance toward electric linear drives — but not in every application.

This guide gives you the data to decide. Written by the engineers at NILAB, manufacturers of tubular linear motors and electric actuators since 2003.

1. Technology Overview

Pneumatic Cylinder

A pneumatic cylinder converts compressed air pressure into linear mechanical force. It is simple, fast, and inexpensive to purchase — which is why it became the default choice for repetitive linear motion in industrial automation throughout the 20th century.

How it works:
- A compressor generates compressed air (typically 6–8 bar)
- Air is routed through valves to one or both sides of a piston
- The pressure differential moves the piston rod linearly
- Position is usually controlled by mechanical end stops

Inherent limitations:
- Position is binary (fully in / fully out) unless expensive proportional valves are added
- Force is difficult to control without additional hardware
- Energy is wasted continuously — the compressor runs even when no motion occurs
- Air leakage is unavoidable and progressive over time

Electric Linear Actuator / Linear Motor

An electric actuator converts electrical energy directly into linear mechanical motion, either through a rotary motor + screw mechanism or — in the case of NILAB tubular linear motors —
through direct electromagnetic drive with no rotating parts.

How it works:
- A servo drive controls current to the motor windings
- The magnetic field interaction produces direct linear force
- An encoder provides closed-loop position feedback
- The controller can command any position, velocity, or force profile

Key advantages over pneumatics:
- Infinite intermediate positioning (not just end stops)
- Programmable force, speed, and acceleration profiles
- No compressed air infrastructure required
- Energy consumed only during actual motion

2. Side-by-Side Comparison

Paramter	Pneumatic Cylinder	NiLAB Electric Actuator
Positioning	Binary (2 positions)	Infinite (closed-loop)
Position repeatability	+/-0.5 - 2.0 mm on mechanical stop	+/-0.01 - 0.05 mm
Force control	Difficult / Imprecise	Precise / programmable
Speed control	Limited (flow valves)	Full profile, programmable
Energy at idle	Compressor runs = waste	Zero or very consumption
Energy in motion	25% - 35% efficiency	85 - 92 % efficiency
Maintenance	Seals, valves, filters	Minimal (only replacable IGUS)
Noise	High (exhaust air)	Low
Cleanliness	Il mist risk	Clean room compatible
IP protection	Standard up to IP54	Up to IP 68
Initial cost	Low	Medium-High
TCO over 5 years	High (energy + maintenance)	Low
Integration complexity	Low (valve + tubing)	Medium to low (same valve control)

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3. Energy Consumption: The Real Numbers

This is where the electric actuator wins decisively in most applications.

A typical pneumatic system wastes energy in three ways:
- Compressor inefficiency: only ~10–15% of electrical energy input reaches the cylinder as useful work
- Distribution losses: leakage in pipes and fittings (typically 20–30% of total air produced)
- Idle losses: the compressor maintains pressure even when no cylinder is moving

Example calculation — 2-shift production (16h/day):

A single Ø50mm pneumatic cylinder, 200mm stroke, 6 bar, 30 cycles/minute:

Cost Item	Pneumatic	NiLAB Electric Actuator
Air consumption	85 l/min	-
Compressor power equivalent	1.8 kW continuos	-
Motor power	-	180 W peak / 45 W average
Annual energy cost (0.25 €/kWh)	2628€ /year	263€ / year
Maintenance (seals, valves)	400€ / year	€50 / year
Total annual cost	3028€ / year	313€/year
Savings	-	2715€/year

ROI on electric replacement: typically 12–18 months for 2-shift operations.

👉 Calculate your exact savings: NILAB Pneumatic to Electric Tool — Free Online Calculator

Enter your cylinder diameter, stroke, working pressure, and cycle rate.
The tool returns energy consumption, CO₂ equivalent, annual cost, and the recommended NILAB electric actuator.

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4. When to Choose Pneumatic

Electric is not always the answer. Pneumatic cylinders remain the better choice when:

* Very high cycle rates (>200 cycles/min) with simple end-to-end motion — pneumatics can be faster and simpler for pure bang-bang applications
* Extreme force-to-cost ratio is required and precision is irrelevant (e.g., clamping, punching, pressing at fixed force)
* ATEX / explosive atmospheres — electric drives require careful selection; pneumatics are inherently safe
* Existing pneumatic infrastructure with very low utilization rates — payback period may exceed 3 years
* Very short strokes (<10mm) with no positioning requirement — the cost delta is not justified

5. When to Choose Electric

Choose an electric linear actuator when:

* Multi-position control is required (3 or more positions per stroke)
* Force control is needed (soft landing, variable clamping force, press-fit assembly)
* Energy efficiency is a KPI — electric saves 70–90% of energy vs. pneumatic
* Cleanroom or food/pharma environment — no oil mist, IP65/IP67 available
* Quiet operation is required (food retail, labs, medical)
* Predictive maintenance is part of the strategy — servo drives provide motor current data that predicts wear
* Eliminating the compressor is a goal — one compressor typically serves dozens of cylinders; removing pneumatics simplifies the entire plant utility system

6. NILAB Tubular Linear Motor — Direct Drive Advantage

Most electric actuators use a rotary motor + ballscrew or belt to convert rotation into linear motion.
NILAB tubular linear motors are direct drive: the electromagnetic force acts directly on the forcer,
with no intermediate mechanical transmission.

This means:
* Zero backlash — no gearbox, no screw, no belt
* No mechanical wear on the drive element
* Higher acceleration — moving mass is only the forcer, not motor + coupling + screw
* Simpler mechanics — fewer parts, fewer failure points

Series	Peak Force	Stroke	Protection	Typical application
NL080QX & NL120QX	up to 247N	up to 300-400mm	IP65	Ligh assembly, pick and place
GD160DTQ	up to 152N	up to 500mm	IP65	Food & bevarage, pharma
GD250DQTX	up to 1748N	up to 500mm	IP65	Machine tools, woodworking

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7. Migration Guide: Replacing a Pneumatic Cylinder

Follow these steps to select the correct NILAB actuator for your pneumatic replacement:

Step 1 — Document your current cylinder:
- Bore diameter (mm)
- Stroke (mm)
- Working pressure (bar)
- Cycle rate (cycles/min)
- Required force (N) — calculate: F = P × A = pressure(Pa) × bore_area(m²)
- Environmental conditions (IP, temperature, washdown)

Step 2 — Use the NILAB P2E Tool:
→ Pneumatic to Electric Calculator

Input your parameters. The tool outputs:
- Recommended NILAB model
- Force-velocity curve for your duty cycle
- Energy savings vs. pneumatic (annual kWh and €)
- CO₂ reduction equivalent
- Payback period

Step 3 — Download the datasheet and CAD files:
→ NILAB Datasheet Engine
→ 3D CAD File Download (STEP, IGES, Parasolid)

Step 4 — Select the servo drive:
NILAB tubular motors are compatible with:
- NILAB Epulse series (CANopen DS402, Modbus RTU, EtherCAT)
- Siemens SINAMICS
- Beckhoff TwinCAT NC
- Any DS402-compatible servo drive

Related Tools & Resources

Resource	Link
Pneumatic → Electric Calculator	NILAB P2E Tool
Motor Sizing (WebSmart)	NILAB WebSmart Dimensionatore
Datasheet Download	Datasheet Engine
3D CAD Files	CAD Download
Product Catalogue	Download PDF Catalogue

Contact & Application Support

Need help sizing your application or evaluating a pneumatic-to-electric migration?

→ Contact NILAB Engineering Team
→ Product User Forum
→ Direct: katharina.pirker@nilab.at | +43 720 513 258