When can a ball screw replace hydraulics?

Drive Technology Ball Screw Or Hydraulics?

2025-07-11 By Lars Brandstäter, Marketing Director Rollon GmbH, Düsseldorf | Translated by AI 4 min Reading Time

Related Vendors

Rollon GmbH

FAULHABER Drive Systems

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Taiwan Machine Tool & Accessory Builders' Association (TMBA)

Wuxi InfiMotion Technology Co., Ltd.

In certain applications, electromechanical drive systems with ball screws offer advantages over hydraulic systems and can replace them.

Ball screws or hydraulic cylinders? In hydraulic steel structures, both types of actuators can be used.(Image: © fottoo - stock.adobe.com) — Ball screws or hydraulic cylinders? In hydraulic steel structures, both types of actuators can be used.
(Image: © fottoo - stock.adobe.com)

In many industries, hydraulic systems are considered the ultimate solution, especially when high forces and loads are involved. However, there is competition—for example, in the form of electromechanical cylinders with ball screws (KGT). Electromechanical drive elements are conquering more and more application fields and also perform well in the heavy-duty sector.

"Ball screw drives are more energy-efficient, precise, compact, low-maintenance, and environmentally friendly, and they can replace hydraulics in many applications," argues Andreas Kaiser, Senior Sales Manager DACH/NL at KGT provider Rollon GmbH. "While the initial investment is slightly higher, it quickly pays off thanks to reduced operating costs. Over the lifecycle, users benefit from significant cost savings."

Advantages And Disadvantages of Hydraulic Systems

Hydraulic systems ensure high power transmission and maximum power density. However, their characteristics also include higher sensitivity to high temperatures and energy losses due to heat. Maintenance can be complex and is not always predictable. Additionally, there is a risk of leaks, which can lead to energy losses and environmental pollution. The requirements for the cleanliness of hydraulic oil are also high, and the viscosity of the oil changes with age and oil temperature.

Strengths of Ball Screws

For certain applications, switching to ball screw drives is therefore worthwhile. These offer high energy efficiency (80% of input power), enable more precise control of speed and positioning, higher speeds, and require less maintenance and generate less noise. Typically, fewer components are needed; the system complexity is lower, and integration into electronic controls can be easier: since ball screw drives are electrically powered, they are often easier to integrate into digital control systems than hydraulic cylinders, which require additional valves and regulators. Furthermore, (apart from lubricant) there is no risk of leakage.

What Do Ball Screw Manufacturers Say?

Shuton-Ipiranga is the specialist for ball screws within the Rollon Group(Image: Rollon) — Shuton-Ipiranga is the specialist for ball screws within the Rollon Group
(Image: Rollon)

A specialist in ball screw drives, for example, is Shuton-Ipiranga, which belongs to the Rollon group. Their high-performance models are used in machine tools, injection molding technology, presses, automation systems, lifting equipment, semiconductor manufacturing, and elevation devices. Andreas Kaiser explains: "In production, we use both the economical rolling process, e.g., for simpler transport applications, as well as the highly precise, flexible, and durable whirling process to meet all requirements."

Customized Solutions for Heavy-Duty Applications

Whirled heavy-duty ball screw drives offer high load capacity in a compact design and are available in various diameters and spindle lengths. Nearly all parameters of these components can be individually tailored to an application—whether spindle diameter, pitch, direction of rotation, stroke length, load capacity, design, nut configuration, ball return system, lubrication, etc. Zero backlash is also possible.

Andreas Kaiser emphasizes that the flexibility in the profiles ensures that ball screw drives can handle very high loads despite their compact dimensions. "For example, we can achieve higher load capacities by using a larger profile while maintaining the same size," he explains. Different coatings provide the necessary protection, for instance, in harsh environments or hygiene-sensitive areas such as the food industry.

Typical Application Fields for Electromechanical Systems

The ball screws of the XL Xtrem Load product family from Shuton-Ipiranga have been optimized for heavy-duty applications.(Image: Rollon) — The ball screws of the XL Xtrem Load product family from Shuton-Ipiranga have been optimized for heavy-duty applications.
(Image: Rollon)

Ball screw drives are particularly interesting when precision, energy efficiency, and a clean working environment are crucial, such as in many assembly tasks or material handling. Other possible application areas include plastic injection molding machines (opening/closing of mold halves, clamping, tensioning), forming technology (pressing, rolling, bending), test benches and measurement systems—for example, in the automotive industry—, CNC and machine tools, as well as conveyor and lifting technology.

For high safety requirements, a safety nut can be used. These are self-locking nuts that prevent the ball screw nut from loosening on its own. Safety is also a central topic in liquid valve technology. Ball screw drives with spring preload ensure that no flow occurs in the event of a power failure. Designers of simulators—for instance, for pilot training, Formula 1 teams, or amusement parks—are increasingly relying on ball screw drives instead of hydraulics. A characteristic feature in this application is the varying load distribution.

Visualization of the hydraulic cylinder functional principle: Condition-based maintenance and digital assistance systems are state-of-the-art in hydraulics. (Image: ©dizfoto1973 - stock.adobe.com)

From Medical Technology to Hydraulic Steel Structures

In medical technology, the high positioning and repeat accuracy, as well as the quiet operation of ball screws, come into play. These ensure precise control of movements and forces, for example, in surgical robots and hospital beds. Leakage-free operation is also an important aspect.

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An interesting application field for heavy-duty ball screw drives is hydraulic steel structures, with their high mechanical loads and challenging requirements regarding weather and environmental conditions. Applications such as lock gates, spillway gates, and ferry docks benefit from features like high efficiency, resistance to heat and cold, and the absence of oil. Additionally, the space-saving design of ball screw drives allows for more compact constructions.

Summary

Ball screw drives ensure efficient power transmission with high positioning and repeatability accuracy, high load capacity, and compact design. "Of course, not all hydraulic applications can be replaced by ball screw drives. For instance, hydraulics will certainly continue to be used in agricultural, forestry, and construction machinery," limits Andreas Kaiser. "However, in many applications, switching to ball screw drives makes sense."