ACTUATORS

ACTUATORS
Introduction
Most mechatronics systems involve motion or action of some
equipments.
This motion is created by a force or torque that results in
acceleration and displacement. Actuators are behind this.
Thus, actuator is a device that converts one form of energy into
linear/angular kinetic energy to perform mechanical work.
Power source and a way of transmitting this power to the point
of operation can be done in one of three ways:
• Mechanical
• Electrical
• Fluid
Mechanical power transmission elements

•Gears
•Belts
•Chains
•Bearings
•Couplings
Fluid power is the method of using pressurized fluid to
transmit energy. i.e. oil, water, air, and other liquids/gases

Liquid or Gas is referred to as a fluid. Accordingly, there are

two branches of fluid power; Pneumatics, and Hydraulics.

Now depending on the type of energy being used, actuators

can be classified into three systems:
i. Hydraulic systems,
ii. Pneumatic systems, and
iii. Electrical system
 i. Actuators in hydraulic systems

This system use liquid (oil) at relatively low speed but at high
pressure to supply power.

Hydraulic systems are commonly used where mechanisms

require large forces and precise control.

Hydraulics plays an important role in manufacturing or

processing industries, transportation and construction
sectors.

Examples: Vehicle power steering and brakes, hydraulic jacks

and heavy earth moving machines.
 Brake pedal
Vehicle brake hydraulic systems Master
cylinder

When the brake pedal is pressed

as illustrated in figure, the
Brake
hydraulic pressure is lines

transmitted to the piston in the Front

brake
calipers
brake caliper of the brakes. Rear wheel
cylinder
pistons
Pads
Rotor

The pressure forces the brake

pads against the brake rotor,
which is rotating with the
wheel. The friction between
the brake pad and the rotor
causes the wheel to slow
down and then stop.
Components of hydraulic systems

 Pump /Compressor - Source of liquid flow –Driven by motor to provides the energy to
perform the work

 A pressure regulator - Limit the pressure in the system to control the force of the actuator

 Valves - Control direction of flow

 Distribution system composed of hoses or pipes, and

 Actuators - Convert compressed liquid energy to linear/angular power. Make things move
Advantages of hydraulic systems
• High power - to weight ratio
• Does not need lubrication
• No additional cooling system needed
• Easy to control speed
• High stiffness of cylinders – load can stopped at any position

Disadvantage:
• Large infrastructure (high-pressure pump, tank, lines)
• Potential fluid leaks
• Noisy operation
• Vibration
• Expensive maintenance
• Characteristics liquid change with temperature and moisture
Applications of hydraulic systems
• Heavy Plant
– Steel press
– Large-scale precision

• Motion tables
• Mobile Systems
– Steering, brakes
– Propulsion and transmission

• Aerospace
– Aerolon actuation in aircraft
– Fin actuation in missiles/rockets
ii. Actuators in Pneumatic Systems
Are similar to hydraulic systems except use compressed air as
working fluid rather than hydraulic liquid.

Air Production System Air Consumption System

2
Components of pneumatic systems

• Compressor
• Air treatment
• Reservoir
• Pressure regulator
• Control valve
• Actuator
Advantage:
• Constant force
• No return lines needed
• Adaptable infrastructure
• Possible light, mobile pneumatic systems
• Fast system response
• Low cost and easy to install
• Clean and easy to maintain

Disadvantage:
• Low power densities
• Poor control properties (usually on/off)
• Difficult to achieve position control (compressible air)
• Noisy
• Limited use with larger actuators
Pneumatic applications
• Manufacturing
– Robot grippers
– Movement of parts
– Assembly operations
• Medical Systems
– Drills/cutting tools
– Suction and clamping
• Robotics
– Animatronics
– Grippers
– Subsea
 Valves
Valves are device used both in hydraulic and pneumatic systems to
control the direction, pressure and flow of the fluids (air or oil) in
a system.
Hydraulic systems are high pressure systems while pneumatic are
low pressure systems
Then, hydraulic valves are made of strong materials (e.g. steel) and
precisely manufactured, while pneumatic valves are made from
cheaper materials (e.g. aluminium and polymer) and are cheaper
to manufacture.

Valves can be divided into three major types:

a) Directional control valves
b) Pressure control valves
c) Volume control valves
a) Directional control valves

Determine the passage and the flow of fluid by means of

appropriate moving parts contained in them actuated from
the outside. These valves use sliding piston or spool.

Types
• Check valves
• Rotary valves
• Spool valves
• Pilot controlled poppet valve
• Electro-hydraulic valves
Spool valve

Rotary valves
b) Pressure control valves
Are used to maintain required pressure range within a
system, e.g.
Pressure Regulator: Adjust pressure output to working levels
for actuators
Relief and pressure limiter are the two kinds of pressure
regulators.

Pressure relief valve pressure limiter valve

Unloading valve

This valve directs pump output oil back to the reservoir at low
pressure after system pressure has been reached.
They may be installed in the pump outlet line with a tee
connection
c) Volume control valves

Restrict flow in or out of the component

(actuator) whose speed is being
regulated

By the use of flow regulators the

outstroke speed and in stroke speed of a
piston rod or rotation speeds of
hydraulic motor can be independently
adjusted
 Hydraulic and Pneumatic Actuators
These are mechanical devices used for moving or controlling something.
Convert fluid energy into mechanical power.

They can be categorized into two groups

Linear: Often called cylinders, gives linear movement

Rotary: Gives rotary movement.

• Limited Rotation: Used for suspension systems
• Self-contained
• Rack and pinion or lever
• Air Motors or turbines

Clamp
Linear actuators

Convert fluid energy to a mechanical straight motion of a

piston or cylinder. They can be in:

Single acting cylinder: The cylinder is only powered in one

direction and need another force to return it such as an
external load or spring. No hydraulic fluid is present is on
the low pressure side.
Double acting cylinder

Give force in both directions. Fluid power will both extend

and retract the cylinder
Rotary actuators

Hydraulic Motors
A motor is a rotary actuator that rotates
in a full circle.
They convert hydraulic energy to
mechanical rotation energy (torque)

Types
• Gear motors
• Vane motors
• Piston motors
Application of hydraulic rotary actuator
iii. Electric actuation systems

Electric actuators are continuous actuators that convert electric

energy into mechanical energy in a form of angular motion.

Electric actuators are available in one of two types, direct

current (DC) and alternating current (AC).
They can be used to rotate pumps, fans, compressors, wheels,
etc.

Common conversional electrical actuators available

a) DC motor
b) AC motor
c) Solenoid
a) DC motor

A DC motor runs on direct current (DC) electricity. It consists

of two main parts. These are,
• Stator
• Rotor

The stator consists of the housing,

permanent magnets, and brushes.
The rotor consists of the output
shaft, windings and commutator
Operating principles
The principle of operation of any electric motor is based on
Ampere’s law, which states the conductor of length L will
experience a force F if an electric current I flows through the
conductor at right angle to a magnetic field with a flux density
B

 
F = (B× I )L = B I Lsinθ
When to use a DC Motor

• Accurate position or velocity control

• Low noise, high efficiency
• Cost not too critical
• Speed and power payoff (gearing)
Are more widely used in control applications and are referred as
servomotors

Some Examples
• Consumer Products:
– CDs, disk drives
– Fans, drills, etc
• Manufacturing
– Robots
– CNC machines
• Aerospace
– Sensor pointing
– Fly-by-wire inputs
• Cars:
– Windscreen wipers
– Fuel management

b) AC Motor
Run on alternating current (AC) electricity. It consists of;
An outside stationary stator having coils supplied with AC
current to produce a rotating magnetic field, and
An inside rotor attached to the output shaft that is given a
torque by the rotating field
It can be single or three phase motor depending to number of
independent windings connected to a separate AC line
phase

Principle of operations
The current in the stator generates a magnetic field which induces a
current in the rotor conductors. The induced current in the rotor in
turn generates its own magnetic field.

The interaction of the two magnetic fields (the magnetic field of the
rotor trying to keep up with the magnetic field of the stator)
generates the torques on the rotor.
When to use a AC Motor

• High power required

• Complex control profiles:
– Point to point
– Velocity
• Load Demand
– High duty cycle
– Efficiency
– Reliable

Example s of applications of AC Drives

• Large Cranes or material handling systems
Applications cont…
• Belts or conveyors
• High speed trains
• Electric drive haul trucks

Step Motor
Also called stepper motor, is electromechanical construction in
such that it moves in discrete mechanical steps.

A change in phase current from one state to another creates a

single step change in the rotor position. If the phase current
state is not changed, the rotor position stays in that stable
position.
 A simplified version of a stepper motor cross section
Operating principle (as per next figure)
The rotor has one north and one south pole permanent magnet;
and the stator has four-pole, two-phase winding with four
switches.
At any given time either switch 1 or 2, and 3 or 4 can be ON to
affect the polarity of electromagnets. For each state, there is
a corresponding stable rotor position.
When to use a step motor

A stepper motor can be a good choice whenever

controlled movement is required such as to control
rotation angle, speed, position and synchronism.

Some examples
Printers, plotters, office equipment, hard disk drives,
medical equipment, fax machines, automotive and many
more.
c) Solenoid
A solenoid is coil with an iron
plunger inside it. When a current
flow in the coil, plunge is
energized and try to move out of
the coil. But the movement is
resisted by the spring, hence the
distance moved by the plunger is
proportion to the current in the
coil.
Solenoid is used as an electrical
switch or in hydraulic and
pneumatic valves to move the
valve element ( piston or spool)
Thanks
• Applications

• Actuators are used everywhere there is automation

– robot, conveyor system, etc.

– Need good precision, electrical actuator

– Need large forces, hydraulic actuator
– Low cost, pneumatic actuator
• Note: can get high precision expensive pneumatic actuators
• Electric motors used for high precision
– Precise robot applications such as automotive and
pharmaceutical
– Now up to 10,000 lbf
• Hydraulic actuators used for increased torque
– High force and torque applications up to 32,000 lbf
– High precision achievable
• Pneumatic actuators are used for lower cost and
lower precision applications