Mechatronics System Design

Linear Actuators
Dr. Ashraf Saleem

Linear Actuators
Stepper linear actuators
DC linear actuators
AC linear actuators
Fluid (hydraulic and pneumatic) cylinders

Linear Motors and Linear Motion

Technology

Over the last 5 years linear motion applications become

more demanding than ever before, due to its Faster
throughput, more exact positioning, longer life, less
maintenance, fewer moving parts etc
Imagine if we unwrap a conventional rotary servo motor.
Then we ca consider what was the stator is now a forcer
and the rotor becomes a coil or magnet rail. With this
design, the load is connected directly to the motor. Direct
linear motion is achieved without any rotary to linear
transmission devices.

Advantages

High speeds, the maximum speed of a linear motor is limited only

by the bus voltage and the speed of the control electronics. Typical
speeds for linear motors are 3 meters per second with 1 micron
resolution.
High Precision, the accuracy, resolution, and repeatability of a
linear motor driven device are controlled by the feed back device.
With the wide range of linear feedback devices available, resolution
and accuracy are primarily limited to budget and control system
bandwidth.
Fast Response, the response rate of a linear motor driven device
can be over 100 times that of a mechanical transmission. This
means faster accelerations and settling times, thus more
throughputs.
Stiffness, because there is no mechanical linkage, increasing the
stiffness is simply a matter of gain and current. The spring rate of a
linear motor driven system can be many times that of a ball screw
driven device.
Maintenance Free Operation, because the linear motors of today
have no contacting parts there is no wear and therefore.

Disadvantages

Cost: Linear Motors are expensive. This is due to the relative low
volume produced, and the price of magnets
Heating: In most linear motor applications, the forcer is attached to
the load. Any losses are then directly coupled to the load. If an
application is sensitive to heat, thermal management techniques
need to be applied. Air and water cooling options are popular and
common.
No Friction: This may not sound like a problem, but it certainly can
be. For instance, a linear motor is travelling at 3 meters/second (120
ips) and loses power. Without some resistance in the system, it does
not take long before the motor reaches the end of stroke and
mechanical stops.

Linear Motors Control

In response to an input command, electric drives

efficiently control the speed and the position of the
mechanical load, consequently eliminating the need for
the throttling valve. The controller, by comparing the
input command for speed and position with the actual
values measured through sensors, provides appropriate
control signals to the power-processing unit (PPU)
consisting of power semiconductor devices.
Electric Drive

Fixed Form

Power
Processing Unit
(PPU)

Motor

Load
Speed/
Position

Adjustable Form

Sensor
Power

Controller

Signal
Input command
(speed/position)

Power Process Unite

The PPU gets its power from the utility

source with sinusoidal voltages of a fixed
frequency and amplitude. In response to
the control input, the PPU converts these
fixed-form input voltages into an output of
appropriate form (in frequency and
amplitude) that is optimally suited for
operating motor.

Hydraulic Actuators

Principle of Operation
An actuator of this type works by changes of
pressure. This system can be used in both linear
and rotary actuation. The general linear
mechanism consists of a piston encased in a
chamber with a piston rod protruding from the
chamber. The piston rod serves as the power
transmission link between the piston inside the
chamber and the external world

Advantages and Disadvantages

Advantages

One of the main advantages of hydraulic actuators is that these

systems can deliver a great deal of power compared to their
actuator inertia.
Low compressibility of hydraulic fluids and, the high stiffness
leads to an associated rapid response. This means that the robot
using hydraulic actuators can execute very quick movements
with great force.
They tend to be reliable and mechanically simplistic as well as
having a low noise level, and relatively safe during operation.
As for this method of actuation, design characteristics are well
known so the process of design is made easier due to this extent
of knowledge.

Advantages and Disadvantages

Disadvantages

One of the larger concerns with hydraulic systems is the

containment of the fluid within the actuation system. Not only is
this because of the contamination of the surrounding
environment, but the leakage can also contaminate the oil and
possibly lead to damage of interior surfaces.
Additionally, the hydraulic fluid is flammable and pressurized so
leaks could pose an extreme hazard to equipment and
personnel.
Other drawbacks include lags in the control of the system due to
the transmission lines and oil viscosity changes from
temperature.
The degradation of the interior surfaces and the contamination of
the fluid result in a marked drop in the performance of the
system.

Pneumatic Actuators

Principle of operation
This type of actuators are the direct descendents of the
hydraulic systems. The difference between the two is
that pneumatic systems use a compressible gas (i.e. air )
as the medium for energy transmission. This makes the
pneumatic system more passively compliant than the
hydraulic system. With pneumatic actuators, the
pressure within the chambers is lower than that of
hydraulic systems resulting in lower force capabilities. In
Figure 4 there is a cut away view of the basic pneumatic
actuator. It is quite similar to the hydraulic counterpart
however there are no return hydraulic lines for fluid. In a
typical actuator of this type the fluid, namely air, is simply
exhausted through the outlet valve in the actuator.

Advantages and Disadvantages

Advantages
Pneumatic

actuators have less force capability than

hydraulic actuators. Since, in contrast, the system
operates at a lower pressure than the hydraulics and
does not require return lines for the fluid, the support
structure of the manipulator is much lighter than the
other system.
Pneumatics are cleaner and nonflammable which
makes its uses in certain environments ( i.e.
cleanrooms, operating rooms) more desired.
Additionally, installation, operation and maintenance
is easier and cost is lower.

Advantages and Disadvantages

Disadvantages
Pneumatic

systems have a high friction force to

overcome in order to maneuver and the diversion of
power to combat friction gives these systems a lower
working force. The release valve that allows
pressurized air to escape has a tendency to be load if
a muffler is not employed.
Of course due to the medium which is compressible,
control of motion is handled differently than
hydraulics.

Hydraulic and Pneumatic Control