Technologies for high-speed linear strokes

1. Which technologies are suitable for fast linear strokes?

When particularly fast linear movements are required in a machine or system, a key question quickly arises: Which drive technology is best suited for this task?

In practice, three main technologies are used:

1. Hydraulics
2. Pneumatics
3. Electromechanics (e.g., screw jacks, linear chains, electric actuators)

Each of these technologies has specific strengths, but also clear limitations. This article explains how they work, their typical speeds, advantages and disadvantages, and common applications, enabling a well-founded comparison.

2. Hydraulic drives – Powerhouses with limited dynamics

Operating principle

Hydraulic systems use pressurized fluids (usually oil). The generated pressure moves a piston inside a cylinder, creating linear motion.

Typical speed

1. Moderate to high speeds possible
2. However, not designed for extremely high stroke speeds
3. Limiting factors: oil pressure, leakage compensation, valve response time

Advantages

1. Very high forces within a compact installation space
2. Robust and durable
3. Well suited for heavy, slow to medium-speed movements

Disadvantages

1. Limited dynamics due to oil compressibility and valve behavior
2. Leakage, oil changes, and maintenance effort
3. Temperature sensitivity
4. Complex infrastructure (hydraulic power unit, hoses, piping)

Typical applications

Presses, injection molding machines, construction and agricultural machinery, heavy lifting applications.

→ Not the first choice when extremely fast stroke movements are required.

3. Pneumatic drives – Very fast, but imprecise

Operating principle

Pneumatic systems use compressed air to move a piston. Due to low friction, very fast movements are possible.

Typical speed

1. Very high speeds possible (up to > 1 m/s)
2. However, difficult to control, especially with varying loads

Advantages

1. Low initial cost
2. Very lightweight and compact
3. Extremely fast motion
4. Ideal for simple “on/off” cycles

Disadvantages

1. Poor controllability (air is compressible)
2. Hardly any constant speed under load
3. Low energy efficiency
4. High operating costs due to compressed air
5. Difficult positioning / very limited precision

Typical applications

Pick-and-place units, slide movements, stoppers, packaging machinery.

→ Ideal when speed is the only requirement — but not precision or load stability.

4. Electromechanical drives – High speed, high precision

Operating principle

An electric motor generates rotational motion, which is converted into linear motion via a mechanical system (e.g., ball screw, belt, rack-and-pinion, linear chain). Alternatively, linear motors generate linear force directly without mechanical conversion.

Typical speed

1. Very high speeds possible
2. At the same time, precisely controllable
3. Speed, acceleration, and position can be digitally controlled

Advantages

1. Highest precision in positioning and repeatability
2. Excellent speed controllability
3. Low maintenance requirements
4. Clean, quiet, and energy-efficient
5. Easy integration into modern automation systems

Disadvantages

1. Higher initial investment (often pays off over the service life)
2. Mechanical components (e.g., screws) are subject to wear
3. Extremely high forces like those achievable with hydraulics are rarely possible

Typical Applications

Robotics, machine tools, semiconductor manufacturing, medical technology, packaging machinery, high-speed stroke applications.

→ The best combination of speed, precision, and efficiency — especially for fast, repeatable stroke motions.

5. Direct comparison of those three technologies

6. Conclusion: Which technology is the right choice?

1. Hydraulics are ideal for very high forces — but not for the highest speeds.
2. Pneumatics offer extreme speed, but very limited control.
3. Electromechanics combine high speed, precision, and energy efficiency, making them the best choice for fast, controlled, and highly repeatable stroke movements.

If you’re looking for high speed combined with controlled motion and low maintenance, there is practically no alternative to an electromechanical solution.