Companies are increasingly turning to electric linear actuators to replace hydraulic systems as they seek greater efficiency, lower running costs, and improved control, according to UK-based motion control specialist INMOCO.
While hydraulic systems have long been valued for their power, advances in electric actuator design mean the technology now rivals hydraulics in most industrial applications. Gerard Bush, Engineer at INMOCO, said electric systems could exert forces of up to 222kN — sufficient for use in presses, cranes, and other high-load machinery — while offering higher precision and reliability.
“Electric actuators can match hydraulic force in almost every application, but with far greater efficiency and control,” said Bush. “Hydraulic systems typically achieve around 50% efficiency, whereas electric designs operate at 75–80%, making them less expensive to run and nearly maintenance-free.”
Electric actuators, such as Tolomatic’s RSX and RSH ranges, deliver tightly controlled motion and repeatable accuracy, enabling higher throughput and better product quality. Their ability to manage force, position, velocity, and acceleration in real time also allows for more flexible machine functions.
Despite these advantages, many manufacturers remain hesitant to retrofit existing systems. The perceived complexity and cost of conversion often discourage investment, Bush said, even though electric systems typically provide long-term savings and reduced downtime.
One key challenge in retrofitting is accurate sizing — ensuring the electric actuator matches the application’s true load requirements. Traditional sizing methods, such as using rated system pressure, tend to overspecify components, leading to higher costs.
Bush recommends determining both the peak and continuous working forces of the existing hydraulic cylinder for a precise conversion. “Accurate sizing begins with understanding the actual forces acting on each side of the piston,” he said. “Measuring hydraulic pressure as close to the cylinder as possible provides the most reliable data, though readings taken at the valve can still give acceptable accuracy within about 15%.”
Proper measurement of return pressures and the dynamic forces on both the piston and rod ends is also necessary to ensure that the electric actuator delivers the required performance.
INMOCO, which represents Tolomatic in the UK, supports customers with hydraulic replacement projects, including the sizing and specification of electric linear actuators. Founded in 1987, the company provides a broad range of motion control equipment, including servo amplifiers, PLC controllers, linear motors, and sensors.
