What Is the Shocking Difference Between Cylinders and Actuators That 80% of Engineers Get Wrong?

Engineers waste millions on wrong equipment choices every year. Procurement teams order “cylinders” when they need “actuators” – or vice versa. This confusion costs companies productivity, efficiency, and profits.

The difference between cylinders and actuators is that cylinders are a specific type of linear actuator that uses fluid pressure (pneumatic or hydraulic) for motion, while actuators are the broader category encompassing all devices that convert energy into mechanical motion, including electric, pneumatic, hydraulic, and mechanical types.

Two months ago, I got a frantic call from Sarah, a project manager at a German automotive plant. Her team had ordered 50 pneumatic cylinders for a precision assembly line, but the application actually required electric servo actuators for the positioning accuracy needed. The cylinders couldn’t achieve the ±0.05mm precision required. We helped them specify the correct electric actuators, and their reject rate dropped from 12% to 0.3% within a week.

Table of Contents

• What Defines a Cylinder vs an Actuator?
• How Do Cylinders and Actuators Differ in Construction?
• What Are the Key Performance Differences?
• How Do Power Sources Distinguish Cylinders from Actuators?
• What Control Capabilities Separate These Technologies?
• How Do Application Requirements Determine the Choice?
• What Are the Cost Implications of Each Technology?
• How Do Maintenance Requirements Compare?
• What Environmental Factors Influence the Selection?
• Conclusion
• FAQs About Cylinders vs Actuators

What Defines a Cylinder vs an Actuator?

Understanding the fundamental definitions reveals why these terms are often confused and when each applies correctly.

A cylinder is a specific type of linear actuator that uses fluid pressure (pneumatic or hydraulic) contained within a cylindrical chamber to create linear motion, while an actuator is the broader category of devices that convert various energy forms into controlled mechanical motion.

Cylinder Definition and Scope

Cylinders specifically refer to fluid-powered linear actuators that use compressed air (pneumatic) or pressurized liquid (hydraulic) to create motion. The term “cylinder” describes the cylindrical pressure vessel that contains the working fluid.

All cylinders are actuators, but not all actuators are cylinders. This relationship is crucial for proper terminology and equipment selection in industrial applications.

Cylinder operation relies on Pascal’s Law¹, where fluid pressure acts on a piston surface to generate linear force. The cylindrical shape optimally contains pressure while guiding linear motion.

Common cylinder types include pneumatic cylinders using compressed air, hydraulic cylinders using pressurized oil, and specialized variants like telescopic or rotary cylinders.

Actuator Definition and Categories

Actuators encompass all devices that convert energy into controlled mechanical motion. This broad category includes linear actuators, rotary actuators, and specialized motion devices.

Energy sources for actuators include electrical, pneumatic, hydraulic, mechanical, and thermal power. Each energy type offers different characteristics for force, speed, precision, and control.

Motion types produced by actuators include linear, rotary, oscillating, and complex multi-axis movements. The motion type determines actuator selection for specific applications.

Control complexity ranges from simple on/off operation to sophisticated servo control with position, velocity, and force feedback for precise automation.

Classification Hierarchy

The actuator family tree shows cylinders as a subset of linear actuators, which are themselves a subset of all actuators. This hierarchy helps clarify terminology and selection criteria.

Linear actuators include cylinders, electric linear actuators, mechanical actuators (screws, cams), and specialized designs like voice coil actuators for specific applications.

Rotary actuators include electric motors, rotary cylinders, pneumatic vane motors, and hydraulic motors for applications requiring rotational motion.

Specialized actuators combine linear and rotary motion or provide unique motion profiles for specific industrial applications and automation requirements.

Terminology Importance

Proper terminology prevents specification errors that cost time and money. Using “cylinder” when you need “electric actuator” leads to wrong equipment selection and project delays.

Industry standards define these terms precisely. Understanding standard definitions ensures clear communication with suppliers, engineers, and maintenance personnel.

Regional variations exist in terminology usage. Some regions use “cylinder” more broadly while others maintain strict technical distinctions between device types.

Technical documentation requires precise terminology for safety, maintenance, and replacement procedures. Incorrect terms can lead to dangerous equipment substitutions.

How Do Cylinders and Actuators Differ in Construction?

Construction differences reflect the fundamental operating principles and performance characteristics of each technology type.

Cylinders differ from other actuators in construction through their cylindrical pressure vessels, fluid sealing systems, and piston-based force generation, while electric actuators use motors and drive mechanisms, and mechanical actuators employ screws, gears, or linkages.

Cylinder Construction Elements

Cylinder construction centers around the pressure vessel that contains working fluid. The cylindrical shape optimally withstands internal pressure while providing linear guidance for the piston.

Piston assemblies include the piston itself, sealing systems, and force transmission components. Piston design affects performance, efficiency, and service life significantly.

Sealing systems prevent fluid leakage while allowing smooth motion. Seal technology represents a critical design element that affects reliability and maintenance requirements.

Rod assemblies transmit force from internal pistons to external loads while maintaining pressure integrity. Rod design must handle applied forces without buckling or excessive deflection.

Electric Actuator Construction

Electric actuators use motors as the primary energy conversion device, typically servo motors, stepper motors, or AC/DC motors depending on performance requirements.

Drive mechanisms convert rotary motor motion to linear output through ball screws², belt drives, rack-and-pinion systems, or direct-drive linear motors for different characteristics.

Feedback systems include encoders, resolvers, or potentiometers that provide position information for closed-loop control and precise positioning capabilities.

Housing designs protect internal components while providing mounting interfaces and environmental protection for reliable operation in industrial conditions.

Mechanical Actuator Construction

Mechanical actuators use purely mechanical energy conversion through screws, cams, levers, or gear systems that transform input motion into desired output motion.

Screw-type actuators employ lead screws or ball screws driven by manual handles, motors, or other power sources to create precise linear motion with high force capability.

Cam mechanisms provide complex motion profiles through specially shaped cam surfaces that guide follower motion for specific application requirements.

Linkage systems use mechanical advantage principles to amplify force or modify motion characteristics through lever arms and pivot points.

Material and Component Differences

Cylinder materials must withstand fluid pressure and chemical compatibility requirements. Common materials include steel, aluminum, and stainless steel with appropriate pressure ratings.

Electric actuator materials focus on electromagnetic properties, heat dissipation, and mechanical strength. Motor components use specialized magnetic materials and precision bearings.

Mechanical actuator materials emphasize wear resistance and mechanical strength. Hardened steels, bronze, and specialized alloys provide durability for mechanical contact applications.

Environmental protection varies by technology. Cylinders require fluid sealing, electric actuators need moisture protection, and mechanical actuators may need contamination barriers.

Assembly and Integration

Cylinder assembly involves pressure testing, seal installation, and fluid system integration. Proper assembly techniques ensure leak-free operation and optimal performance.

Electric actuator assembly includes motor alignment, encoder calibration, and electrical connections. Precision assembly affects positioning accuracy and system performance.

Mechanical actuator assembly focuses on proper lubrication, adjustment, and alignment to ensure smooth operation and prevent premature wear.

Quality control procedures differ by technology type, with pressure testing for cylinders, electrical testing for electric actuators, and mechanical testing for mechanical systems.

What Are the Key Performance Differences?

Performance characteristics vary dramatically between cylinders and different actuator types, affecting application suitability and system design.

Key performance differences include force output capabilities where hydraulic cylinders excel, speed characteristics where pneumatic cylinders dominate, precision levels where electric actuators lead, and efficiency ratings where electric systems typically perform best.

Force Output Capabilities

Hydraulic cylinders provide the highest force output, typically ranging from 1,000N to over 1,000,000N depending on size and pressure. High fluid pressure enables compact designs with enormous force capability.

Pneumatic cylinders offer moderate forces from 100N to 50,000N, limited by practical air pressure levels of 6-10 bar in most industrial applications.

Electric actuators provide variable force ranges from 10N to 100,000N depending on motor size and gear reduction. Force output remains constant regardless of position.

Mechanical actuators can provide very high forces through mechanical advantage, but typically operate at slower speeds due to the force-speed trade-off.

Speed and Response Characteristics

Pneumatic cylinders achieve the highest speeds, up to 10 m/s, due to low moving mass and rapid air expansion characteristics that enable fast acceleration.

Electric actuators provide variable speeds with excellent control, typically 0.001-2 m/s, with programmable acceleration and deceleration profiles for smooth operation.

Hydraulic cylinders operate at moderate speeds, 0.01-1 m/s, with excellent force control but limited by fluid flow rates and system response time.

Mechanical actuators typically operate at lower speeds but provide precise, repeatable motion with mechanical advantage for high-force applications.

Precision and Accuracy

Electric servo actuators provide the highest precision, achieving positioning accuracy of ±0.001mm with proper feedback systems and control algorithms.

Mechanical actuators offer excellent repeatability through direct mechanical positioning, typically achieving ±0.01mm accuracy with proper design and maintenance.

Hydraulic cylinders provide good precision, ±0.1mm, when equipped with position feedback and servo control systems for closed-loop operation.

Pneumatic cylinders have limited precision, ±1mm, due to air compressibility and temperature effects that affect positioning accuracy.

Energy Efficiency Comparison

Electric actuators achieve the highest efficiency, 85-95%, with minimal energy waste and the ability to recover energy during deceleration in some applications.

Hydraulic systems provide moderate efficiency, 70-85%, with losses in pumps, valves, and fluid heating, but excellent power-to-weight ratios.

Pneumatic systems have the lowest efficiency, 25-35%, due to compression losses and heat generation, but offer other advantages like cleanliness and safety.

Mechanical actuators can be highly efficient for specific applications but may require external power sources that affect overall system efficiency.

How Do Power Sources Distinguish Cylinders from Actuators?

Power source requirements create fundamental differences in system design, installation, and operational characteristics between cylinder and actuator technologies.

Power sources distinguish cylinders from actuators through compressed air or hydraulic fluid requirements for cylinders versus electrical power for electric actuators, creating different infrastructure needs, energy costs, and system complexity levels.

Pneumatic Power Systems

Pneumatic cylinders require compressed air systems including compressors, air treatment equipment, distribution piping, and storage tanks for reliable operation.

Compressor sizing must handle peak demand plus system losses with adequate reserve capacity. Undersized compressors cause pressure drops and poor performance.

Air treatment systems including filters, dryers, and lubricators ensure clean, dry air that prevents component damage and extends service life.

Distribution systems require proper sizing to minimize pressure drops and ensure adequate flow capacity at all usage points throughout the facility.

Hydraulic Power Systems

Hydraulic cylinders need hydraulic power units including pumps, reservoirs, filtration systems, and cooling equipment for continuous operation.

Pump selection affects system efficiency and performance. Variable displacement pumps provide better efficiency while fixed displacement pumps offer simpler control.

Fluid management includes filtration, cooling, and contamination control that significantly affects system reliability and component life.

Safety considerations include fire hazards from hydraulic fluids and high-pressure safety requirements for personnel protection.

Electrical Power Requirements

Electric actuators require electrical power with appropriate voltage, current capacity, and control interfaces for proper operation and performance.

Power supply sizing must consider motor ratings, duty cycles, and regenerative braking capabilities that may feed power back to the supply.

Control power requirements include motor drives, controllers, and feedback systems that add complexity but enable sophisticated control capabilities.

Electrical safety considerations include proper grounding, overcurrent protection, and compliance with electrical codes and standards.

Power Infrastructure Comparison

Installation complexity varies significantly, with pneumatic systems requiring air distribution, hydraulic systems needing fluid handling, and electric systems requiring electrical infrastructure.

Operating costs differ dramatically between power sources. Compressed air is expensive to generate while electricity offers variable cost depending on usage patterns.

Maintenance requirements vary by power source. Pneumatic systems need filter changes, hydraulic systems require fluid maintenance, and electric systems need minimal routine maintenance.

Environmental impact considerations include energy efficiency, fluid disposal, and noise generation that affect facility operations and regulatory compliance.

Energy Storage and Distribution

Pneumatic systems use compressed air storage in receivers that provide energy storage and help smooth demand fluctuations throughout the system.

Hydraulic systems may use accumulators for energy storage and peak demand handling, improving efficiency and system response characteristics.

Electric systems typically don’t require energy storage but may benefit from regenerative capabilities that recover energy during deceleration phases.

Distribution efficiency varies significantly, with electrical distribution being most efficient, hydraulic moderate, and pneumatic least efficient due to leakage and pressure drops.

What Control Capabilities Separate These Technologies?

Control sophistication and capabilities create major distinctions between cylinder and actuator technologies in automation applications.

Control capabilities separate cylinders from electric actuators through basic on/off operation for simple cylinders versus sophisticated servo control for electric actuators, with hydraulic cylinders offering moderate control and pneumatic cylinders providing limited precision control options.

Basic Cylinder Control

Simple pneumatic cylinders use basic directional valves for extend/retract control with limited speed adjustment through flow control valves.

Position control relies on limit switches or proximity sensors for end-of-stroke detection rather than continuous position feedback throughout the stroke.

Force control is limited to pressure regulation and doesn’t provide active force feedback or adjustment during operation.

Speed control uses flow restriction methods that may vary with load and don’t provide consistent velocity profiles across different operating conditions.

Advanced Cylinder Control

Servo-controlled hydraulic cylinders provide closed-loop position, velocity, and force control through proportional valves and feedback systems.

Electronic controls enable programmable motion profiles with variable acceleration, constant velocity, and controlled deceleration phases.

Pressure feedback systems allow force control and overload protection through continuous monitoring of chamber pressures during operation.

Network integration enables coordination with other system components and centralized control through industrial communication protocols.

Electric Actuator Control

Servo control provides precise position, velocity, and acceleration control through closed-loop feedback systems with high-resolution encoders.

Programmable motion profiles enable complex motion sequences with multiple positioning points, variable speeds, and coordinated multi-axis operation.

Force control capabilities include torque limiting, force feedback, and compliance control for applications requiring controlled force application.

Advanced features include electronic gearing, cam profiling, and synchronization capabilities for sophisticated automation applications.

Control System Integration

PLC integration varies by technology, with electric actuators offering the most sophisticated integration capabilities and simple cylinders providing basic I/O.

Network communication protocols enable distributed control architectures with real-time coordination between multiple actuators and system components.

Safety integration includes safe torque off, safe position monitoring, and integrated safety functions that meet functional safety requirements.

Diagnostic capabilities provide performance monitoring, predictive maintenance information, and troubleshooting support for system optimization.

Programming and Setup

Electric actuators typically require programming for motion parameters, safety limits, and communication settings through specialized software tools.

Hydraulic servo systems need tuning for optimal performance including gain settings, response characteristics, and stability parameters.

Pneumatic cylinders require minimal setup beyond basic valve adjustment and flow control settings for speed optimization.

Commissioning complexity varies significantly, with electric actuators requiring the most setup time and simple cylinders needing minimal configuration.

How Do Application Requirements Determine the Choice?

Application requirements drive the selection between cylinders and different actuator types based on performance needs, environmental conditions, and operational constraints.

Application requirements determine choice through force and speed needs favoring cylinders for high-speed or high-force applications, precision requirements favoring electric actuators, environmental constraints affecting technology suitability, and cost considerations influencing final selection.

Force and Speed Requirements

High-force applications typically favor hydraulic cylinders that can generate enormous forces in compact packages, making them ideal for pressing, forming, and heavy lifting.

High-speed applications often use pneumatic cylinders that achieve rapid motion due to low moving mass and fast air expansion characteristics.

Precision positioning applications require electric actuators with servo control for accurate placement and repeatable performance in assembly and inspection operations.

Variable force applications may need electric actuators with programmable force control or hydraulic systems with proportional pressure control.

Environmental Considerations

Clean room applications favor pneumatic cylinders or electric actuators that don’t risk oil contamination, making them suitable for food, pharmaceutical, and electronics manufacturing.

Harsh environments may require hydraulic cylinders with robust construction and environmental protection, or sealed electric actuators with appropriate IP ratings.

Explosive atmospheres need intrinsically safe³ designs or special protection methods that vary by actuator technology and certification requirements.

Temperature extremes affect all technologies differently, with specialized materials and designs required for extreme temperature applications.

Duty Cycle Requirements

Continuous duty applications often favor electric actuators with high efficiency and minimal heat generation compared to fluid power systems.

Intermittent duty allows pneumatic or hydraulic systems that may overheat in continuous operation but perform well in cyclic applications.

High-cycle applications require robust designs with appropriate component ratings and maintenance schedules to ensure reliable long-term operation.

Emergency operation requirements may favor pneumatic systems that can operate during power outages if compressed air storage is available.

Space and Installation Constraints

Compact installations may favor cylinders that integrate actuation and guidance in single packages, reducing overall system size and complexity.

Distributed systems might use electric actuators with network communication capabilities that eliminate complex fluid distribution systems.

Mobile applications often prefer electric or pneumatic systems that don’t require heavy hydraulic power units and fluid reservoirs.

Retrofit applications may be constrained by existing infrastructure, favoring technologies that integrate with available power sources and control systems.

Safety and Regulatory Requirements

Food safety regulations may require specific materials and designs that eliminate contamination risks, favoring pneumatic or electric technologies.

Pressure equipment regulations affect hydraulic and pneumatic systems differently, with high-pressure hydraulics requiring more extensive safety measures.

Functional safety requirements may favor electric actuators with integrated safety functions or require additional safety systems for fluid power applications.

Environmental regulations affect fluid disposal and leakage prevention, potentially favoring electric systems in environmentally sensitive applications.

What Are the Cost Implications of Each Technology?

Cost analysis reveals significant differences in initial investment, operating expenses, and lifecycle costs between cylinder and actuator technologies.

Cost implications show pneumatic cylinders having the lowest initial cost but higher operating expenses, hydraulic cylinders requiring high infrastructure investment, and electric actuators offering higher initial cost but better long-term economics through efficiency and reduced maintenance.

Initial Investment Costs

Pneumatic cylinders offer the lowest initial equipment cost, typically 50-70% less than equivalent electric actuators, making them attractive for budget-conscious applications.

Electric actuators have higher initial costs due to sophisticated motors, drives, and control systems, but this investment often pays back through operational savings.

Hydraulic cylinders have moderate equipment costs but require expensive power units, filtration systems, and safety equipment that increase total system cost.

Infrastructure costs vary dramatically, with pneumatic systems requiring compressed air generation, hydraulic systems needing power units, and electric systems requiring electrical distribution.

Operating Cost Analysis

Energy costs favor electric actuators with 85-95% efficiency compared to 25-35% for pneumatic systems and 70-85% for hydraulic systems.

Compressed air costs typically range $0.02-0.05 per cubic meter, making pneumatic systems expensive to operate in high-usage applications.

Hydraulic fluid costs include initial fill, replacement, disposal, and cleanup expenses that accumulate over system lifetime.

Electric power costs vary by location and usage patterns but generally provide the most predictable and manageable operating expenses.

Maintenance Cost Comparison

Pneumatic systems require regular filter changes, drain maintenance, and seal replacement with moderate labor requirements and low parts costs.

Hydraulic systems need fluid changes, filter replacement, leak repair, and component rebuilding with higher labor and parts costs.

Electric actuators require minimal routine maintenance but may have higher repair costs when components fail, offset by longer service intervals.

Preventive maintenance costs vary significantly, with pneumatic systems requiring the most frequent attention and electric systems needing the least.

Lifecycle Cost Analysis

Total cost of ownership⁴ over 10-15 years often favors electric actuators despite higher initial costs due to energy savings and reduced maintenance.

Pneumatic systems may have the lowest 3-year costs but become expensive over longer periods due to energy consumption and maintenance.

Hydraulic systems can be cost-effective for high-force applications where electric alternatives would be much larger and more expensive.

Replacement costs favor standardized technologies with readily available components and service support throughout the system lifetime.

Hidden Cost Factors

Downtime costs from system failures can dwarf equipment costs, making reliability and maintainability critical factors in technology selection.

Training costs vary by technology complexity, with electric servo systems requiring more specialized knowledge than simple pneumatic systems.

Safety compliance costs include pressure equipment certification, electrical safety measures, and environmental protection that vary by technology.

Space costs in expensive facilities may favor compact technologies even if equipment costs are higher due to space utilization efficiency.

How Do Maintenance Requirements Compare?

Maintenance requirements create significant operational differences between cylinder and actuator technologies affecting reliability, costs, and system availability.

Maintenance requirements show pneumatic cylinders needing frequent filter changes and seal replacement, hydraulic cylinders requiring fluid maintenance and leak repair, while electric actuators need minimal routine maintenance but more specialized service when repairs are required.

Pneumatic Cylinder Maintenance

Daily maintenance includes visual inspection for air leaks, unusual noises, and proper operation that can identify developing problems before failures occur.

Weekly tasks involve air filter inspection and replacement, pressure regulator checks, and basic performance verification to maintain system reliability.

Monthly maintenance includes guide lubrication, sensor cleaning, and detailed performance testing to identify degrading components before they fail.

Annual service encompasses seal replacement, internal inspection, and comprehensive testing to restore like-new performance and prevent unexpected failures.

Hydraulic Cylinder Maintenance

Fluid analysis programs monitor oil condition, contamination levels, and additive depletion to optimize fluid change intervals and prevent component damage.

Filter replacement schedules maintain clean fluid that prevents component wear and extends system life significantly beyond systems with poor filtration.

Leak detection and repair programs prevent environmental contamination and fluid loss while maintaining system performance and safety.

Component rebuilding includes seal replacement, surface refinishing, and dimensional restoration that can extend component life beyond original specifications.

Electric Actuator Maintenance

Routine maintenance is minimal, typically limited to periodic cleaning, connector inspection, and basic performance verification on extended intervals.

Bearing lubrication may be required on some designs, but many use sealed bearings that require no maintenance throughout their service life.

Software updates and parameter backup ensure system configuration is preserved and performance optimization continues throughout system life.

Predictive maintenance using vibration analysis, thermal imaging, and performance monitoring can identify developing problems before failures occur.

Maintenance Skill Requirements

Pneumatic system maintenance requires basic mechanical skills and understanding of air system components, making training relatively straightforward.

Hydraulic maintenance needs specialized knowledge of fluid systems, contamination control, and safety procedures for high-pressure systems.

Electric actuator service requires electrical and electronic skills plus specialized software tools for programming and diagnostics.

Cross-training benefits facilities using multiple technologies, but specialization may be more efficient for facilities with predominantly one technology type.

Spare Parts and Inventory

Pneumatic systems use standardized components with wide availability and relatively low costs for filters, seals, and basic components.

Hydraulic systems require fluid inventory, specialized seals, and filtration components that may have longer lead times and higher costs.

Electric actuators may need expensive electronic components with longer lead times, but failures are typically less frequent than fluid power systems.

Inventory optimization strategies differ by technology, with pneumatic systems benefiting from local stock and electric systems using just-in-time approaches.

Maintenance Planning and Scheduling

Preventive maintenance schedules are most critical for pneumatic systems due to frequent filter changes and seal replacement requirements.

Condition-based maintenance works well for hydraulic systems using fluid analysis and performance monitoring to optimize service intervals.

Predictive maintenance is most effective for electric actuators using advanced monitoring techniques to identify developing problems early.

Maintenance coordination with production schedules is essential for all technologies but may be most flexible with electric systems due to longer service intervals.

What Environmental Factors Influence the Selection?

Environmental conditions significantly impact the suitability and performance of different cylinder and actuator technologies in real-world applications.

Environmental factors influence selection through temperature extremes affecting fluid properties and seal performance, contamination levels determining protection requirements, humidity causing corrosion issues, and hazardous atmospheres requiring special safety certifications.

Temperature Environment Impact

Extreme temperatures affect all technologies differently. Pneumatic systems suffer from condensation at low temperatures and reduced air density at high temperatures.

Hydraulic systems face fluid viscosity changes that affect performance and may require heated reservoirs or coolers for temperature control.

Electric actuators handle temperature extremes better with appropriate motor designs but may need environmental enclosures for protection.

Thermal cycling creates expansion and contraction stresses that affect seal life in cylinders and bearing life in electric actuators.

Contamination and Cleanliness

Dusty environments accelerate seal wear in cylinders and may require frequent filter changes and protective covers for reliable operation.

Clean room requirements favor pneumatic cylinders or electric actuators that don’t risk oil contamination in sensitive manufacturing processes.

Chemical contamination attacks seals and metal components differently in each technology, requiring material compatibility analysis for proper selection.

Washdown environments need special sealing and materials that vary by technology, with stainless steel construction often required.

Moisture and Humidity Effects

High humidity increases condensation risk in pneumatic systems, requiring air dryers and drainage systems for reliable operation.

Corrosion affects all technologies but impacts hydraulic and pneumatic systems more due to water contamination in fluids.

Electrical systems need appropriate IP ratings⁵ and environmental sealing to prevent moisture ingress that could cause failures or safety hazards.

Freeze protection may be required in cold climates, with different solutions needed for each technology type.

Hazardous Area Classifications

Explosive atmospheres require intrinsically safe designs or explosion-proof enclosures that vary significantly by technology and certification requirements.

Pneumatic systems may be inherently safer in some explosive environments due to the absence of electrical ignition sources.

Electric actuators need special certifications and protection methods for hazardous areas, potentially increasing costs and complexity.

Hydraulic systems may present fire hazards from pressurized flammable fluids that require special safety measures and fire suppression systems.

Vibration and Shock Environment

High vibration environments affect all technologies but may cause particular problems with electrical connections and electronic components.

Shock loads can damage internal components differently in each technology, with hydraulic systems often being most robust.

Mounting and isolation requirements vary by technology, with proper vibration isolation being critical for reliable operation.

Resonance frequencies must be avoided in system design to prevent amplification of vibration effects that could cause premature failure.

Regulatory and Compliance Issues

Food safety regulations may prohibit certain materials or require special certifications that favor some technologies over others.

Pressure equipment regulations affect pneumatic and hydraulic systems differently, with high-pressure hydraulics requiring more extensive compliance.

Environmental regulations may restrict hydraulic fluids or require containment systems that increase costs and complexity.

Safety standards may mandate specific technologies or protection methods for personnel safety in certain applications or industries.

Conclusion

The difference between cylinders and actuators lies in scope and specificity – cylinders are fluid-powered linear actuators within the broader actuator category that includes electric, mechanical, and other motion technologies, each offering distinct advantages for different applications, environments, and performance requirements.

FAQs About Cylinders vs Actuators