MECHANICAL ENGINEERING DEPARTMENT

INTRODUCTION TO MECHATRONICS (MENG 5271)

CHAPTER TWO
ACTUATION SYSTEMS
2015 EC

Compiled by Genaye M.
 ACTUATORS

Definition:
 Actuators are the muscle behind a Mechatronics system that
accepts a control command and produces a change in the
physical system by generating force, motion (displacement and
velocity), heat, flow, etc.
 An actuator is also a transducer because it changes one type of
physical quantity into some alternative form
 An actuator is usually activated by a low-level command signal,
so an amplifier may be required to provide sufficient power to
drive the actuator
 ACTUATION SYSTEM
Actuation system- are the elements of control system responsible for transformation
of output of a microprocessor into a controlling action on machine or device.
 Electrical output of controller transforms into linear motion of a load.
 Electrical output of controller transforms into an action which controls the amount of liquid passing
along a pipe.

Logical Signal Processing Final Actuation

Signal & Amplification Element

Actuator
Sensor
 ACTUATION SYSTEM: TYPES

 Actuation systems can be classified in to three categories:

 Hydraulic and pneumatic actuation system
 Mechanical actuation system
 Electrical actuation system
 HYDRAULIC AND PNEUMATIC ACTUATORS
 Fluid power denotes the use of a pressurized fluid to drive linear
or rotary actuators.
 The subject can be broadly divided into two fields:- hydraulics and
pneumatics .
 In Hydraulics the working fluid is usually oil (sometimes water-oil
emulsions)
 In Pneumatics it is compressed air
 Still high power - Hydraulic signals can be used.
 Pneumatic? – compressibility of air.
 Hydraulic ? – very expensive, liquid leakage.
 PNEUMATICS VS. HYDRAULICS: DIFFERENCES
The two fields have a great deal in common, but there are also some basic
differences:

1. Pressure Levels:- Typically pressures in industrial pneumatic circuits range from

5 to 10 bar whereas hydraulic circuits commonly operate at pressures up to
700 bar, or even much higher.

2. Actuating Forces:- Because of the relatively low air pressures used, pneumatic
actuators can produce only low or medium size forces, whereas hydraulic
actuators are suitable for very high loads.

3. Element Cost:- Hydraulic cylinders and valves can cost from 5 to 10 times
more than similar-size pneumatic elements.
 CONT…
4. Transmission Lines:-
 Hydraulic transmission lines are usually made of metal tubing with
expensive fittings, needed to withstand the high working pressures and
to avoid leaks.
 In pneumatics, inexpensive flexible plastic tubing is used, and the
fittings can usually be connected by hands, without using wrenches.
 Also, in hydraulic systems, return lines are needed to return the oil from
each cylinder back to the reservoir. In pneumatic systems, by
comparison, only a single line is needed, since the air is simply
exhausted back to the atmosphere after it has done its job.

5. Speed Control:-
 Because of the compressibility of air, it is difficult to control the speed
of pneumatic cylinders or motors accurately. Therefore, whenever
constant actuator speeds are required–despite sudden load changes–a
hydraulic system should be used.
 CONT…
6. The Power Source:-
 In hydraulic systems, constant displacement pumps are used, so that the
oil flow rate is constant, regardless of load pressure. The pump does not
produce pressure, but rather a constant flow. The pressure developed in
the system depends on the opposing load.
 The situation is exactly the opposite in pneumatic systems: a pressure
regulator connected at the compressor-receiver outlet keeps air pressure
essentially constant, whereas the air flow rate into any given cylinder is
determined by the load.

7. Actuation Speeds:-
Since compressed air expands very quickly, the piston velocities in
pneumatic cylinders are usually very high, provided the actuating valves
and air supply tubing are properly sized.
In hydraulic cylinders, piston velocity is usually low, being determined by
the flow rate of the pump.
HYDRAULIC AND PNEUMATIC SYSTEM: COMPONENTS

Power supply

Directional control valves

Pressure control valve

Flow control valves

Cylinders
 POWER SUPPLIES

Hydraulic power supply

ACCUMULATOR

 It smooth out any short term

fluctuations in output oil pressure.
 A container in which the oil is held
under pressure against an external
force
Pneumatic power supply
 DIRECTION CONTROL VALVE

 Directional Control Valves

 Direct the fluid flow through a system
 They do not alter rate of flow
 ON/OFF devices.
 Might be activated by means of mechanical, electrical, fluid pressure
signals
Spool valve
 VALVE SYMBOLS

 Square: for each switching position

 Eg: a 2 position valve- 2 squares
:a 3 position valve- 3 squares
 Arrow headed lines-to indicate
direction of flow
 Blocked-off lines: closed flow lines
 Connections: ports to the valve

(a) Flow path (b) Flow shut off

(c) Initial connections
 VALVE ACTUATION SYMBOLS

 Various ways the valves can be actuated

 EXAMPLE: SINGLE SOLENOID VALVE
 Solenoid operated spool valve
 The valve is actuated by a current passing through the solenoid

 And return to its original position by spring

 PRESSURE CONTROL VALVES

Three principal types

Pressure regulating valves: maintains constant pressure
Pressure limiting valves: safety device to limit the pressure.
Pressure sequence valves: sense pressure in external line and gives
a signal if it reaches a preset value.
 PRESSURE SEQUENCE VALVE
 Used to allow flow to occur to some part of the system when the
pressure has risen to the required level
 Eg: we might require some operation to start when the clamping
pressure applied to a work piece is at some particular value.
 PROCESS CONTROL VALVES
Used to control the rate of fluid flow.
Basics: an actuator being used to move a plug into the flow pipe and so alter the
cross-section of the pipe through which the fluid can flow.
Eg: diaphragm actuator
P.A=k.x; Where P: gauge pressure =Control pressure-atmospheric pressure A:
diaphragm area
 CYLINDERS
Cylinders
Hydraulic /Pneumatic cylinders are actuation devices that utilize
pressurized fluid to produce linear motion and force.
Hydraulic/Pneumatic cylinders are used in a variety of power
transfer applications.
Operating specifications(force, speed), configuration or mounting,
materials of construction, and features are all important parameters
to consider when searching for hydraulic cylinders.
 CONT…
 Cylinder Type
 As we know, cylinders cause linear action from pressure pushing
against piston in a cylinder. There are two common types of
cylinders:

Single acting: Fluid may only enter the cylinder from one side,
therefore can only push the cylinder in one direction. Springs are
commonly used to return the cylinder to the original form when the
pressure is leased.

Double acting: Fluid may enter the cylinder from either side of the
piston, allowing control to move the piston under pressure in either
direction.
 Mechanical Actuators/MECHANISMS
 Many jobs previously done by mechanisms are now replaced by
microprocessors.
 Mechanisms are devices used to convert one form of motion to
another, say linear to rotary.
 Mechanisms are still used for the following
 Force amplifier: lever
 Change of speed: gear
 Motion transfer(one axis to other): timing belt
 Particular type of motion: quick return motion
 They use linkages, cams, gears, rack & pinion, chain, belt drives.
 Rack & pinion: rotational motion to linear
 Parallel shafts gears: to reduce shaft speed
 Bevel gears: rotary motion through 900.
 Toothed belts & chains: rotary motion b/n different shafts
 KINEMATICS OF MECHANISMS
Is study of motion with out the effect of forces.
Rigid body motion: combination of translational and rotational motion.
Any motion can be broken into a combination of
Translational motion: is a movement which can be resolved into components along one
or more of the three axis x,y or z
Rotational motion: is one which has components rotating about one or more of the axis
 FREEDOM AND CONSTRAINTS
The number of degrees of freedom are the number of components of
motion that are required in order to generate the motion.
A body that is free in space can move in three independent, mutually
perpendicular directions and rotate in three ways about those directions. It
is said to have six degree of freedom.
 If a joint is constrained to move along a line then it has one degree of freedom
 If a joint is constraint to move on a plane then it has two degree of freedom
 KINEMATIC CHAINS
 Mechanisms are composed of individual
 Links: part of mechanism which has motion relative to some other part
(represented as rigid body with two or more points of
attachments…..nodes)
 Node:“points of attachment to other links”.
 Joint: is a connection between two or more links at their nodes and which
allows some motion between the connected links.
 kinematic chain: A sequence of joints and links.
 CONT…
Examples of links: levers, cranks, connecting rods & pistons sliders, pulleys, belts
and shafts
Kinematic chain: Simple Engine Mechanism
 Link 1 crankshaft,
 Link 2 the connecting rod,
 Link 3 the fixed frame,
 Link4 the slider i.e. the piston which move relative to the fixed frame
 CAM & CAM FOLLOWER
Composed of two essential components
Cam : a body which rotates or
oscillates and in doing so imparts
a reciprocating or oscillatory
motion to a second body called
Follower
 CAMS
O As the cam rotates so the follower is made to rise, dwell and fall;
the length of times spent at each of these positions depends on the
shape of the cam
The rise section: is the one that drives the follower upwards,
The fall section: is the one that lowers
thefollower.
The dwell section: is the one that allows the
follower to remain at the same level for a
significant period of time. It is circular with a
radius that does not change
(a)-Eccentric
(b)-Heart shaped
(c)-Pear shaped
 OTHER MECHANISMS

Gear Trains- to transfer and transform rotational motion.

Rack and pinion- to transform linear to rotational or vice versa
Ratchet and pawl- to lock a mechanism when it holds a load.
Belt and chain drives- transforming motion.
CONT…
ELECTRICAL ACTUATORS
Switching devices-
 Mechanical switches – Keyboards, limit switches, Momentary contact switches
 Relays, reed switches
 Solid-state switches: Diodes, Thyristors, Triacs, Transistors, MOSFET

Solenoid type devices – used in hydraulic/pneumatic systems

Drive systems – electric motors
 MOMENTARY CONTACT SWITCHES
(NORMALLY OPEN & NORMALLY CLOSED)
 The most fundamental control of any equipment is the ability to turn
it on/off. The easiest way to do this is using switches.
 ROLLER ACTUATED SWITCHES

Disadvantage of switches
They have to be manually (physically) turned on/off. They are relatively large and occupy more space.
 RELAYS
Relays are basically switches, which are turned on/off by application of a low
voltage across the relay terminals.
The relay is essentially an electromechanical switch that permits the opening and
closing of electrical contacts by means of an electromagnetic structure moving an
arm.
They are universally found in automatic control applications, since they can control
equipment directly through electric signals instead of requiring physical operation.
 CONT…
 Relays may be Normally Open, or Normally Closed.
 In Normally Open, the contacts are connected only when the
actuation terminals are energized.
 In Normally Closed relays, the device is connected to the power
supply when the relay actuation terminals are not connected.
 Relays with high current capacity (over 40 Amps) are called
contactors.
 REED SWITCH
In electro-pneumatic control circuits, reed switches are commonly used to sense
the position of pneumatic cylinder piston rods.
are characterised by their small size and fast switching time.
 SOLENOIDS

 Solenoid valves are electro-

pneumatic relays.
 The state of an electrical input
controls the state of a pneumatic
output.
 Solenoid valves are the
interface between electronic
control systems and pneumatic
power.
 ELECTRIC MOTOR CLASSIFICATION
 DC-motors
 AC-motor

Electric Motors

Direct Current (DC) Alternating Current (AC) Stepper (Reluctance)

Motors Motors Motors

Separately Self Excited Synchronous Induction

Excited

Series Compound Shunt Single-Phase Three-Phase

 Stator
(Rotating)
Commutator
Armature

Brushes
 BASIC PRINCIPLE
Field circuit: an electric magnet fed by a dc power source(often permanent magnet
in small motors)
Armature circuit: composed of windings, commutator, and brushes.
Windings and commutator are mounted on the rotor shaft.
The brushes are mounted on the stator and are stationary, but in contact with the
rotating commutator segment.
Function of the commutator and brushes is to switch the coils mechanically.
 The rotor windings are composed of several coils;
each has two terminals connected to the commutator
segments on opposite sides.
 The commutator segments are electrically isolated
from one another. The segments are exposed, and
the brushes touch two opposing segments.
 The brushes allow the commutator segments to be
connected to an external d.c. source.
 CONT…
The stator field produces flux, φ, from the north pole to the south pole.
The brushes touch the terminals of the rotor coil under the pole.
When the brushes are connected to an external d.c. source of potential, V, a
current, /, enters the terminal of the rotor coil.
The presence of the stator flux and rotor current produces a force, F, on the coil
known as the Lorentz force.
The coil that carries the current moves away from the brush and is disconnected
from the external source. The next coil moves under the brush and carries the
current /. This produces a continuous force F and continuous rotation.
 D. C. MOTOR WITH FIELD COILS
Can be classified into four groups based on the arrangement of their field
windings.
 Separately excited motor: The field and armature circuits are
excited by separate sources.
 Shunt motor: The field winding is connected in parallel with the
armature circuit. A common source is used for the field and
armature windings.
 Series motor: This type is designed to carry large currents and is
connected in series with the armature winding.
 Compound motor: This type uses the shunt and series windings.
 SHUNT WOUND MOTOR
A shunt motor has its field winding connected across the same voltage source used
for the armature circuit.
The source current, /, is equal to the sum of the armature current, /a, and the field
current, /f.
The shunt motor exhibits characteristics identical to those of the separately excited
motor.
 SERIES WOUND MOTOR
Armature and field coils are in series.
 COMPOUND MOTOR
Gives combined features i.e. highest starting torque and better speed regulation.
 STEPPER MOTORS
Is a motor that produces rotation through equal
angles, the so called steps, for each digital pulse
supplied to its input.
They don’t turn continuously, but move in a series of
steps.
The center shaft has a series of magnets mounted on
it, and the coils surrounding the shaft are alternately
given current or not, creating magnetic fields which
repulse or attract the magnets on the shaft, causing
the motor to rotate.
Has no commutator.
 CONT…
Variable reluctance stepper motor:
It has ferromagnetic rotor rather than the permanent magnet rotor.
When an opposite pair of windings has current switched to them a magnetic field
is produced with lines of force which pass from the stator poles through the nearest
set of poles on the rotor.
The rotor will move until the rotor and stator poles line up.
 AC MOTORS
Classification
 Single phase(induction/ synchronous)
 Three phase(induction/ synchronous)

Single phase induction:

 No external electrical connections to the rotor
 The stator with a set of windings
 Not self-starting: use an auxiliary starting winding to give to give the rotor an initial push
 CONT…
When an ac current passes through the stator windings an alternating magnetic
field is produced. As a result of electromagnetic induction, e.m.f.s are induced in
the conductors of the rotor and currents flow in the rotor.
The rotor rotates at a speed determined by the frequency of the ac current
applied to the stator.
The speed of rotation of the magnetic field is termed the synchronous speed.
The difference in speed b/n the rotation of the magnetic field and the rotor is
termed slip.
 CONT…
Three phase induction:
 Has three windings located 120 deg. apart.
 B/se the three phases reach their max. at different times the magnetic field can be considered to
rotate round the stator poles, completing one rotation in one full cycle of the current.
 Rotation of the field is much smother than single phase motor.
 CONT…
Synchronous motors:
 Have stators similar to those described above for induction motors
but a rotor which is a permanent magnet.
 The magnetic field produced by the stator rotates and so the
magnet rotates with it.
 CONT…
U V W

V V

S N

U U i
W W

Synchronous A.C. Motor Induction motor

the rotor is a permanent (asynchronous), the rotor is
magnet composed of one or more
windings in short-circuit
MOTOR CONTROL
oA motor controller is a device or set of devices that help in regulating
the manner in which a motor works.
oThere are two modes through which motor control components can
start or stop the motor, either manual or automatic.
oThe controller is also able to engage the motor into forward or
reverse rotation as well as regulating and limiting the rotary speed,
torque, and protecting against electrical fails and overloads.
Speed control
DC AC
PWM VFD
Rotation
H-circuit F/R-circuit
MOTOR SELECTION CRITERIA
Power supply,
Speed, Torque, HP
Motor class,
Motor Duty Cycle,
Bearing type,
Method of mounting the motor,
The cost and size of the motor,
Method of speed control,
Environmental conditions.
 ASSIGNMENT
Electrical actuator
1. List out types of electrical AC motor
1. Write the working mechanism/principle
2. Writ the control system ac motor.
2. List out types of electrical DC motor
1. Write the working mechanism/principle
2. Writ the control system dc motor.

Reading Assignment
 Micro actuators and sensors
~END~