Thomson Adds Built-In Sync to Electrak HD Actuators

When machines move out of sync, bad things happen. For industrial equipment relying on multiple actuators to lift, position, or stabilize heavy loads, even slight misalignment can lead to binding, buckling, or system failure. The risk grows as payloads become more complex and dynamic. And while traditional hydraulic or electric systems offer power, coordinating them safely across multiple axes has often required bulky, external controllers and tedious setup. To address these challenges, Thomson Industries has introduced an enhanced synchronization option for its Electrak HD smart electric actuators. Designed to simplify multi-actuator coordination, the upgraded control solution enables position-based synchronization built directly into each actuator’s onboard electronics. The result is faster setup, improved safety, and real-time load balancing, without the need for extra control boxes or wiring headaches.

Complex payloads increase the risk of a system failure. Image used courtesy of Thomson Linear

Built-In Intelligence and Real-Time Communication

At the heart of the new functionality is a real-time communication loop between up to eight Electrak HD actuators connected via a CAN bus network. Each actuator constantly broadcasts a position “heartbeat,” allowing the system to adjust. If one actuator encounters more resistance, it signals others to slow down, keeping all units in step. If any unit detects a fault, whether due to power loss, overheating, or communication drop, the entire system halts automatically to prevent mechanical damage or unsafe operation.

The Thomson Elektrak linear actuator helps coordinate the operation of complex systems. Image used courtesy of Thomson Linear

What makes Thomson’s approach stand out is the integration of this intelligence directly within the actuator hardware. Traditional position-based systems often rely on large external controllers to synchronize motion, adding cost, complexity, and space constraints. By embedding the synchronization logic into the actuator itself, the Electrak HD becomes a plug-and-play solution. Once mounted and wired, the actuators begin synchronizing immediately with no specialized setup required.

Unlocking New Use Cases

With a load capacity of up to 16 kN, the Electrak HD has long been a workhorse in settings where hydraulic cylinders were once standard. However, the improved synchronization unlocks new use cases where dynamic, position-sensitive control is critical. In work platforms, the actuators ensure the surface stays level as users move. In material handling, they help conveyor belts or guided vehicles maintain smooth, even movement. Packaging systems benefit from precision placement during stacking or loading, while solar applications use synchronized motion to raise, tilt, or secure panel arrays.

Solar panels, all perfectly aligned to face the sun. Image used courtesy of Pexels

Advancing Automation with Plug-and-Play Synchronization

Beyond application flexibility, this integrated approach marks a broader shift toward smarter, self-contained components in automation. The fewer external parts a system requires, the easier it becomes to scale, troubleshoot, and adapt across machine designs. For manufacturers seeking to increase throughput while minimizing downtime, the value is immediate: reduced failure risk, simplified design, and more responsive operation. Thomson is giving machine builders a new way to simplify complex motion systems without compromising power or precision, with the enhanced synchronization option now available for order. Whether moving people, parts, or entire structures, synchronized motion (when done well) makes everything safer, stronger, and smarter.

Coordinating motion across multiple actuators has always been a delicate dance. By embedding position-based synchronization directly into the Electrak HD platform, Thomson eliminates the need for an intermediary, making it easier for equipment builders to balance heavy loads and operate with precision, with no additional hardware required.