In mechanical engineering, we often treat automation as a series of trade-offs. If a design requires the precision and repeatability of an electromechanical actuator, we typically size the motor to handle 100% of the load. Conversely, if we only need basic lifting assistance, we opt for the cost-effective reliability of a gas spring.
However, as industrial applications demand higher speeds and heavier loads, this “either/or” mentality often leads to oversized, expensive motors or manual systems that lack the safety of automation.
By looking at a Hybrid Motion approach, pairing the Industrial POWERISE® electromechanical actuator with ACE Gas Springs, engineers can unlock a new level of system efficiency that neither component can achieve alone.
The Problem with Oversizing
When an actuator is tasked with lifting a heavy industrial hatch or safety gate entirely on its own, the motor must overcome the full force of gravity from a dead stop. This requires high peak currents, larger drive units, and risks motor failure. Furthermore, if power is lost, these heavy loads can become nearly impossible to move manually.
How Hybrid Synergy Works
Integrating an ACE gas spring into an automated POWERISE® system creates a “counterbalance” effect. The gas spring is sized to handle the majority of the static load (the weight of the lid or component), while the POWERISE® provides the dynamic force required for controlled, precise movement.
This synergy offers three distinct technical advantages:
- Reduced Motor Strain & Energy Consumption: Because the gas spring handles the heavy lifting, the actuator operates with significantly lower torque. This allows for a smaller footprint, less heat generation, and a longer service life for the electromechanical components.
- Increased Travel Speeds: With the load effectively neutralized by the gas spring, the POWERISE® can achieve higher cycle speeds. This is critical in high-throughput automation where every second of opening/closing time counts toward overall OEE (Overall Equipment Effectiveness).
- The “Power-Off” Safety Factor: One of the most overlooked benefits of the hybrid approach is manual override. In the event of a power failure, a purely electromechanical system may “lock” or require immense force to move. In a hybrid setup, the gas spring ensures the load remains manageable, allowing operators to move the component safely and ergonomically by hand.
Application Spotlight: Precision Meets Power
We are seeing this hybrid approach revolutionize sectors like Medical Technology and High-End Industrial Enclosures. In these environments, you need the “hands-free” convenience of automation, but you cannot afford the bulk or noise of a massive actuator.
The Industrial POWERISE® is uniquely suited for this because of its best-in-class noise dampening. When paired with a gas spring, you get a system that is not only powerful and fast but also whisper-quiet and safe for human-centric environments.
Is a Hybrid System Right for Your Project?
If you are currently struggling with an application that feels “too heavy” for a standard actuator or “too complex” for a simple gas spring, a hybrid solution may be the answer.
At ACE Controls, we don’t just provide the parts; we provide the calculation. Our engineers can help you size both the actuator and the gas spring simultaneously to ensure your system is perfectly balanced for performance, cost, and safety.
Contact an ACE Application Engineer Today or Download the POWERISE® Technical Datasheet to learn more.