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Cost Evaluation of Pneumatic and Electric Actuator Deployments

Version 1.01, March 2011

Purpose: This spreadsheet is intended to provide an approximate comparison of the total costs
Replacement costs, electrical energy consumption, and process improvement cost savings are

Organization: The spreadsheet has five tabs.

Instructions (this page)


Pneumatic Solution Cost Cost evaluation of pneumatic actuators and compressor
AC Actuator Solution Cost Cost evaluation for electric actuators that are powered by the AC lin
DC Actuator Solution Cost Cost evaluation of electric actuators that require DC power supplies
Electric Productivity Savings Calculation of cost reductions from man-hour savings and elimin
Summary Pneumatic vs. Electric side by side cost comparison of pneumatic and electric.

Each spreadsheet requires information to be input. These are shown as pink boxes. Each spread

Input requirements: When evaluating compressors, electric actuators, motors, controls, and po
for the devices handy. The more accurate the information input, the more useful the output wil

Limitations: The spreadsheet is only a generalization. While most applications employ a variety
average component, done for simplicity. The spreadsheet facilitates comparisons of compres
address how to size a compressor for a given installation of pneumatic actuators. That is beyon
toprovide a usefulestimate, but the results arenot guaranteed. To the maximum extent perm
the implied warranty of fitness for a particular purpose and the implied warranty of merchantab

ployments

comparison of the total costs of deploying electric and pneumatic actuators.


mprovement cost savings are taken into account.

and compressor
hat are powered by the AC line voltage
hat require DC power supplies
man-hour savings and elimination of lost production.
pneumatic and electric.

wn as pink boxes. Each spreadsheet provides output as well.

ors, motors, controls, and power supplies, it helps to have manufacturers specifications
he more useful the output will be.

applications employ a variety of components, the spreadsheet only allows input for an
ates comparisons of compressors, pneumatic cylinders, and actuators, but it does not
matic actuators. That is beyond the scope of this spreadsheet. The spreadsheet is meant
To the maximum extent permitted by law, all warranties, expressed or implied, including
plied warranty of merchantability areexpressly disclaimed.

Pneumatic Solution Annual Cost


Enter the criteria in the Input cells below to calculate the annual cost to operate a pneumatic solution.
Compressor Costs
kWh Electrical Cost
Hours per Week Full Load
Hours per Week Idling
Weeks per Year in Operation

Input
$0.00
0
0
0

Compressor Horse Power


% Compressor efficiency, full load
% Compressor efficiency, idle

0
0%
0%

Annual Full Load Use (Hours)

Number of Pneu Actuators


Avg Replacement cost of Pneu Actuators
Pneu Actuators Avg Life Yrs.

0
$0
0

Annual kWH Cost


Full Load
#N/A

Idle Load
#N/A

Annual kWH

#N/A

Annual Replacement Cost

#N/A

Total Annual Pneumatic System Cost


Cost per Pneumatic Device per Year

#N/A
#N/A

AC Powered Electric Actuator Solution Cost


Enter the criteria in the Input cells below to calculate the annual cost to operate an AC actuator solution.
kWh Electrical Cost
Operating Hours per Week
Total Operating Weeks per Year
Total Annual Operating Hours
% of Hours Operating at Full Load
% of Hours Operating at Idle Load

Input
$100.00
0
0
0
2%
98%

Number of AC Electric Actuators

Avg. Unit Cost of AC Powered All-in-One Elect Actuator

$0

Avg. cost of Modular Elect Actuator


Avg. Unit Cost of Motor

$0
$0

AC - All-in-One Actuator
Voltage input
Current Draw Amps - Full Load
Current Draw Amps - Idle (Not Off)

0
0
0

Electrical power consumption costs


Unit @ Full
Unit @ Idle
Per Unit Total
$0.00
$0.00
$0.00
Annual kWh Cost
Annual Replacement Cost
Total Annual Cost

$0.00
#N/A
#N/A

DC Powered Electric Actuator Solution Cost


Enter the criteria in the Input cells below to calculate the annual cost to operate a DC actuator solution.
kWh Electrical Cost
Operating Hours per Week
Total Operating Weeks per Year
Total Annual Operating Hours
% of Hours Operating at Full Load
% of Hours Operating at Idle Load

Input
$0.00
0
0
0
2%
98%

Number of DC Electric Actuators

Avg. unit cost of DC power supply

$0

Avg. Unit Cost of All-in-One DC Elect Actuator

$0

Avg. cost of Modular DC Elect Actuator


Avg. Unit Cost of Motor
Avg. Unit Cost of Controller

$0
$0
$0

Avg. Actuator Life (Yrs)


Avg. Motor Life (Yrs)
Avg. Controller and Power Supply Life (Yrs)

0
0
0

DC - All-in-One Actuator
Power Supply
Input voltage
Maximum current draw
Maximum output current
Actuator
Current Draw Amps - Full Load
Current Draw Amps - Idle (Not Off)

0
0
0
0
0

Electrical power consumption costs


Unit @ Full
Unit @ Idle
Per Unit Total
#N/A
#N/A
#N/A
Annual kWh Cost
Annual Replacement Cost
Total Annual Cost

DC Modular Actuator + Controller


Power Supply
Input voltage
Maximum current draw
Maximum output current
Controller
Current Draw Amps - Full Load
Max Current Output
Motor
Current Draw Amps - Full Load
Current Draw Amps Idle

0
0
0
0
0

#N/A
#N/A

Electrical power consumption costs


Unit @ Full
Unit @ Idle
Per Unit Total
#N/A
#N/A
#N/A
Annual kWh Cost
Annual Replacement Cost
Total Annual Cost

0
0

#N/A

#N/A
#N/A
#N/A

Additional Manufacturing or Other Electrical Solution Savings


For example: Ethernet control to your electric solution provides "Set-Up On the Fly", eliminating manual conversion.

Manufacturing Set Up Savings


Cost of labor
Number of People
Man Hour Labor Cost
Hour Saved per Week Per Man
Weeks per Year

Input
0
$0.00
0
0
Labor Savings

Cost of lost production


Production Rate (units/hour)
Cost per unit

0
$0.00

$0

Lost Product Opportunity in Dollars


Input other savings Dollars

$0
$0

Additional Electric Solution Annual Savings

$0

Summary Comparison of Pneumatic versus Electric Actuator Annual Operating Cost


Annual Cost - Electric
Annual Cost - Pneumatic

Actuator Annual
Operating Cost

Additional
Mfg. Savings

Total Solution
Cost

AC - All in One Actuator

#N/A

#N/A

#N/A

AC Modular Actuator + Controller

#N/A

#N/A

#N/A

DC - All in One Actuator

#N/A

#N/A

#N/A

DC Modular Actuator + Controller + Power Supply

#N/A

#N/A

#N/A

#N/A