Mechatronics 2 CH 3

Chapter(3) Actuators
 Course Syllabus
o Microcontroller programming and interfacing including:
Microcontroller architectures using a specific example with details of its assembly language
programming and interfacing some common peripheral.
 Sensors including:
position and speed measurement, Stress and strain measurement, Temperature measurement,
Vibration and acceleration measurement, Pressure and flow measurement and semiconductor
sensors and MEMS (micro-electromechanical systems).
o Actuators including:
Solenoids and relays, Electric motors, Stepper motors, Hydraulic and pneumatic actuators.
o Mechatronic systems including:
Control architectures and a number of case studies, using code sign concepts and VHDL
 Chapter Outlines
o Actuators including:
Solenoids and relays, Electric motors, Stepper motors, Hydraulic and pneumatic
actuators
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Mechatronics (2) Dr. Ali M. Gaballa
 Flow of Energy
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 Actuators
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Chapter(3) Actuators Converters
 Power/Energy Converters can be of many types including:

 Rotary:
o Electrical → Mechanical Energy:
 AC Motors
 DC Motors
o Combustion → Mechanical Energy:
 Gasoline Engine
 Gas Turbine
 Linear:
o Electrical → Mechanical Energy:
 Power Screw Linear Actuators
 Solenoids
o Pressure → Mechanical Energy:
 Hydraulic/Pneumatic Actuators
 Hydraulic Pumps
 Compressors
Solenoids and relays, Electric motors, Stepper motors, Hydraulic and pneumatic
actuators
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Chapter(3) Actuators Solenoids
 One of the more common practical applications of the moving - iron transducer is the
solenoid shown in Figure below, in which the movable part is connected to springs to
return it. Solenoids find application in a variety of electrically controlled valves.
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Chapter(3) Actuators Relays
 What is a relay system?

An electromagnetic device for remote or automatic control that is actuated by the
variation in condition of an electric circuit and that operates in turn other devices
(such as switches) in the same or different circuit.
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 What is a relay system?
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The letter P symbolizes Pole, and the letter T symbolizes Throw.

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Some Simple Relay Circuits
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 Relay Driver
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Chapter(3) Actuators Pneumatics Actuators
Pneumatics Actuators: Linear Types Rotary air motors
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Chapter(3) Actuators Symbols of Pneumatic Supply Components
Pneumatics Actuators: Linear Types Rotary air motors
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Control of Single Acting Cylinder Motion

 The piston of a single-acting cylinder is to travel out when a button is operated and return
at once to its end position when the button is released.
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Control of Double Acting Cylinder Motion
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Indirect Control of a S Acting Cylinder
The piston of a large-volume single acting cylinder (large diameter, large stroke length) is to
travel out after actuating a valve and return to its end position after the valve has been
released.
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Indirect Control of a D Acting Cylinder

A double acting cylinder is to be controlled by two valves 2, and 3 such that the piston travels
out when Valve 2 is actuated and remains FIXED in the forward end position after 2 has been
released until the reverse signal for the return movement is input through 3.
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Chapter(3) Actuators Case Studies: Basic Pneumatic Circuits
Manual control of a single-acting cylinder
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Unidirectional speed control of a single-acting cylinder
Throttle Valve (TC)

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Bidirectional speed control of a single-acting cylinder
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OR control of a single-acting cylinder.

 Initially, the cylinder is fully retracted, with both push buttons PB1 and PB2 released (see Fig. a).
The system is equipped with an OR element. The cylinder can be operated if any of the two push
buttons, PB1 or PB2, are depressed—positions (b) and (c)
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AND control of a single-acting cylinder

 To out-stroke the cylinder, both directional control valves must be operated (see Fig. a). This
provides an AND logic function. The cylinder retracts if any or both of the two directional
control valves are released (see Fig. b, c, and d).
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Logic NOT control.
 The logic NOT function is provided by a normally open directional control valve (see
{a}). Thus, the cylinder extends if the DCV is NOT operated. The cylinder retracts by
switching the DCV (see{b}).
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Chapter(3) Actuators Electric Motors
 Electric Motors convert electrical power to mechanical power.
 Electrical Power
𝑷𝑬 = 𝑰 ∗ 𝑽
 Mechanical Power
𝑷𝑴 = 𝑭 ∗ 𝒗 (𝒇𝒐𝒓 𝒍𝒊𝒏𝒆𝒂𝒓 𝒔𝒚𝒔𝒕𝒆𝒎𝒔)
𝑷𝑴 = 𝑻 ∗ 𝝎 (𝒇𝒐𝒓 𝒓𝒐𝒕𝒂𝒓𝒚 𝒔𝒚𝒔𝒕𝒆𝒎𝒔)
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 Electric Motors convert electrical power to mechanical power.
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 Brushless AC Motor:
• A brushless AC motor is driven with an AC sine wave voltages.
• The permanent magnet rotor rotates in synchronization with the rotating
magnetic field.
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 AC Induction Motor (1):

• The stator windings of an AC induction motor are distributed to produce a
roughly sinusoidal distribution. When three phase ac voltages are applied to the
stator windings, a rotating magnetic field is produced.
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 AC Induction Motor (2):

o The rotor of an induction motor also consists of windings or more often a copper
squirrel cage imbedded within iron laminates. An electric current is induced in the
rotor bars which also produce a magnetic field.
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 Brushed DC Motor:
o Just as the rotor reaches alignment, the brushes move across the commutator
contacts and energize the next winding. In the animation the commutator
contacts are brown and the brushes are dark grey. A yellow spark shows when
the brushes switch to the next winding.
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 Brushed DC Motor:
o Just as the rotor reaches alignment, the brushes move across the commutator
contacts and energize the next winding. In the animation the commutator
contacts are brown and the brushes are dark grey. A yellow spark shows when
the brushes switch to the next winding.
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 Brushed DC Motor Applications:

• Brushed DC motors are widely used:
– Door Locks
– Windshield wipers
– Car Mirror adjust
– Anti-Lock Braking System (ABS)
– Golf carts
– Electric Toothbrush
– Toys
– Many others….
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 Brushless DC Motor:
o A brushless DC motor has a rotor with permanent magnets and a stator with
windings. The control electronics replace the function of the commutator and
energize the proper winding.
Stator (with Windings) & Rotor (Permanent Magnet)

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 Brushless DC Motor Applications:

• Brushless DC motors are widely used:
– Quadcopters and Model airplanes
– Medical Surgical tools
– Microscopes
– Artificial heart
– And others ….
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 Stepper motors
Stepper motors can be considered as a step-controlled discrete motors that is capable

of accurately control the position of the rotor.
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 Stepper Motor Applications:
• Stepper motors are widely used:

– Film Drives
– Printers/Scanners
– ATM machines
– Blood Analyzers
– And others…
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 Which one is Servo?

• The word Servo motor is widely used, however basic search results
produce different results:
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 What is Servo?
• The meaning of Servo is mainly related to accurate position control.
• Through the utilization of internal feedback sensors, it is possible to
continuously measure the actual position and compare it to the desired, then
correct it.
• Provide much smoother motion than the stepper motor.
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 What is Servo?
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 Which to Select ??
o DC Motors:
 Easy to Control torque via current
 Low Voltage
 Linear Torque-Speed relation
 Quick Response
o AC motors:
 Speed fixed by AC frequency
 Low Torque at low speed
 Difficult to start
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 Electric and magnetic fields: Lorentz force

o A current-carrying wire in a magnetic field experiences
a force.
o The magnitude and direction of this force depend on
four variables: the magnitude and direction of the
current (I), the length of the wire (L), the strength and
direction of the magnetic field (B), and the angle
between the field and the wire (𝜽).
o 𝐹 = 𝐼 𝐿 𝑋 𝐵 = 𝐼 𝐿 𝐵 sin θ 𝑛
o When current is in amperes, length in meters, and
magnetic field in Tesla, the force is in Newton.
o The direction of the force is perpendicular to both the
current and the magnetic field, and is predicted by the Fleming's Left Hand (Motor) Rule
right-hand cross-product rule.
o The direction of the magnetic field surrounding

the conductor can be found using your right
hand
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 Construction of dc motor
 D.C. Motor Principle

o A machine that converts DC. power into mechanical power is known as a DC. motor.
Its operation is based on the principle that when a current carrying conductor is placed
in a magnetic field, the conductor experiences a mechanical force. The direction of
this force is given by Fleming’s left hand rule and magnitude is given by;
o 𝐹 =𝐿𝐼𝑋𝐵 Or in scalar terms: 𝐹 = 𝐼 𝐿 𝐵 sin(θ)
o Basically, there is no constructional difference between a DC motor and a DC
generator. The same DC machine can be run as a generator or motor.
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 D.C. Motor Principle

o A Motor Armature in a Fixed Magnetic Field
o Direction of Force (Torque) acting to turn the
Armature (Conductor).
o The magnetic field surrounding a current
carrying conductor interacts with an existing
magnetic field.
Fleming's Left Hand (Motor) Rule
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 At Start:
o When the motor is turned on, the following will happen:
o At start Force (𝐹 ) increases,
o Thus, rotor speed (𝑣 ) increase,
o But, e𝑖𝑛𝑑 will start to increase,
o Inducing current in opposite direction,
o Current (I) will decrease,
o Thus, Force (𝐹) will drop again,
o Accordingly, the speed (𝑣 ) decrease.
 Until (v) reaches a constant speed
 At Sudden load: 𝒗𝒍𝒐𝒂𝒅 <
𝒗 𝒏𝒐 − 𝒍𝒐𝒂𝒅
o At steady-state, if sudden load is applied to the rotor:
o The net Force (𝐹𝑛𝑒𝑡) decreases, based on 𝐹𝑛𝑒𝑡 = 𝐹 − 𝐹 𝑙𝑜𝑎𝑑
o Thus, rotor speed (𝑣 ) decrease, 𝑩 𝒊𝒔 𝒄𝒐𝒏𝒔𝒕𝒂𝒏𝒕
o Leading to 𝑒𝑖𝑛𝑑 to decrease, 𝒊 = 𝑽 / 𝑹 (𝑶𝒉𝒎’𝒔 𝑳𝒂𝒘)
o Induced Current ( 𝑖𝑖𝑛𝑑 ) will decrease, 𝑭 = 𝑩 ∗ 𝒊 ∗ 𝒍
o Total current in wire ( I ) will increase,
o Thus, Force (𝐹) will increase again,
o Accordingly, the speed (𝑣 ) increase again.
 Thus (v) will reaches a constant speed
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DC Motors
Permanent Magnetic Self Excited
Separately excited Series Shunt Compound
𝑭 = 𝑳 𝑰 𝑿 𝑩 = 𝑰 𝑳 𝑩 𝒔𝒊𝒏 𝜽 𝒏
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 Separately excited motors: The field winding is composed of a large number of turns
with small cross section wire. This type of field winding is designed to withstand the
rated voltage of the motor. The field and armature circuits are excited by separate
sources.
𝑉𝑡
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 Separately excited motors
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 Series Motors: The field winding is composed of a small number of turns with a large
cross section wire. This type is designed to carry large currents and is connected in series
with the armature winding.
𝑉𝑡
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 Series Motors
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 Shunt Motors: The field circuit is the same as that for separately excited machines, but
the field winding is connected in parallel with the armature circuit. A common source is
used for the field and armature windings.
𝑉𝑡
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 Shunt Motors
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 Shunt Motors
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 Compound Motors: This type uses the shunt and series windings
𝑉𝑡
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 Compound Motors
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 Permanent Magnetic
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 Speed control Methods of DC Motors

(1) Armature voltage control
(2) Field control
(3) Armature resistance control (Ra)
 Speed control of shunt or separately excited motors
 For a given torque, the motor speed is a function of the following three quantities:
o Resistance in armature circuit: When a resistance is inserted in the armature circuit, the speed
drop, ∆𝜔, increases and the motor speed decreases.
o Terminal voltage (armature voltage): Reducing the armature voltage, Vt, of the motor reduces
the motor speed.
o Field flux (or field voltage): Reducing the field voltage reduces the flux, 𝜑 and the motor
speed increases.
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o Controlling speed by adding resistance
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o Controlling speed by adjusting armature voltage
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o Controlling speed by adjusting field voltage
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 Overview:
o Stepper motors can be considered as a step-controlled discrete motors that is
capable of accurately control the position of the rotor.
 The advantages of stepper motors are:

o speed does not depend on the torque applied on the axis;
o controls are more simple;
o great speed range available.
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 Full-Step Stepper Motor (1):

o This animation demonstrates the principle for a stepper motor using full step
commutation. The rotor of a permanent magnet stepper motor consists of permanent
magnets and the stator has two pairs of windings. Just as the rotor aligns with one of the
stator poles, the second phase is energized. The two phases alternate on and off and also
reverse polarity. There are four steps. One phase lags the other phase by one step. This
is equivalent to one forth of an electrical cycle or 90°.
R
S

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 Full-Step Stepper Motor (2):
o Just as the rotor aligns with one of the stator poles, the second phase is
energized. The two phases alternate on and off and also reverse polarity. One
phase lags the other phase by one step. This is equivalent to one forth of an
electrical cycle or 90°.
o The Control Sequence of a full-step stepper motor is shown:
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 Half-Step Stepper Motor (1):

o This animation shows the stepping pattern for a half-step stepper motor. The
commutation sequence for a half-step stepper motor has eight steps instead of
four. The main difference is that the second phase is turned on before the first
phase is turned off. Thus, sometimes both phases are energized at the same time.
During the half-steps the rotor is held in between the two full-step positions. A
half-step motor has twice the resolution of a full step motor. It is very popular for
this reason.
R
S

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 Half-Step Stepper Motor (2):

o The main difference is that the second phase is turned on before the first phase is
turned off. Thus, sometimes both phases are energized at the same time. During
the half-steps the rotor is held in between the two full-step positions. This is
equivalent to 45°.
o The Control Sequence of a Half-Step stepper motor is shown:
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o The Control Sequence of a Half-Step stepper motor is shown:
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Mechatronics 2 CH 3

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Chapter(3) Actuators

 Power/Energy Converters can be of many types including:

 What is a relay system?

 What is a relay system?

The letter P symbolizes Pole, and the letter T symbolizes Throw.

Some Simple Relay Circuits

Pneumatics Actuators: Linear Types Rotary air motors

Pneumatics Actuators: Linear Types Rotary air motors

Control of Single Acting Cylinder Motion

Control of Double Acting Cylinder Motion

Indirect Control of a S Acting Cylinder

Indirect Control of a D Acting Cylinder

Manual control of a single-acting cylinder

Unidirectional speed control of a single-acting cylinder

Throttle Valve (TC)

Bidirectional speed control of a single-acting cylinder

OR control of a single-acting cylinder.

AND control of a single-acting cylinder

Logic NOT control.

 Electric Motors convert electrical power to mechanical power.

 Electric Motors convert electrical power to mechanical power.

 AC Induction Motor (1):

 AC Induction Motor (2):

 Brushed DC Motor Applications:

Stator (with Windings) & Rotor (Permanent Magnet)

 Brushless DC Motor Applications:

Stepper motors can be considered as a step-controlled discrete motors that is capable

 Stepper Motor Applications:

• Stepper motors are widely used:

 Which one is Servo?

 Electric and magnetic fields: Lorentz force

o The direction of the magnetic field surrounding

 D.C. Motor Principle

 D.C. Motor Principle

Fleming's Left Hand (Motor) Rule

Permanent Magnetic Self Excited

Separately excited Series Shunt Compound

 Separately excited motors

 Separately excited motors

 Separately excited motors

 Speed control Methods of DC Motors

 Speed control Methods of DC Motors

 Speed control Methods of DC Motors

 Speed control Methods of DC Motors

 The advantages of stepper motors are:

 Full-Step Stepper Motor (1):

Stator (with Windings) & Rotor (Permanent Magnet)

 Full-Step Stepper Motor (2):

o The Control Sequence of a full-step stepper motor is shown:

 Half-Step Stepper Motor (1):

Stator (with Windings) & Rotor (Permanent Magnet)

 Half-Step Stepper Motor (2):

o The Control Sequence of a Half-Step stepper motor is shown:

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