Tandem Hydraulic Actuator Configurations

Tandem Hydraulic Actuator Configurations

Maximising Force and Control in Hydraulic Systems

In industries where performance, precision, and control are non-negotiable, the hydraulic actuator remains an indispensable component. Yet, as operational demands increase, so does the need for more powerful configurations enter the tandem hydraulic actuator. By combining two or more actuators in series, this setup significantly increases force output without enlarging the cylinder bore, offering a space-efficient solution to heavy-duty challenges.

Whether you’re maintaining an oil and gas valve system or optimising automation in a manufacturing plant, tandem configurations provide a versatile upgrade. At Natrade, we supply an extensive range of actuator brands and components tailored to these needs. Visit our Products page to explore compatible options from Fisher, Bettis, and Bray.

How Tandem Hydraulic Actuators Work

When it comes to boosting output force in compact spaces, tandem hydraulic actuator setups shine. This configuration links multiple pistons in a linear sequence, using shared hydraulic pressure to generate a combined thrust, ideal for limited-space environments requiring high actuation force.

These systems operate under the same core principles as single-cylinder actuators but multiply force without compromising on stroke precision or system responsiveness. Let’s explore how this design works in practical terms.

Dual-Piston Powerhouse – Layering for Higher Force Output

In a tandem configuration, two or more pistons share a common shaft but are arranged in series within separate chambers. Each piston contributes to the total output force when pressurised simultaneously:

  • Single input, multiple outputs: Shared hydraulic fluid input feeds each piston chamber.

  • Compact force amplification: Combines forces while maintaining cylinder diameter.

  • Smooth linear motion: Balanced load distribution across pistons.

This makes it particularly useful for actuating heavy-duty valves or load-bearing equipment, especially in confined installations like those found in energy or marine applications.

Tandem vs. Single-Stage: A Functional Comparison

While single-stage actuators remain common, tandem configurations bring several advantages:

  • Force without bulk: Unlike single actuators, which may require larger bore sizes to increase force, tandem setups achieve higher power in the same footprint.

  • Redundancy and durability: If one piston chamber malfunctions, the other may still provide limited movement, enhancing operational safety.

  • Custom configurations: Can be adapted for either synchronous or sequential operation.

Clients working with brands such as Bettis or Bray often find tandem options suitable for automation-heavy environments where failure is not an option.

Key Advantages of Tandem Hydraulic Actuators

Choosing a tandem hydraulic actuator over conventional models can dramatically change system performance. This section outlines critical advantages from both a design and operational perspective.

Top 3 Benefits of Tandem Hydraulic Actuators

  • Increased Force Without Expanding Diameter
    Delivers greater actuation power within tight spatial constraints, ideal for offshore rigs or embedded plant systems.

  • Customisable Stroke Lengths and Power Distribution
    Offers flexibility for precision-control requirements, especially when integrated with advanced process systems like ABB Totalflow.

  • Enhanced Load Balancing
    Minimises wear and reduces side-loading risks, which is particularly valuable in multi-cycle or high-pressure environments.

These benefits enable longer service life and decreased maintenance, making them a cost-effective solution over time.

Use Cases in Real-World Applications

Tandem actuators are widely employed in:

  • Subsea valve actuation: Where spatial limits and pressure resistance are critical.

  • Industrial automation: Including robotic arms and linear motion platforms in controlled environments.

  • Power plants and refineries: For managing high-load valves under constant pressure cycles.

Our clients, including users of Cummins-powered equipment, rely on this configuration for its unmatched reliability in rugged operating conditions.

Design Considerations and Challenges

Despite their strengths, hydraulic actuator configurations, especially tandem, require specific design foresight. Neglecting key factors can lead to inefficiencies or even system failures.

What Engineers Must Consider Before Choosing Tandem

Before implementing a tandem design, consider:

  • Fluid compatibility: Ensure the hydraulic fluid supports all chambers equally without cross-contamination risks.

  • Precision control systems: Multiple pistons require synchronised actuation, potentially increasing control complexity.

  • Mounting space: While compact in width, tandem setups require more longitudinal space than single cylinders.

These elements are especially relevant when integrating with high-precision brands like Bently Nevada, known for their asset management solutions.

Overcoming Limitations with Smart Engineering

Challenges such as fluid leakage, stroke misalignment, or system fatigue can be resolved with:

  • Load sensors and limit switches: For precise stroke management

  • Proper sealing and housing materials: To prevent wear or contamination

  • Maintenance scheduling: Using predictive tools like those offered by Emerson

Using components from reputable sources like those listed on our About Us page helps mitigate these risks early.

Frequently Asked Questions (FAQs)

1. What is a tandem hydraulic actuator used for?

A tandem hydraulic actuator is used when high force is needed in a restricted space. It combines multiple pistons in one line to boost force output without increasing cylinder diameter. This is often used in industrial, energy, and maritime applications.

2. How long does a tandem actuator last?

With proper maintenance, a hydraulic actuator in a tandem configuration can last over 10 years. Lifespan depends on usage intensity, hydraulic fluid quality, and the actuator's material build.

3. Can I retrofit a single-stage actuator with a tandem setup?

Yes, in many cases. But you must check compatibility with existing control systems and ensure enough axial space is available for installation. Partnering with professional suppliers is key for successful retrofitting.

4. Is it safe to use tandem actuators in extreme environments?

Absolutely, as long as materials and seals are rated for the environment. Many of our products include components designed for high-pressure, high-temperature, and even corrosive conditions.

5. Why would I choose a tandem over a larger single-bore actuator?

A tandem configuration offers the same (or more) power without increasing the bore diameter. This is ideal for tight installations or applications where larger cylinders would interfere with other components.

Conclusion

The tandem hydraulic actuator configuration is a smart solution for industries needing compact yet powerful motion control. By distributing force across multiple pistons, it achieves superior performance without sacrificing space or precision.

For companies operating in challenging environments, whether offshore rigs or complex manufacturing lines, these actuators offer unmatched reliability and control. Explore our full range of compatible systems and components from trusted brands on the Natrade Products page or reach out via our Contact Us page to discuss your requirements with a knowledgeable team.