Sizing a multi-actuator system comes down to two critical numbers: total force output and total current draw. Miss either, and you’ll either fall short on load or overload your power supply. This Parallel and Series Actuator Configuration Calculator shows you total force, current, and required PSU wattage based on actuator count, individual force, current, and supply voltage. This matters anywhere a single load relies on more than one actuator – from factory floors to hospital lifts and automotive jigs. You’ll find formulas, a sample calculation, technical detail, and a practical FAQ below.
What is Parallel and Series Actuator Configuration?
Parallel configuration means several actuators push or pull together on the same load, so the forces add up directly. Series configuration means actuators are stacked end-to-end, so you get a longer stroke, but the total force stays the same as for one actuator.
Simple Explanation
If you've got parallel actuators, picture four people shoulder-to-shoulder moving a car. Each person’s strength adds to the total. Series arrangement is more like sections of a telescope: each one adds reach, but you can't use more push than a single section gives. Use parallel if you're running out of force, and series if you’re running out of stroke.
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Parallel vs Series Actuator Configuration
Interactive Calculator
This calculator is intended for education, concept evaluation, and preliminary design. Results are based on the equations and assumptions described on this page, but cannot account for every real-world load case, tolerance, material property, environmental condition, installation detail, safety factor, code, or regulatory requirement. Verify all inputs, assumptions, units, and results independently before selecting components or using the result in a real application. Safety-critical, structural, medical, lifting, transportation, or regulated applications must be reviewed by a qualified engineer.
📹 Video Walkthrough — How to Use This Calculator
Parallel and Series Actuator Configuration Interactive Visualizer
See how actuator configuration affects total force output and current draw. Parallel configurations multiply force while series configurations extend stroke length.
TOTAL FORCE
450 lbs
TOTAL CURRENT
12.0 A
PSU POWER
288 W
FIRGELLI Automations — Interactive Engineering Calculators
How to Use This Calculator
- Input the number of actuators and the rated force (lbs or N) for one actuator.
- Enter the current draw for one actuator (amps) and your power supply voltage.
- Select your configuration: Parallel for actuators side by side on the same load, Series for actuators connected end-to-end.
- Press Calculate to see the totals.
Simple Example
For a parallel system using 3 actuators each rated at 100 lbs force and 4 A running on 12 V:
- Total force: 300 lbs
- Total current draw: 12 A
- Required PSU: 144 W at 12 V
Mathematical Equations
Parallel Configuration:
Use the formula below to calculate total force, current, and power in a parallel actuator configuration.
Itotal = n × Iindividual
Ptotal = V × Itotal
Series Configuration:
Use the formula below to calculate total voltage requirement and power in a series actuator configuration.
Itotal = Iindividual
Vtotal = n × Vindividual
Ptotal = Vtotal × Itotal
Where: n = number of actuators, F = force, I = current, V = voltage, P = power
Technical Guide to Actuator Configurations
Understanding Parallel vs Series Configurations
If you're building with multiple FIRGELLI linear actuators, you have to decide whether to go parallel or series. Each approach brings benefits and trade-offs that affect your force output, wiring, and how much the system draws from your power source.
Parallel Configuration Fundamentals
With a parallel setup, each actuator pushes on the load at the same time, independently, all at the same voltage. The total force is simply the sum of the actuators—nothing fancy—but each actuator also pulls its normal current. The system is like hooking batteries in parallel: the current adds, but the voltage stays the same.
Biggest advantage? More actuators equals more force. For example: two actuators rated at 100 lbs each in parallel get you 200 lbs of total push. This force scales linearly, and that makes it a practical approach for anything that needs to move heavy loads. That said, current is also adding up; you'll need a power supply and wiring that can actually handle the total current—not just a little more than for a single actuator, but multiplied by however many you put in.
Series Configuration Characteristics
Series setups connect actuators end-to-end, so the extension of one adds onto the extension of the next. This wiring isn’t used much for linear actuators, but when it is, it's because you’re after extra travel, not extra force. The total stroke is the sum of what you get from each actuator, but the force is no greater than any one actuator in the lineup. With the wiring, the current draw stays the same as for one actuator, but the required supply voltage is the sum — you need enough voltage to run all the actuators in line.
Real-World Applications
Parallel gets used everywhere high force is needed: heavy machinery, lift systems, factory jigs, and automotive production lines. You might see four 500-lb actuators lifting a 2000-lb engine. The redundancy also means if one actuator goes out, the others pick up some slack, so you’re not stuck mid-cycle.
In medical work, parallel setups show up on patient lifts or adjustable hospital beds. Sticking with parallel gives smoother lifts, more total push, and backup in case one actuator fails.
Most applications needing series configuration are after one thing: longer stroke. Think telescoping antennas or reaching tools—cases where stroke length, not extra force, is the limitation.
Worked Example: Hospital Bed Positioning System
Suppose you’re specifying a hospital bed that needs to lift 400 lbs with a safety factor, and you’re on 12V DC. If each actuator can do 150 lbs at 5A, you'd run three in parallel.
Using the calculator for this setup:
- Number of actuators: 3
- Individual force: 150 lbs
- Individual current: 5 A
- Voltage: 12 V
- Configuration: Parallel
The results would be:
- Total force: 450 lbs (over your minimum requirement)
- Total current draw: 15 A
- Required PSU: 180 W at 12V
This setup covers your load and gives some redundancy; if a single actuator fails, the bed can still be lowered in an emergency (now with 300 lbs total force).
Design Considerations and Best Practices
If you go parallel, synchronization matters. All actuators need to extend and retract together, or you get unwanted binding or uneven wear. You’ll either need a mechanical linkage, electronic controls, or built-in actuator feedback to keep them moving in sync.
Load needs to be shared as evenly as possible between actuators. Uneven loads mean some actuators do all the work and wear out early. Good mounting and alignment are not optional if you want the system to last.
Don’t skimp on PSU sizing. The total current can get large fast, and power-up spikes—plus future upgrades—mean you should add a safety margin (20-30% over calculated needs is usually enough). Undersize the PSU and you’ll get nuisance trips or brownouts.
For harsh environments or when downtime is expensive, parallel offers more resilience: if one actuator stops, the others can bail you out. Series setups don’t have this tolerance. But remember, series is only for applications where stroke, not force, is the true limit.
Control System Integration
When you have more than one actuator, closed-loop control with feedback (like PID) helps keep everything moving together, especially true in parallel setups. As actuator count goes up, so do complexity and potential failure modes. Use sensors for position and current wherever possible — that’s your early warning before problems turn critical.
For bigger installations, networked control (CAN, Modbus, or similar) lets you synchronize, balance loads, and flag errors quickly. You’ll spend less time troubleshooting, and more time running.
Economic Considerations
Parallel configurations cost more up front—more actuators, bigger wiring, bigger PSU—but reduce your risk of sudden downtime. Redundancy can be worth the premium in production or safety-critical setups.
Series can be cheaper where you’re only after extra stroke and force is not the bottleneck. Since current doesn’t rise, you may get away with a smaller PSU; just make sure your voltage source can supply the total required.
The quick calculator helps nail the electrical numbers, but always take a step back: include installation, maintenance, and downtime costs before making your final call.
Frequently Asked Questions
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About the Author
Robbie Dickson
Chief Engineer & Founder, FIRGELLI Automations
Robbie Dickson brings over two decades of engineering expertise to FIRGELLI Automations. With a distinguished career at Rolls-Royce, BMW, and Ford, he has deep expertise in mechanical systems, actuator technology, and precision engineering.
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