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Hydraulics vs. Pneumatics

There are two basic tooling options when looking for equipment with relatively small mechanical components that can be easily transmitted, and provide great multiplication of force. There are hydraulic cylinders and then there are pneumatic cylinders. Pneumatic cylinders are more suited for providing low to medium forces at relatively high to moderate speeds. Hydraulic cylinders on the other hand provide many tons of force at low to moderate speeds. Both cylinders have their advantages and disadvantages.

The biggest and most obvious difference between hydraulic components and pneumatic is that hydraulics are pressurized with oil or water whereas pneumatics are pressurized with compressed air. Hydraulic equipment such as hydraulic pistons cylinders is associated with high initial costs, but lower operating cost. Equipment that utilizes compressed air has higher operating costs but lower initial costs. The reason behind the expensive of hydraulic systems is due to the need for highly durable equipment that can withstand high pressures. Hydraulic equipment designed to last more than 15 years where pneumatics are only designed to last for 10 years.

Hydraulic systems operate under much higher pressures than their pneumatic counterpart. Pneumatic machines and tools operate at pressures between 80 and 100 psi whereas hydraulics operate under pressures between 1,000 and 5,000 psi. That is a rather large gap. Hydraulic systems may operate at higher pressures but pneumatic systems are cleaner. Hydraulic systems have the potential to leak oil and contaminate a workplace.

Both systems have their advantages depending on the application. Hydraulics are often used to lift and crush objects such as in hydraulic jacks and baling machines. Pneumatic systems are easy to transport and are well suited to run equipment in wet or dirty environments. They are extensively utilized in mining and construction operations where electrical equipment may be difficult to manage and even dangerous. Another major factor is the durability of hydraulic machines.