[BLOG] Why Modular Design Strategies Favor Electric Actuators Over Hydraulic Systems

Hydraulics and electric actuators mainly differ in where the functionality resides. In hydraulic systems, functionality is distributed across the system. A pump generates pressure, valves regulate flow, and cylinders create movement. Everything must be carefully coordinated. In electric actuators, this functionality is integrated into a single unit. Drive, motion, and increasingly control are built into the actuator itself.

Less complex infrastructure, more design freedom

Modern electric actuators are built around a fixed core. Key components such as the drive, housing, and basic control remain the same for every application. Around this core, additional functions can be added or adapted. Think of different motors, feedback types, or integrated control. Components such as adapters and connections can also be tailored to the specific situation.

An important development is the integration of electronics. This makes actuators more flexible and intelligent. Software can now handle control, analysis, and monitoring—something that was difficult or impossible with hydraulic systems. Thanks to this smart technology and adaptable components, it becomes easier and more cost-effective to add extra features. Examples include force feedback, load dampening, and manual override.

Modular features make the difference

The strength of modularity lies not only in the design, but especially in the functions that can be added. Because these are developed independently of the core, they can be easily integrated into the actuator.

Electronics enable this modularity

The foundation of this development lies in the integration of electronics. Because sensors, software, and control are embedded in the actuator itself, functions can easily be added—often simply by connecting an additional module. In hydraulic systems, expansion usually requires modifications throughout the entire system, making it less flexible and harder to scale.

For engineers, this also changes the way of working. Instead of building a system from separate components, you work with a configurable solution. This means less coordination, less commissioning effort, and shorter lead times. It also becomes easier to reuse solutions, as the core remains the same and only the configuration is adapted to the application.

Modular electric actuators are changing the role of the actuator within a machine. Instead of being a component within a complex system, they become a standalone, configurable building block. As a result, the basis for decision-making shifts—from purely force or robustness to design freedom, simplicity, and control.

Electric actuators are therefore not just an alternative to hydraulics, but in many cases the logical next step.