2.

007 Actuator Information & Index

ActuatorList|BasicPneumatics|PneumaticConnections|BasicElectronics|ElectricalConnections
Thispagecontainsthebasicinformationthatevery2.007studentshouldknowaboutthehowtheactuators work,andhowtoconnectthem. Studentswhoareinterestedinmoreadvancedinformationonthehowtheactuatorsworkshouldreadthe AdvancedActuatorHandout* afterunderstandingthecontentsofthisone. Studentswhoareinterestedinmoreadvancedinformationonwiringandplumbingtheelectricalandpneumatic actuatorsshouldreadtheAdvancedConnectingandControlHandoutafterunderstandingthecontentsofthis one.

The List of Actuators

Double-ActingAirCyclinder
VaneTypeRotaryAirActuator
TheFordMotor
TheBoschMotor
TheGreenMaxonMotor
TheSiverMaxonMotor
ThePolaroidMotor(&DriveAssembly)
TheDeccoSolenoid

Basic Pneumatics
Pneumaticsystemsuseadifferenceinpressuretomoveapistonorvane.Asimplecylinderisconstructedas shownbelowincross-section.

Itconsistsofanopeningintowhichairisallowedtoenter.Thepressurizedairpushesagainstthepistoninside thecylinder.Thisforceisdependentontwothings:thepressureoftheairandtheareaofthepiston.(Forthis

contest,itisimpossibletochangeeitherofthesevalues.)Theairpressureissetat60psiorpoundspersquare inch.Thediameterofthepistonis10mm,thusithasaneffectivesurfaceareaof78mm2or0.1217in2.Witha pressureof60psithismeanstheforcecanbecalculated.Force=(Pressure)*(Area).Thusthepushingforce equals7.3lbfor32.5N. Becausethepistonrodreducestheeffectiveareaononesideofthepiston,thepullforceisnotasgreatasthe pushforce.Forthepullforce,theeffectivearea=(Pistonarea)-(rodarea).Therodis4mmindiameter,so therodareais12.5mm2.Thustheeffectiveareais65.5mm2andthepullforceistherefore27.1Nor6.09lbf. Amoredetailedlookatyourpneumaticpistonsrevealstwoportswithatwopartthumbscrewoneach.These areflowcontrols,andastheirnameimplies,theyregulatethespeedatwhichavolumeofairentersthe cylinderbychangingthesizeoftheinlethole.Thusifoneweretoadjustthescrewallthewaydown,noair wouldbeabletoenterthecylinderfromthatside.Theseportscanbeadjustedindependentlyandthus,the speedatwhichthecylinderextendsandretractscanbechangedindependently.

Making Pneumatic Connections

Thepneumaticconnectorsarelabeledwithfourcolors:red,yellow,greenandblue.Youshouldcolorcode yourconnectorstomatchsothatyouwillnotmixuptheconnectionsatthecontest. TheconnectorsontheY-connectors,theflowcontrolsandtheconnectionsattheumbilicalallworkonthe sameprinciple.Yousimplyinsertthepneumatictube(4mmO.D.)intotheconnectorandthenpullbackgently. Toremove,DONOTJUSTYANKHARD!!.Pushthesmallcollardownintotheconnector(usuallyblue orgreen)andwhileholdingthecollardown,pulltubeout.Itismucheasierthisway!

Basic Electronics
Electricalsystemsareanalyticallyremarkablysimilartopneumaticsystemswhichwereexplainedabove. Insteadofpressure,thereisvoltage,andinsteadofflowthereiscurrent(orthemeasureofcurrentwhichis amps.)Thepowersupplyoutputs13.8volts.Thisislikeplacingthetwowiresonyourmotorbetweennine batteries(suchasCcells.) TheDCmotorsyouhaveinyourkitarepermanentmagnetDCmotors.Eachmotorrequiresthatbothwiresbe hookedtotheumbilicalortoeithersideofabattery. Toreversethedirectionofthemotor,simplyflipthewiresateitherthemotorortheconnectortotheumbilical. (Itisusuallymucheasiertoswitchatthemotorconnections.) Flippingthewireshasnoeffectonthesolenoid.Itissimplyonoroff.Thesolenoidwillonlypull.Itcannot push,itneedssomeotherforcetopulltheplungeroutsoitcanbeusedagain(i.e.spring,gravity,etc.) Eachcontestanthasfourelectricallines,andthereforecancontrolfourmotorsindependently.Tocontrolmore motorsyoucoulddoso,butnotindependently.Tocontrolmoremotorsyoumusthookuptwomotorstothe sameline.Thiswouldmeanthatwhenyouflippedtheswitchtoon,bothmotorswouldturnon.Youcould makeonemotorturnonewaywhiletheotherturnedintheoppositedirectionandthenflippingtheswitch wouldcausethemtobothchangedirection.Whenyouhookupmultiplemotorstoonelineyoumayuseeither aseriesorparallelconnection.Aseriesconnectionwillmakeeachmotor"see"about6.9volts,whileaparallel connectionwillmakeeachmotor"see"13.8volts.Bothareshownbelow.Notethatifyouuseeitherofthe Polaroidmotors,youshouldconnectasecondoneinseriessotheyeachsee6.9voltsastheyarenotratedto 13.8volts.ThePolaroidmotorscan,however,berunatthehighervoltageforshortperiodsoftime.

Themaximumtorqueamotorcanproduceiscalledthestalltorque.Thisisthepointwhentheshaftspeedis zero.Themaximumspeedofamotoriscalledthenoloadspeed.Thisisthepointwhenthereisnoopposing loadontheshaft.Forpermanentmagnetmotorsthetorquevs.speedcurveisastraightlinethatconnectsthe noloadspeed(wheretorqueiszero)andthestalltorque(wherespeediszero).Themotorsinthekitarenot designedtobeoperatednearthestalltorquelimitforextendedperiodsoftime. Whencalculatingthespeedyourmotorwillturnatyoushouldnotusethenoloadspeed.Thetorqueappliedto themotorwilldeterminethespeedofthemotor.Youshouldtrytorunyourmotorsathalfofthestalltorque formaximumpoweroutput.Atypicaltorquevs.speedcurveisshownbelow.

Making Electrical Connections

Therearethreebasicwaystomakeelectricalconnectionsin2.70:soldering,crimpingandinterferencefits. (TherearemanyotherwaysdiscussedbrieflyintheAdvancedWiringsection.)

Soldering:
Solderingusesahotprobecalledasolderingirontoheatsolder(usuallyamixoftinandleadinroughlyequal proportions.)Thehotsolderflowsaroundothermetalpartsandwhenallowedtocoolbondsthepartstogether mechanicallyandelectrically. Tosoldertwowires(ortwometalobjects)togetheryoushould: Strip(Removetheinsulatingmaterialfrom)bothwiresroughly1/4"-1/2"fromtheendstobesoldered. 1. Ifthewireismadeupofmanysmallerwires,twistthemtightlywithyourfingers. 2. Usingasolderingironwithacleantip,(ifnotcleanseeinstructionsbelow)applyasmallamountof solderdirectlytothetipofthesolderingiron.Bringthesolderingirontotheundersideofthewire whileplacingthesolderonthesideortopofthewire.Thewirewillheatupandthesolderwillstartto melt.Applyenoughtocoatthewirefullybutnotsomuchastoformglobs.Dothistobothwires(this iscalledtinningthewires.) 3. Bringbothwiresincontactaftertheyhavebeentinned.Wrapwirestogetherandapplythesoldering irontothewires.Thesoldershouldflowandformaconnection.Youmayhavetoapplyasmall amountofadditionalsolderbutthisisusuallynotnecessaryifthewireshavebeentinnedcorrectly. 4. Wraptheexposedwirewithelectricaltape. Tocleanthesolderingiron: 1. Awetspongemayalsobeusedtocleanoffsmallamountsofsolder. 2. Applyasmallamountofsolderdirectlytothetipandthenwettipwithspongetocleanoffexcess.

Crimpinginvolvesusingacrimpingtool(orapliersifacrimpnigtoolcannotbefound)todeformmetal prongsaroundawire.

Interference:
InterferencefitsareusedintheAMPconnectorandsimplyinvolveforcingtwopartstogetherthatdeform slightlyandmakesurfacecontactthusprovidinganelectricalconnection

Allcontentscopyright1997MIT KeithBreinlingerorRogerCortesi

SMC Double-Acting Air Cylinder

Foroptionaladvancedinformationonhowapneumaticpistonworks,readthepneumaticsectionofthe AdvancedActuatorHandout*.

Specs:
Manufacturer: PartNumber: TheoreticalPull Force@60psi:
TheoreticalPush Force@60psi:
Strokelength: Bodydiameter: Pistondiameter: SMC NCJ2D10-45 Metric English 27.1N 6.09lbf
32.5N 7.31lbf
45mm 1.77in
11mm 0.43in
10mm 0.39in

Nosemountthread: M8x1.00
Roddiameter: Rodthread: Rearclevishole: Rearclevisslot: Pistonweight: 4mm 0.157in
M4 x 0.7
3.2mm 0.125in
3.3mm 0.130
57 g 0.125lbs

Clevisholediameter: 3.2mm 0.125in

Clevisslot: 3.3mm 0.130in
Clevisweight: 20 g 0.044lbs

Notes on Usage:
1. Typicallylinearactuatorsofthistypearemountedinoneoftwoways:anosemountoraclevis(pivot) mount. 2. Touseanosemount,onewouldthreadthebodyintoamatchingpartandthusclampthebodyatthe "nose"ofthecylinder.Thiswouldtypicallybeusedinpushingapplicationswhenthecylinder providesboththe"guidance"andtheforce. 3. Touseapivotorclevismount,onesimplyneedstoplacearodthroughtheholeattheendofthe (oppositethenose)ofthecylinder.Thismountingisusedformostlinkages(wheretheotherlinks pivotandprovidethe"guidance".) 4. Donotclamparoundthebodyofthecylinderinanyway.Theclampingforcetendstodeformthe cylinderslightlyandthenthepistondoesnotslideaswellorgetsstuckatthedeformedarea. 5. Nobendingmomentsshouldbeplacedonthecylinderorrodotherwisethepistonwillbind.

6. Use#4-40boltsorweldingrodaspivotsinsertedintotheclevisholes.

Mounting:

SMC Vane Type Rotary Air Actuator

Foroptionaladvancedinformationonhowapneumaticrotaryactuatorworks,readthepneumaticrotary actuatorsectionoftheAdvancedActuatorHandout*.

Specs:
Manufacturer: PartNumber: SMC
NCRB1BW15-270SE
Metric English TheoreticalTorque@60psi: 24.9N-cm 2.2in-lbf Max.OperatingFreq:
2 Hz
RotationAngle:
270degrees
Bodydiameter:
34mm 1.34in
BodyHeight:
20mm 0.79in
TopShaftDiameter:
5.0mm 0.197in
TopShaftLength:
13mm 0.51in
BottomShaftDiameter:
5.0mm 0.197in
BottomShaftLength:
7.2mm 0.28in
MountingHoles(6)
M3x0.5
ActuatorWeight:
48 g 0.10lbs

Notes on Usage:
1. Theactuatorhasbuiltinbearingsandthuscanbeusedtodirectlysupportsmallloads,however,if movingaheavyload,youshoulduseadditionalsupport.Theactuatorcansupportstaticloadsuptoa 15N(3.37lbf.)radialloadanda10N(2.24lbf.)axialload.Dynamicloadingshouldbe limited to even less. 2. Youshouldadjusttherotationspeedstotheslowestpossiblespeedsoasnottoexceedthekinetic energylimit(0.024N-cm).Themaximumrotationspeed(withnoloadandflowcontrolsfullyopen) is0.03sec./90degrees.Speedsslowerthan0.03sec./90degreesmayresultinsomestickingorjerky movement. 3. ThespeedofanypnuematicactuatorshouldbeadjustedbyrestrictingtheoutflowairandNOTthe inflowair.Thisway,stickandslipeffectscanbeavoided.

Mounting:

WhenpressureisappliedtotheAside,theshaftwill rotateclockwise.WhenpressureisappliedtoB side,theshaftwillrotatecounter-clockwise.

Allcontentscopyright1997MIT KeithBreinlingerorRogerCortesi

Ford Windshield Wiper Motor

ForoptionaladvancedinformationonhowaDCmotorworks,readtheDCmotorsectionoftheAdvanced ActuatorHandout* .

Specs:
Manufacturer: FordMotor Company

PartNumber: Clockwise NoLoadHigh

Speed@13.8volts 47rpm
3.02 26.7 StallTorque(hi) N-m in-lbf NoLoadLowSpeed 38rpm @13.8volts 44.5 StallTorque(low) 5.03 N-m in-lbf Counter Clockwise NoLoadHigh
Speed@13.8volts 28rpm
2.01 17.8 StallTorque(hi) N-m in-lbf NoLoadLowSpeed 30rpm @13.8volts 44.5 StallTorque(low) 5.03 N-m in-lbf 13.8 Volts 197 OverallLength mm 101 OverallHeight mm M6x ShaftMounting 1.0 BodyDiameter 61 mm MountingHoles(3) M6x 1.0 OverallWeight 1417g NominalVoltage

7.75in 4.0in

2.4in

3.13lbs

Notes on usage:

1. Thespeedandtorqueofthemotorarerotationdependent.Lookingattheshaft,clockwiserotations tendtohavehighertorqueandspeed,andthespeedincreaseswithtime(timeconst.approx.2 seconds).Counter-clockwiserotationsslowdownwithtimeandtypicallyhavelesstorque. 2. UseanM6boltandaluminumflangestomounttoaload. 3. Usethe5colorconnectorandcarefullyinsertitintothereceptacleonthemotoruntilthetapengages. Whenremovingtheconnector,firstreleasethelockingtab,donotjustyankitout. 4. Theconnectorhas5wires,ofwhichonly2areneededtooperatethemotor.Youcanchooseeitherthe highspeed(yellow&white)orlowspeed(black&white).Theblueandgreenwiresareusedfor wipercontrolinFordcars.Also,notethereisoneotherspeed(yellow&black),butthisisnota connectionthatFordrecommendsandithasaverylowtorque(approx..1.7in-lbf.CWand1.7in-lbf CCW). 5. YoucanusesthelargesizeTygontubingtomakeflexiblecouplingstoabearingsupporteddrive shaft. 6. Tofixthebaseofthemotortoaflatplate,youmayusetheM6screwstotapthe3holesaroundthe outputshaft.Then,usetheflatheadM6boltswithcountersunkholestomounttoaplate.Oryoucan bendtwoUshapedpiecesofweldingrodandthreadtheendstomakeaclamp.Bothareshown below.(Note:YourholesmayalreadybetappedinwhichcasetheyareprobablynotM6but1/4"-20.)

Mounting:

Torque Speed Data:

Bosch Motor

ForoptionaladvancedinformationonhowaDCmotorworks,readtheDCmotorsectionoftheAdvanced ActuatorHandout* .

Specs:
Manufacturer: PartNumber: NoLoadSpeed@ 13.8volts StallTorque NominalVoltage OverallLength OverallHeight BodyDiameter BasetoShaft Height ShaftMounting 95rpm 0.60 N-m 13.8 Volts 125mm 4.92in 54.5mm 2.14in 42 mm 1.65in 5.38 in-lbf BoschAutomotive

15.5mm 0.61in 4mmx4mm 0.881 lbs

MountingHoles(2) #10-32 OverallWeight 400g

Notes on Usage:
1. Use4mmx4mmsteelsquareshaft.(Roundingthetipoftheshaftslightlywithafilewillease insertionintothemotor). 2. Usefemalespadeconnectorstomakeelectricalconnections.Donotsolderdirectlytoelectrical contacts. 3. YoucanuseTygontubingtomakeflexiblecouplingtoabearingsupporteddriveshaft. 4. Tofixthebaseofthemotortoaflatplate,use#10-32screwsfromoppositeside.Nonutsareneeded. 5. Tolimittranslationalmotionofthesteelshaft,threadtheshaftwitha#10-32die.Donotusecotter pinsasitisdifficulttogetagoodfit.Youshouldusetwonylonwashersoneachsidetolimitrubbing friction.

Mounting:

Torque Speed Data:

Allcontentscopyright1997MIT KeithBreinlingerorRogerCortesi

Green Maxon Motor

ForoptionaladvancedinformationonhowaDCmotorworks,readtheDCmotorsectionoftheAdvanced ActuatorHandout* .

Specs:
Manufacturer: PartNumber: NoLoadSpeed @13.8volts StallTorque NoLoadSpeed (gearbox) StallTorque (gearbox) 8350rpm 0.0041 N-m 610rpm 0.053 N-m 0.47 in-lbf 0.0036 in-lbf MaxonMotorCo.

NominalVoltage 13.8 Volts OverallLength BodyDiameter SmallShaft Diameter Large(gearbox) ShaftDiameter MountingHoles (gearbox) OverallWeight 111.8 mm 22 mm 2mm 4mm M2x 0.4 142g 0.313 lbs 4.4in 0.87in 0.079in 0.157in

Notes on Usage:
1. Tomounttoeithershaft,useTygontubingtomakeflexiblecouplingtoabearingsupporteddrive shaft.YoumayalsouseaclampcollarmadefromDelrinoraluminum. 2. Thereshouldbenoradialloadsontheshaft.Theywillhurtthebearingsinthegearbox. 3. Usefemalespadeconnectorstomakeelectricalconnections.DONOTsolderdirectlytotheelectrical contacts. 4. Tofixbaseofmotortoaflatplate,useM2machinescrewsinthreeboltpatternonthegearboxside. DONOTsupportthemotorfromtheblackflangeonthemotorside.Unlessyou'reusingthesmall

outputshaft. 5. Themotorisgreenandthegearboxisametalliccolor.Thesmallershaftrotatesfasterwithlesstorque thanthelargeshaftexitingthegearbox. 6. Thegearboxhasaratioof14:1 7. IftheblackplatefallsoffthemotorbringittoaTAtogetitfixed. 8. Thesmallershaftispronetobendingandshouldbeprotectedfromanyforcesthatmightdamageit.If theshaftdoesgetbend,itwillruinthemotor.Thisshaftisnormallyusedtodriveanencoder.

Mounting:

Silver Maxon Motor

ForoptionaladvancedinformationonhowaDCmotorworks,readtheDCmotorsectionoftheAdvanced ActuatorHandout* .

Specs:
Manufacturer:
PartNumber:
NoLoadSpeed@13.8volts
3750rpm
StallTorque
NominalVoltage
OverallLength
BodyDiameter
ShaftDiameter
MountingHoles(2)
OverallWeight
0.00722N-m 0.163in-lbf
13.8Volts
54 mm 40 mm 3mm M2.5x0.45
???g ???lbs
2.125in
1.575in
0.118in
MaxonMotorCo.

Notes on Usage:
1. Tomounttoshaft,useTygontubingtomakeaflexiblecouplingtoabearingsupporteddriveshaft. YoumayalsouseaclampcollarmadefromDelrinoraluminum. 2. Thereshouldbenoradialloadsontheshaft. 3. Usefemalespadeconnectorstomakeelectricalconnection.Donotsolderdirectlytoelectrical contacts. 4. TofixthebaseofthemotoronaflatplateuseM2.5machinescrewsinthetwoholesonthesameside astheoutputshaft.

Mounting:

Torque Speed Data:

Polaroid Motor and Gear Box

ForoptionaladvancedinformationonhowaDCmotorworks,readtheDCmotorsectionoftheAdvanced ActuatorHandout* .

Specs:
Manufacturer:
PartNumber:
NoLoadSpeed@13.8volts:
19,000rpm
StallTorque:
NominalVoltage:
OverallLength:
BodyWidth:
BodyHeight:
ShaftDiameter:
OverallWeight:
WeightwithTransmission:
0.049N-m 0.043in-lbf
6.9Volts
35.8mm 22.3mm 15.0mm 2mm 28 g 57 g 1.41in
0.878in
0.590in
0.079in
0.062lbs
0.125lbs
PolaroidCo.

Notes on Usage:
1. Theseare6voltmotorsandtheelectricalsystemwillonlyoutput13.8volts.Therefore,toprevent burningthemotorsout,youshouldhookupbothmotorsinseriessothateachmotorwill"see"only6 volts. 2. Thedriveassemblyisquiteintricateandyoucanuseitintactbyattachingittooneoftheoutputgears. Thetiminggearreductionis367:1.Thespreadgeartrainhasareductionof25:1.Allgearsare64 pitchexceptforoneofthegearsonGear3andthespreadgearwhichare48pitch. 3. Gearingisasfollows MotorPinionGear-20Teeth,64Pitch Gear4-9Teeth&37Teeth,64Pitch Gear1 -14Teeth&32Teeth,64Pitch TimingGear-96Teeth,64Pitch Gear2-14Teeth&32Teeth,64Pitch SpreadGear-36Teeth,48Pitch Gear3 -9Teeth64Pitch,12Teeth48Pitch Picktravels0.0052"/1degreemotorrotation 4. Tohookupelectrically,carefullysolderonwirestothetwoleadsofthemotor.Youshoulduseafine tipsolderironorthiswillbeverydifficult. 5. Youcanpopthegearoffthemotorbyusingastraightbladescrewdriverandpryingbetweenthegear andthemotorbody.YoucanthenattachaTygontubingflexiblecouplingoraclampcollar.There shouldbenoradialloadontheshaft.

Mounting:

Torque Speed Data:

Decco Solenoid

ForoptionaladvancedinformationonhowaSolenoidworks,readthesolenoidsectionoftheAdvanced ActuatorHandout*.

Specs:
Manufacturer: PartNumber: Pull@1.5mm& 13.8volts: Pull@6.3mm& 13.8volts: Pull@12.7mm& 13.8volts: MaximumStroke: NominalVoltage: OverallLength: BodyDiameter: BodyLength: NoseMount Threading: PlungerDiameter: OverallWeight: 33N 10.7N 4.4N 12.3 mm 13.8 Volts 73.1 mm 28.7 mm 54.1 mm 3/4-16 12.7 mm 227g 0.5in 0.5lbs 2.881 in 1.13in 2.13in 7.4lbf 2.4lbf 1.0lbf 0.5in DeccoCo.

Notes on Usage:
1. ThisisatubularDCpull-typesolenoid.Whenafieldisappliedtheplungerispulledin.Toreleasethe plunger,thefieldmustbeturnedoffandanexternalforce(e.g.aspring)applied. 2. Reversingthefieldwillnotpushtheplungerout. 3. Thisisanintermittentdutysolenoidsoitcannotbeturnedoncontinuouslyformorethen oneminute.Ifitisleftonformorethenoneminuteitwillburnoutandbeuseless.Thisshouldnot beaproblemasthecontestonlylasts30seconds,butbecarefulinpractice! 4. TheE-clip(snap-ring)preventstheplungerfrombottomingoutanddamagingthehousing.Donot

removewheninuse. 5. Thenon-magneticdiscabsorbsshockandgreatlyreducesresidualmagnetism.Ifremoveditwillbe hardtoremovetheplungerevenafterthepoweristurnedoff. 6. Notethatthemaximumstrokeis12.7mm(0.5in).Althoughtheplungercanbepulledoutfurther thanthis,thesolenoidwillnotbeabletopullitinatlongerstrokes. 7. Notethepullforcevs.strokelengthcurveisnotlinear.

Mounting:

Force vs. Stroke Data:

Allcontentscopyright1997MIT KeithBreinlingerorRogerCortesi

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