Pneumatic Rack-and-Pinion Actuators

Rack-and-pinion pneumatic actuators, also called limited rotation cylinders, are rotary
actuators used for turning, opening, closing, mixing, oscillating, positioning, steering and
many more mechanical functions involving restricted rotation. These actuators are also
often used for automation of quarter-turn valves, like ball or butterfly valves.

Pneumatic rack-and-pinion actuators convert the energy of compressed air by means of

a pneumatic cylinder to an oscillating rotary motion. The clean, dry, and processed gas
required by this actuator is provided via a central compressed air station, which usually
supports a range of pneumatic devices in a process system.

Pneumatic actuators, in comparison to their electric counter parts, are generally more
durable, better suited for hazardous environments and less expensive. In addition, they
often require less maintenance and provide higher torque in comparison to their size.

Single rack vs. dual rack design

Rack-and-pinion actuators offer the widest ranges of torque and rotation compared to
other conversion mechanisms for converting linear force to rotational torque. It has a
high mechanical efficiency and the torques that they are able to produce range from a
couple of Nm to multiple thousands of Nm.

However, one potential drawback of the rack-and-pinion design is backlash. Backlash

occurs when rack and pinion gears are not completely aligned and there is a small gap
between each geared connection. This misalignment can cause wear on the gears
during the life cycle of the actuator, which in turn increases backlash.

A double rack unit uses a pair of racks on opposite sides of the pinion. This helps
eliminate backlash due to a counter force and also doubles the output torque of the unit
and increases the mechanical efficiency of the system. In the double acting actuator
shown in Figure 3, the two chambers on the sides are filled with pressurized air, which
push the pistons to the center and to return the pistons to the initial position, the
chamber in the center is in turn pressurized.

Function
Rack-and-pinion pneumatic actuators can be either single-acting or double-acting. It is
also possible for these actuators to provide multiple stops.

Single acting vs. double acting

In a single-acting actuator, air is only supplied to one side of the piston and is
responsible for the movement of the piston in only one direction. The movement of the
piston in the opposite direction is performed by a mechanical spring. Single-acting
actuators conserve compressed air, but perform work in only one direction. A downside
of single-acting cylinders is the inconsistent output force through a full stroke due to the
opposing spring force. Figure 4 shows a single-acting double-rack pneumatic rotary
actuator.
Multiple positioning
Some rack-and-pinion actuators are able to stop at multiple positions through the range
of a rotation by controlling the pressure at the ports. The stop positions can be in any
sequence, making it possible for the actuator to selectively pass an inter-mediate stop
position.

Travel stop bolts

Travel stop bolts are on the side of the actuator body (as seen in Figure 6) and allow for
adjustment of the end positions of the pistons by limiting the rotation of the pinion gear
from the inside. When installing the actuator, drive in both travel stop bolts until they
contact the travel stop cap. Continue screwing the left travel stop bolt until the pinion
slot visible on the top rotates to the position that is parallel to the length of the actuator
body.
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Pneumatic Rotary Vane Actuators Definition

Pneumatic Rotary Vane Actuators are a type of Rotary Vane Actuator that is powered
by pneumatic pressure from compressed air or other gases, as opposed to relying on
energy sources such as hydraulics or electrical Stepping Motors or Servo Motors. The
design of fluid powered rotary vane actuators makes use of a mechanical vane
enclosed in the actuator body that is connected to the shaft of the actuator. Pressurized
air or gas entering the actuator body cavity moves the vein, causing rotary motion in the
actuator shaft.
Pneumatic Rotary Vane Actuators are available as single-acting (spring return) or
double-acting configurations. In single-acting designs, the pressurized air produces
motion in the range of travel for one direction only, with a mechanical spring providing a
return of the actuator to a neutral position. Double-acting designs are capable of having
the pneumatic pressure provide motion in both directions of travel.
Some designs make use of a single vane while others employ two diametrically
opposed vanes to generate rotation and torque. Different ranges of travel as measured
by angular degrees are possible with these design variations.

Vane actuators use pneumatic or hydraulic power to open, close, or modulate quarter-turn valves,
dampers, louvers, as well as for precise movement of ergonomic lifting equipment.

Linear motion gas/hydraulic cylinder or piston actuators use gears to convert linear to rotary motion. Vane
actuators employ a rigid vane inside a sealed chamber that is connected directly to the drive shaft at one
end with no gears. The result is much smoother rotary movement and greater cycle life.

Vane actuators operate by introducing a fluid or gas to either side of it's enclosure through inlet/outlet
ports, creating the force required for movement. Advanced vane actuators utilize double sided vanes that
allow for pressurization of both sides, allowing for bi-directional movement. The vane itself provides an
arc movement in the far side (opposite the shaft) of the actuator, translating rotary movement back to its
integrated shaft.

The vane actuator shaft is designed to connect directly to a device (valve, damper, ergo mechanism) for
the transfer of movement. In advanced design vane actuators, the shaft is completely sealed from the
pressurized side of the vane via “lip seals” which act to prevent the loss of air/gas/oil through shaft seals
or bearings. With the help of spring steel supports, the lip seals are kept in constant contact with the inner
surface of the chamber wall at all times during rotation. A side benefit of lip seals are the self-cleaning or
sweeping action they provide to the inside chamber surfaces.

Since the double-sealed vane separates the vane actuator chamber in two sides, movement in either
direction can be changed merely by creating a pressure differential on either side of the vane. Inlet/outlet
ports allow for the pressurization and de-pressurization for either side. As gas or fluid is introduced to one
side, the vane is forced away, toward the opposite side. By reversing the pressure and vent ports, and
pressurizing the opposite chamber, the actuator moves in the opposite direction.

When vane actuators use only gas or fluid as their source for movement in both directions, they are
referred to as “double acting”. When an optional spring is used to provide the power in one direction
(open or close) they are referred to as “spring return”.
Rod locking cylinders are an important component for ensuring safety in the
case of compressed air supply failure. For static applications, they can activate to
provide emergency holding strength during a power outage or disconnection in air
supply. This is important to ensure that heavy machinery does not fall on workers or
equipment. In dynamic applications, rod locking cylinders can be used to stop
machinery in its tracks.

In dynamic applications, rod locking cylinders can brake cylinders anywhere along their
stroke length. Simply by turning off airflow to the cylinder, the operator activates an
internal spring-loaded locking device located on the front plate of the cylinder. At zero
pressure, the springs release to allow a small piston to move axially. Piston displacement
allows a ring of clamping sleeves to rotate along hundreds of tiny steel ball bearings. The
rotation moves the clamping sleeves into a locked position around the piston rod.

The springs are reloaded when the air pressure is reactivated beyond a certain
threshold. As the piston moves back to its original position, the clamping
sleeves rotate back to the unlocked position so that regular motion can be resumed.
Clamping sleeves may feature a groove pattern to strongly grip the cylinder piston
during locking.
Static rod locking devices, on the other hand, are generally flange-mounted externally
onto the front-end cover of the pneumatic cylinder. They may use a cartridge mounted
transversally in the rod lock unit to provide the locking force. When there is no signal
pressure, the piston rod passes through the cartridge and internal springs push on
an over-the-center mechanism to lock the piston. The mechanism uses jaws to clamp
onto the piston rod, holding the cylinder firmly in a static position.

But designers beware: If the piston rod is not stationary before the rod lock unit is
engaged, the jaws can be worn down and not function properly the next time.

It is also important that designers consider rod locking cylinders as a redundant

stopping mechanism for increasing safety. They should consider other technologies as
the main components for planned braking or holding.

Rodless Actuators
Rodless actuators (also called cylinder slides) are devices without rods that enable linear movements of loads, usually
in a factory environment. Pistons fit closely into actuator tubes and move up and down against the compressed air
pressure in the tubes to create the linear movements. The objects are carried to their end points via the external
carriages connected to the pistons.

What are rodless actuators used for?

Simply put, these actuators move objects, usually as part of an industrial process. They can serve as non-rotating
supporting platforms to which tools can be attached too. They are also used for packaging in food processing industries
where parts are picked and placed repeatedly.

Types of rodless actuators

 Magnetically coupled actuators use strong magnets instead of rods to hold the piston and the carriage
together. When the motion starts the carriage and piston move together in sync as a total unit.
  Mechanically coupled actuators have interior and exterior bands that slot into the actuator housing to keep
compressed air in and contaminated matter out. They consist of piston units with carriages attached.
Components like valves, sensors and brakes can be mounted onto these units.

Slide Unit Actuators

Slide unit actuators are a part of pneumatic machinery that moves a sliding device up and down along rails of machinery.
They work by converting highly pressured compressed air into energy for linear motion. They are designed with grooves
in their side to allow for mounting onto different types of surfaces, and are usually a rough rectangular shape.
What are slide unit actuators used for?
Slide unit actuators are common in a number of different industrial processes. This can include picking and placing of
items in a warehouse and precision placement of work pieces, general low friction transport, positioning of pallets and
conveyors, and in vertical movement applications.

Types of slide unit actuators

Slide unit actuators can differ from one another by their stroke length, which describes how far the unit can move at
once, and their bore size, which represents the diameter of the pneumatic cylinder in which the piston operates. They
also come in a range of different sizes, depending on the equipment they are to be fitted to, and may have differing
port connections and cushioning methods.

Hollow Rod Cylinders

Hollow Rod Cylinders are ideal for converting existing fixtures to power clamping. Replaces clamps which use
double cams, flange nuts, draw bars, or other mechanical devices. Generally, no special machining is required,
just a longer stud. Hollow Rod Cylinders can either push or pull. Two styles are available, either Through Hole or
Tapped Hole. In the Through Hole style, the piston rod is hollow to accept a bolt. The Tapped Hole cylinders
accept a bolt threaded into the piston. Because of the piston design, the Tapped Hole style cannot gain stroke.
Removing the return springs make the Hollow Rod Cylinders suitable for air operation.

Hollow rod cylinder operation

The vacuum connection on the rear head has the benefit of being static during cylinder
operation.
Linear Actuators

Operating the cylinder

Linear actuators can be specified in a variety of different bore and stroke lengths giving a range of speeds
and forces so you can achieve the required movement.

They can also be specified as single acting (single port to allow compressed air to enter the cylinder to
move the piston to the desired position) or double acting (port at each end to move the piston forward and
back by alternating the port that receives the air pressure) such as.
Typically, the body of the actuator is connected to a support frame and the end of the piston rod is
connected to the element of the machine that needs to be moved. A control valve directs compressed air
into the extend port while opening (exhausting) the retract port.

Actuators are at the working end of a system, working alongside filters, pressure regulators, lubricators,
control valves and flow controls all fed by a compressor. These components are connected together via
piping or tubing and fittings.

Linear actuators are utilized throughout the industrial sector, in

factory automation, transportation, packaging, life sciences and
much more.

Pneumatic linear actuators are engineered to convert

compressed air into a linear motion, most commonly with a
piston rod extending and retracting, but can also be designed
with a carriage that moves on the cylinder tube or guideway.