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A linear actuator is an actuator that creates linear motion (i.e., in a straight line), in contrast to the circular motion of a conventional electric motor. Linear actuators are used in machine tools and industrial machinery, in computer peripherals such as disk drives and printers, in valves and dampers, and in many other places where linear motion is required. Hydraulic or pneumatic cylinders inherently produce linear motion. Many other mechanisms are used to generate linear motion from a rotating motor.
Mechanical linear actuators typically operate by conversion of rotary motion into linear motion. Conversion is commonly made via a few simple types of mechanism:
Some mechanical linear actuators only pull, such as hoists, chain drive and belt drives. Others only push (such as a cam actuator). Pneumatic and hydraulic cylinders, or lead screws can be designed to generate force in both directions.
Mechanical actuators typically convert rotary motion of a control knob or handle into linear displacement via screws and/or gears to which the knob or handle is attached. A jackscrew or car jack is a familiar mechanical actuator. Another family of actuators are based on the segmented spindle. Rotation of the jack handle is converted mechanically into the linear motion of the jack head. Mechanical actuators are also frequently used in the field of lasers and optics to manipulate the position of linear stages, rotary stages, mirror mounts, goniometers and other positioning instruments. For accurate and repeatable positioning, index marks may be used on control knobs. Some actuators include an encoder and digital position readout. These are similar to the adjustment knobs used on micrometers except their purpose is position adjustment rather than position measurement.
Hydraulic actuators or hydraulic cylinders typically involve a hollow cylinder having a piston inserted in it. An unbalanced pressure applied to the piston generates a force that can move an external object. Since liquids are nearly incompressible, a hydraulic cylinder can provide controlled precise linear displacement of the piston. The displacement is only along the axis of the piston. A familiar example of a manually operated hydraulic actuator is a hydraulic car jack. Typically though, the term "hydraulic actuator" refers to a device controlled by a hydraulic pump.
Pneumatic actuators, or pneumatic cylinders, are similar to hydraulic actuators except they use compressed air to generate force instead of a liquid. They work similarly to a piston in which air is pumped inside a chamber and pushed out of the other side of the chamber. Air actuators are not necessarily used for heavy duty machinery and instances where large amounts of weight are present. One of the reasons pneumatic linear actuators are preferred to other types is the fact that the power source is simply an air compressor. Because air is the input source, pneumatic actuators are able to be used in many places of mechanical activity. The downside is, most air compressors are large, bulky, and loud. They are hard to transport to other areas once installed. Pneumatic linear actuators are likely to leak and this makes them less efficient than mechanical linear actuators.
The piezoelectric effect is a property of certain materials in which application of a voltage to the material causes it to expand. Very high voltages correspond to only tiny expansions. As a result, piezoelectric actuators can achieve extremely fine positioning resolution, but also have a very short range of motion. In addition, piezoelectric materials exhibit hysteresis which makes it difficult to control their expansion in a repeatable manner.
Electro-mechanical actuators are similar to mechanical actuators except that the control knob or handle is replaced with an electric motor. Rotary motion of the motor is converted to linear displacement. Electromechanical actuators may also be used to power a motor that converts electrical energy into mechanical torque. There are many designs of modern linear actuators and every company that manufactures them tends to have a proprietary method. The following is a generalized description of a very simple electro-mechanical linear actuator.
Typically, an electric motor is mechanically connected to rotate a lead screw. A lead screw has a continuous helical thread machined on its circumference running along the length (similar to the thread on a bolt). Threaded onto the lead screw is a lead nut or ball nut with corresponding helical threads. The nut is prevented from rotating with the lead screw (typically the nut interlocks with a non-rotating part of the actuator body). When the lead screw is rotated, the nut will be driven along the threads. The direction of motion of the nut depends on the direction of rotation of the lead screw. By connecting linkages to the nut, the motion can be converted to usable linear displacement. Most current actuators are built for high speed, high force, or a compromise between the two. When considering an actuator for a particular application, the most important specifications are typically travel, speed, force, accuracy, and lifetime. Most varieties are mounted on dampers or butterfly valves. [3] [4]
There are many types of motors that can be used in a linear actuator system. These include dc brush, dc brushless, stepper, or in some cases, even induction motors. It all depends on the application requirements and the loads the actuator is designed to move. For example, a linear actuator using an integral horsepower AC induction motor driving a lead screw can be used to operate a large valve in a refinery. In this case, accuracy and high movement resolution aren't needed, but high force and speed are. For electromechanical linear actuators used in laboratory instrumentation robotics, optical and laser equipment, or X-Y tables, fine resolution in the micron range and high accuracy may require the use of a fractional horsepower stepper motor linear actuator with a fine pitch lead screw. There are many variations in the electromechanical linear actuator system. It is critical to understand the design requirements and application constraints to know which one would be best.
A linear actuator using standard motors will commonly have the motor as a separate cylinder attached to the side of the actuator, either parallel with the actuator or perpendicular to the actuator. The motor may be attached to the end of the actuator. The drive motor is of typical construction with a solid drive shaft that is geared to the drive nut or drive screw of the actuator.
Compact linear actuators use specially designed motors that try to fit the motor and actuator into the smallest possible shape.
In the majority of linear actuator designs, the basic principle of operation is that of an inclined plane. The threads of a lead screw act as a continuous ramp that allows a small rotational force to be used over a long distance to accomplish the movement of a large load over a short distance. The power supply is from a DC or AC motor. The typical motor is a 12v DC, but other voltages are available. Actuators have a switch to reverse the polarity of the motor, which makes the actuator change its motion.
The speed and force of an actuator depend on its gearbox. The amount of force depends on the actuator’s speed. Lower speeds supply greater force because motor speed and force are constant.
One of the basic differences between actuators is their stroke, which is defined by the length of the screw and shaft. Speed depends on the gears that connect the motor to the screw.
The mechanism to stop the stroke of an actuator is a limit or micro switch, which can be seen in the image below. Microswitches are located at the top and bottom of the shaft and are triggered by the up and down movement of the screw.
Many variations on the basic design have been created. Most focus on providing general improvements such as a higher mechanical efficiency, speed, or load capacity. There is also a large engineering movement towards actuator miniaturization.
Most electro-mechanical designs incorporate a lead screw and lead nut. Some use a ball screw and ball nut. In either case the screw may be connected to a motor or manual control knob either directly or through a series of gears. Gears are typically used to allow a smaller (and weaker) motor spinning at a higher rpm to be geared down to provide the torque necessary to spin the screw under a heavier load than the motor would otherwise be capable of driving directly. Effectively this sacrifices actuator speed in favor of increased actuator thrust. In some applications the use of worm gear is common as this allow a smaller built in dimension still allowing great travel length.
A traveling-nut linear actuator has a motor that stays attached to one end of the lead screw (perhaps indirectly through a gear box), the motor spins the lead screw, and the lead nut is restrained from spinning so it travels up and down the lead screw.
A traveling-screw linear actuator has a lead screw that passes entirely through the motor. In a traveling-screw linear actuator, the motor "crawls" up and down a lead screw that is restrained from spinning. The only spinning parts are inside the motor, and may not be visible from the outside.
Some lead screws have multiple "starts". This means they have multiple threads alternating on the same shaft. One way of visualizing this is in comparison to the multiple color stripes on a candy cane. This allows for more adjustment between thread pitch and nut/screw thread contact area, which determines the extension speed and load carrying capacity (of the threads), respectively.
Linear screw actuators can have a static loading capacity, meaning that when the motor stops the actuator essentially locks in place and can support a load that is either pulling or pushing on the actuator. This static load capacity increases mobility and speed.
The braking force of the actuator varies with the angular pitch of the screw threads and the specific design of the threads. Acme threads have a very high static load capacity, while ball screws have an extremely low load capacity and can be nearly free-floating.
Generally it is not possible to vary the static load capacity of screw actuators without additional technology. The screw thread pitch and drive nut design defines a specific load capacity that cannot be dynamically adjusted.
In some cases, high viscosity grease can be added to linear screw actuators to increase the static load. Some manufacturers use this to alter the load for specific needs.
Static load capacity can be added to a linear screw actuator using an electromagnetic brake system, which applies friction to the spinning drive nut. For example, a spring may be used to apply brake pads to the drive nut, holding it in position when power is turned off. When the actuator needs to be moved, an electromagnet counteracts the spring and releases the braking force on the drive nut.
Similarly an electromagnetic ratchet mechanism can be used with a linear screw actuator so that the drive system lifting a load will lock in position when power to the actuator is turned off. To lower the actuator, an electromagnet is used to counteract the spring force and unlock the ratchet.
Dynamic load capacity is typically referred to as the amount of force the linear actuator is capable of providing during operation. This force will vary with screw type (amount of friction restricting movement) and the motor driving the movement. Dynamic load is the figure which most actuators are classified by, and is a good indication of what applications it would suit best.
In most cases when using an electro-mechanical actuator, it is preferred to have some type of speed control. Such controllers vary the voltage supplied to the motor, which in turn changes the speed at which the lead screw turns. Adjusting the gear ratio is another way to adjust speed. Some actuators are available with several different gearing options.
The duty cycle of a motor refers to the amount of time the actuator can be run before it needs to cool down. Staying within this guideline when operating an actuator is key to its longevity and performance. If the duty cycle rating is exceeded, then overheating, loss of power, and eventual burning of the motor is risked.
A linear motor is functionally the same as a rotary electric motor with the rotor and stator circular magnetic field components laid out in a straight line. Where a rotary motor would spin around and re-use the same magnetic pole faces again, the magnetic field structures of a linear motor are physically repeated across the length of the actuator.
Since the motor moves in a linear fashion, no lead screw is needed to convert rotary motion to linear. While high capacity is possible, the material and/or motor limitations on most designs are surpassed relatively quickly due to a reliance solely on magnetic attraction and repulsion forces. Most linear motors have a low load capacity compared to other types of linear actuators. Linear motors have an advantage in outdoor or dirty environments in that the two halves do not need to contact each other, and so the electromagnetic drive coils can be waterproofed and sealed against moisture and corrosion, allowing for a very long service life. Linear motors are being used extensively in high performance positioning systems for applications which require various combinations of high velocity, high precision and high force.
Telescoping linear actuators are specialized linear actuators used where space restrictions exist. Their range of motion is many times greater than the unextended length of the actuating member.
A common form is made of concentric tubes of approximately equal length that extend and retract like sleeves, one inside the other, such as the telescopic cylinder.
Other more specialized telescoping actuators use actuating members that act as rigid linear shafts when extended, but break that line by folding, separating into pieces and/or uncoiling when retracted. Examples of telescoping linear actuators include:
Actuator Type | Advantages | Disadvantages |
---|---|---|
Mechanical | Cheap. Repeatable. No power source required. Self-contained. Identical behavior extending or retracting. | Manual operation only. No automation. |
Electro-mechanical | Cheap. Repeatable. Operation can be automated. Self-contained. Identical behaviour extending or retracting. DC or stepping motors. Position feedback possible. | Many moving parts prone to wear. |
Linear motor | Simple design. Minimum of moving parts. High speeds possible. Self-contained. Identical behavior extending or retracting. | Low to medium force. |
Piezoelectric | Very small motions possible at high speeds. Consumes barely any power. | Short travel unless amplified mechanically. High voltages required, typically 24V or more. Expensive and fragile. Good in compression only, not in tension. Typically used for Fuel Injectors. |
TCP: Twisted and coiled polymer | light and inexpensive | Low efficiency and High temperature range required |
Hydraulic | Very high forces possible. Relatively high power to size ratio (or power density). | Can leak. Requires position feedback for repeatability. External hydraulic pump required. Some designs good in compression only. |
Pneumatic | Strong, light, simple, fast. | Precise position control impossible except at full stops |
Wax motor | Smooth operation. | Not as reliable as other methods. |
Segmented spindle | Very compact. Range of motion greater than length of actuator. | Both linear and rotary motion. |
Moving coil | Force, position and speed are controllable and repeatable. Capable of high speeds and precise positioning. Linear, rotary, and linear + rotary actions possible. | Requires position feedback to be repeatable. |
MICA: Moving iron controllable actuator | High force and controllable. Higher force and less losses than moving coils. Losses easy to dissipate. Electronic driver easy to design and set up. | Stroke limited to several millimeters, less linearity than moving coils. |
A cam is a rotating or sliding piece in a mechanical linkage used especially in transforming rotary motion into linear motion. It is often a part of a rotating wheel or shaft that strikes a lever at one or more points on its circular path. The cam can be a simple tooth, as is used to deliver pulses of power to a steam hammer, for example, or an eccentric disc or other shape that produces a smooth reciprocating motion in the follower, which is a lever making contact with the cam. A cam timer is similar, and were widely used for electric machine control before the advent of inexpensive electronics, microcontrollers, integrated circuits, programmable logic controllers and digital control.
A machine is a physical system that uses power to apply forces and control movement to perform an action. The term is commonly applied to artificial devices, such as those employing engines or motors, but also to natural biological macromolecules, such as molecular machines. Machines can be driven by animals and people, by natural forces such as wind and water, and by chemical, thermal, or electrical power, and include a system of mechanisms that shape the actuator input to achieve a specific application of output forces and movement. They can also include computers and sensors that monitor performance and plan movement, often called mechanical systems.
An actuator is a component of a machine that produces force, torque, or displacement, usually in a controlled way, when an electrical, pneumatic or hydraulic input is supplied to it in a system. An actuator converts such an input signal into the required form of mechanical energy. It is a type of transducer. In simple terms, it is a "mover".
Fluid power is the use of fluids under pressure to generate, control, and transmit power. Fluid power is conventionally subdivided into hydraulics and pneumatics. Although steam is also a fluid, steam power is usually classified separately from fluid power. Compressed-air and water-pressure systems were once used to transmit power from a central source to industrial users over extended geographic areas; fluid power systems today are usually within a single building or mobile machine.
Hydraulic machines use liquid fluid power to perform work. Heavy construction vehicles are a common example. In this type of machine, hydraulic fluid is pumped to various hydraulic motors and hydraulic cylinders throughout the machine and becomes pressurized according to the resistance present. The fluid is controlled directly or automatically by control valves and distributed through hoses, tubes, or pipes.
A pneumatic motor, or compressed-air engine, is a type of motor which does mechanical work by expanding compressed air. Pneumatic motors generally convert the compressed-air energy to mechanical work through either linear or rotary motion. Linear motion can come from either a diaphragm or piston actuator, while rotary motion is supplied by either a vane type air motor, piston air motor, air turbine or gear type motor.
A tappet or valve lifter is a valve train component which converts rotational motion into linear motion in activating a valve. It is most commonly found in internal combustion engines, where it converts the rotational motion of the camshaft into linear motion of intake and exhaust valves, either directly or indirectly.
Motion control is a sub-field of automation, encompassing the systems or sub-systems involved in moving parts of machines in a controlled manner. Motion control systems are extensively used in a variety of fields for automation purposes, including precision engineering, micromanufacturing, biotechnology, and nanotechnology. The main components involved typically include a motion controller, an energy amplifier, and one or more prime movers or actuators. Motion control may be open loop or closed loop. In open loop systems, the controller sends a command through the amplifier to the prime mover or actuator, and does not know if the desired motion was actually achieved. Typical systems include stepper motor or fan control. For tighter control with more precision, a measuring device may be added to the system. When the measurement is converted to a signal that is sent back to the controller, and the controller compensates for any error, it becomes a Closed loop System.
A leadscrew, also known as a power screw or translation screw, is a screw used as a linkage in a machine, to translate turning motion into linear motion. Because of the large area of sliding contact between their male and female members, screw threads have larger frictional energy losses compared to other linkages. They are not typically used to carry high power, but more for intermittent use in low power actuator and positioner mechanisms. Leadscrews are commonly used in linear actuators, machine slides, vises, presses, and jacks. Leadscrews are a common component in electric linear actuators.
A hydraulic cylinder is a mechanical actuator that is used to give a unidirectional force through a unidirectional stroke. It has many applications, notably in construction equipment, manufacturing machinery, elevators, and civil engineering. A hydraulic cylinder is a hydraulic actuator that provides linear motion when hydraulic energy is converted into mechanical movement. It can be likened to a muscle in that, when the hydraulic system of a machine is activated, the cylinder is responsible for providing the motion.
Pneumatic cylinder, also known as air cylinder, is a mechanical device which uses the power of compressed gas to produce a force in a reciprocating linear motion.
A ball screw is a mechanical linear actuator that translates rotational motion to linear motion with little friction. A threaded shaft provides a helical raceway for ball bearings which act as a precision screw. As well as being able to apply or withstand high thrust loads, they can do so with minimum internal friction. They are made to close tolerances and are therefore suitable for high-precision applications. The ball assembly acts as the nut while the threaded shaft is the screw.
The screw is a mechanism that converts rotational motion to linear motion, and a torque to a linear force. It is one of the six classical simple machines. The most common form consists of a cylindrical shaft with helical grooves or ridges called threads around the outside. The screw passes through a hole in another object or medium, with threads on the inside of the hole that mesh with the screw's threads. When the shaft of the screw is rotated relative to the stationary threads, the screw moves along its axis relative to the medium surrounding it; for example rotating a wood screw forces it into wood. In screw mechanisms, either the screw shaft can rotate through a threaded hole in a stationary object, or a threaded collar such as a nut can rotate around a stationary screw shaft. Geometrically, a screw can be viewed as a narrow inclined plane wrapped around a cylinder.
A jack is a mechanical lifting device used to apply great forces or lift heavy loads. A mechanical jack employs a screw thread for lifting heavy equipment. A hydraulic jack uses hydraulic power. The most common form is a car jack, floor jack or garage jack, which lifts vehicles so that maintenance can be performed. Jacks are usually rated for a maximum lifting capacity. Industrial jacks can be rated for many tons of load.
A hydraulic motor is a mechanical actuator that converts hydraulic pressure and flow into torque and angular displacement (rotation). The hydraulic motor is the rotary counterpart of the hydraulic cylinder as a linear actuator. Most broadly, the category of devices called hydraulic motors has sometimes included those that run on hydropower but in today's terminology the name usually refers more specifically to motors that use hydraulic fluid as part of closed hydraulic circuits in modern hydraulic machinery.
In mechanical engineering, backlash, sometimes called lash, play, or slop, is a clearance or lost motion in a mechanism caused by gaps between the parts. It can be defined as "the maximum distance or angle through which any part of a mechanical system may be moved in one direction without applying appreciable force or motion to the next part in mechanical sequence."p. 1-8 An example, in the context of gears and gear trains, is the amount of clearance between mated gear teeth. It can be seen when the direction of movement is reversed and the slack or lost motion is taken up before the reversal of motion is complete. It can be heard from the railway couplings when a train reverses direction. Another example is in a valve train with mechanical tappets, where a certain range of lash is necessary for the valves to work properly.
A linear stage or translation stage is a component of a precise motion system used to restrict an object to a single axis of motion. The term linear slide is often used interchangeably with "linear stage", though technically "linear slide" refers to a linear motion bearing, which is only a component of a linear stage. All linear stages consist of a platform and a base, joined by some form of guide or linear bearing in such a way that the platform is restricted to linear motion with respect to the base. In common usage, the term linear stage may or may not also include the mechanism by which the position of the platform is controlled relative to the base.
A roller screw, also known as a planetary roller screw or satellite roller screw, is a low-friction precision screw-type actuator, a mechanical device for converting rotational motion to linear motion, or vice versa. Planetary roller screws are used as the actuating mechanism in many electromechanical linear actuators. Due to its complexity, the roller screw is a relatively expensive actuator, but may be suitable for high-precision, high-speed, heavy-load, long-life, and heavy-use applications.
A rotary actuator is an actuator that produces a rotary motion or torque.
In engineering, a solenoid is a device that converts electrical energy to mechanical energy, using an electromagnet formed from a coil of wire. The device creates a magnetic field from electric current, and uses the magnetic field to create linear motion.