INTRODUCTION TO ACTUATORS

Dr. Prashanth B N
Assistant Professor (Selection Grade)
Department of Mechanical Engineering
Amrita School of Engineering, Bengaluru
 ACTUATORS
 Actuators and drives are essential components in automation and control systems.
 They convert control signals into mechanical movement, enabling machines and systems
to perform tasks such as positioning, gripping, rotating, and more.
 Understanding the different types and their applications is crucial for selecting the right
components for industrial and robotic systems.
 A hardware device that converts a controller command signal into a change in a physical
parameter.
 The change in the physical parameter is usually mechanical, such as a position or velocity
 change.
 An actuator is a transducer, because it changes one type of physical quantity, such as
electric current, into another type of physical quantity, such as rotational speed of an
electric motor.
 ACTUATORS
 The controller command signal is usually low level, and so an actuator may also require
an amplifier to strengthen the signal sufficiently to drive the actuator.
 Most actuators can be classified into one of three categories, according to the type of
amplifier:
 Pneumatic
 Hydraulic
 Electric
 ACTUATORS

Pneumatic Actuators
 Use compressed air (typically “shop air” in the factory) as the driving power.
 Again, both linear and rotational pneumatic actuators are available.
 Because of the relatively low air pressures involved, these actuators are usually limited to
relatively low-force applications compared with hydraulic actuators.
Hydraulic Actuators
 Use hydraulic fluid to amplify the controller command signal.
 The available devices provide either linear or rotational motion.
 Often specified when large forces are required.
Electric Actuators
 Most common and include electric motors of various kinds, solenoids, and
electromechanical relays.
 Either linear or rotational.
 PNEUMATICS ACTUATORS
 Devices used for converting pressure energy of compressed air into the mechanical
energy to perform useful work.
 In other words, Actuators are used to perform the task of exerting the required force at the
end of the stroke or used to create displacement by the movement of the piston.
 The pressurized air from the compressor is supplied to reservoir.
 The pressurized air from storage is supplied to pneumatic actuator to do work.
 The air cylinder is a simple and efficient device for providing linear thrust or straight line
motions with a rapid speed of response.
 Friction losses are low, often exceeds 5% with a cylinder in good condition, and cylinders
are particularly suitable for single purpose applications and /or where rapid movement is
required.
 Also suitable for use under conditions which prevent the employment of hydraulic
cylinders that is at high ambient temperature of up to 200 to 250.
 PNEUMATICS ACTUATORS
 Limitation is that the elastic nature of the compressed air makes them unsuitable for
powering movement where absolutely steady forces or motions are required applied
against a fluctuating load, or where extreme accuracy of feed is necessary.
 The air cylinder is also inherently limited in thrust output by the relatively low supply
pressure so that production of high output forces can only be achieved by a large size of
the cylinders.
 There are three types of pneumatic actuator: they are
 Linear Actuator or Pneumatic Cylinders
 Rotary Actuator or Air Motors
 Limited Angle Actuators
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
 Pneumatic cylinders are devices for converting the air pressure into linear mechanical
force and motion.
 The pneumatic cylinders are basically used for single purpose application such as
clamping, stamping, transferring, branching, allocating, ejecting, metering, tilting,
bending, turning and many other applications.
 The different classification scheme of the pneumatic cylinders are given below:
 Based on application for which air cylinders are used
• Light duty air cylinders
• Medium duty air cylinders
• Heavy duty air cylinders
 Based on cylinder’s movement
• Rotating type air cylinder
• Non rotating type air cylinder
LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
 Based on the cylinder action
• Single acting cylinder
• Double acting cylinder
o Single rod type double acting cylinder
o Double rod type double acting cylinder
 Based on the cylinder’s design
• Telescopic cylinder
• Tandem cylinder
• Rod less cylinder
o Cable cylinder,
o Sealing band Cylinder with slotted cylinder barrel
o Cylinder with Magnetically Coupled Slide
• Impact cylinder
• Duplex cylinders
• Cylinders with sensors
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on application for which air cylinders are used
 Air cylinders can be classified according to their intended use, as light duty, medium duty
or heavy duty types.
 Governs the strength of the cylinder, and thus typical choice of material of construction
and the form of construction is necessary.
 It should be noted that classification by duty does not necessarily affect the output
performance of the cylinder, as bore size for bore size; identical cylinder diameter will
give the same thrust on the same line pressure, regardless of whether the cylinder is rated
for light, medium or heavy duty.
 This form of rating, however, normally prevents the use of light classification for
cylinders of large size (and thus high thrust); and medium classification for cylinders of
even large size and very high thrust outputs.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on application for which air cylinders are used
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS

Based on the cylinder action

 Based on cylinder action we can classify the cylinders as single acting and double acting.
 Single acting cylinders have single air inlet line.
 Double acting cylinders have two air inlet lines.
 Advantages of double acting cylinders over single acting cylinders are
 In single acting cylinder, compressed air is fed only on one side. Hence this cylinder
can produce work only in one direction. But the compressed air moves the piston in
two directions in double acting cylinder, so they work in both directions
 In a single acting cylinder, the stroke length is limited by the compressed length of
the spring. But in principle, the stroke length is unlimited in a double acting cylinder
 While the piston moves forward in a single acting cylinder, air has to overcome the
pressure of the spring and hence some power is lost before the actual stroke of the
piston starts. But this problem is not present in a double acting cylinder.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder action - Single acting cylinders
 Single acting cylinders are used where force is required to be exerted only in one
direction such as clamping, feeding, sorting, locking, ejecting, braking etc.
 Single acting cylinder is usually available in short stroke lengths [maximum length up to
80 mm] due to the natural length of the spring.
 Single Acting Cylinder exerts force only in one direction.
 Single acting cylinders require only about half the air volume consumed by a double
acting cylinder for one operating cycle.
 Varying designs of single acting cylinders:
 Diaphragm cylinder
 Rolling diaphragm cylinder
 Gravity return single acting cylinder
 Spring return single acting cylinder
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder action - Single acting cylinders
 Diaphragm Cylinder
 Simplest form of single acting cylinder.
 Piston is replaced by a diaphragm of hard rubber, plastic or metal clamped between
the two halves of a metal casing expanded to form a wide, flat enclosure.
 Only short operating strokes can be executed up to a maximum of 50 mm.
 Used for short stoke application like clamping, riveting, lifting, embossing and
riveting.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS

Based on the cylinder action - Single acting cylinders

 Rolling diaphragm cylinder
 Contain a diaphragm instead of piston, which instantly rolls out along the inner
walls of the cylinder when air pressure is applied to the device, thereby causing the
operating stem to move outwards.
 Capable of executing appreciably longer operating strokes (averaging from 50 mm
to 80mm).
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS

Based on the cylinder action - Single acting cylinders

 Gravity Return Single Acting Cylinder
 In a push type, the cylinder extends to lift a weight against the force of gravity by
applying oil pressure at the pressure end.
 In pull type gravity return type single acting cylinder, the cylinder lifts the weight by
retracting.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS

Based on the cylinder action - Single acting cylinders

 Spring Return Single Acting Cylinder
 In push type, the pressure is sent through pressure port situated at blank end of the
cylinder.
 In pull type, the cylinder retracts when the pressure port is connected to the pump
flow and extend whenever the pressure port is connected to the tank.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS

Based on the cylinder action - Double acting cylinders

 Cylinders are equipped with two working ports - one on the piston side and the other on
the rod side.
 To achieve forward motion of the cylinder, compressed air is admitted on the piston side
and the rod side is connected to exhaust.
 During return motion supply air admitted at the rod side while the piston side volume is
connected to the exhaust.
 Force is exerted by the piston both during forward and return motion of cylinder.
 Double acting cylinders are available in diameters from few mm to around 300 mm and
stroke lengths of few mm up to 2 meters.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder action - Double acting cylinders
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder action - Double acting cylinders
 Base cap and Bearing cap are made of cast material, aluminium or malleable cast iron.
The two caps can be fastened to the cylinder barrel by tie rods, threads or flanges.
 Cylinder barrel is usually made of seamless drawn steel tube to increase the life of the
sealing components, the bearing surfaces of the cylinder are precision machined,. For
special applications, the cylinder barrel can be made of aluminium, brass or steel tube
with hard chromed bearing surface. These special designs are used where operation is
infrequent or where there are corrosive influences.
 The Piston rod It is preferably made from heat treated steel. A certain percentage of
chrome in the steel protects against rusting. Generally the threads are rolled to reduce the
danger of fracture. Piston seals are provided in between piston and barrel to avoid
leakage. Sealing ring is fitted in the bearing cap to seal the piston rod. The bearing bush
guides the piston rod and may be made of sintered bronze or plastic coated metal.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder action - Double acting cylinders
 Double acting cylinder with piston rod on one side

 Double acting cylinder with piston rod on both sides

 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder movement
 Rotating type of cylinders are used in applications where cylinder body is connected to a
rotating member and air connection to the cylinder in a stationary housing.
 They are not widely used.
 Non-rotating type of cylinders are widely used in industries.
 Cylinder body is connected, air connection are mounted, stationary housing and piston
rod moves and exerts force.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder’s design
 In industry, differentiation is made between special design of regular cylinder and the
special duty cylinders designed for a special purpose that are known by designation of
their own.
 Special design cylinders are basically natural variations of single or double acting
cylinders.
 Variations in special designs derived from standard production of cylinders and merely
exchanging selected parts for others of different shapes or material.
 Special duty cylinders on the other hand are from the start designed to non-standard
conditions of service or application.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder’s design
 Telescopic Cylinder: A type of hydraulic or pneumatic cylinder that extends in stages (or
sleeves), allowing for a longer stroke length while maintaining a compact retracted size.
 Tandem Cylinder: Consists of two or more cylinders connected in series, sharing a
common rod, but with each cylinder having its own piston.
 Rodless Cylinder: A type of pneumatic or hydraulic cylinder in which there is no
external piston rod. Instead, the piston is internally connected to a carriage that runs along
the body of the cylinder, allowing for linear motion.
 Impact Cylinder: Designed to withstand sudden forces or shocks during its operation.
They typically have reinforced structures and are made from materials that can absorb
impact energy without failure.
 Duplex Cylinder: Essentially two separate cylinders mounted end to end, where the
piston rods are connected in tandem. Each cylinder can be operated independently,
allowing for two-stage motion or separate control of each cylinder.
 Cylinders with Sensors: Standard hydraulic or pneumatic cylinders equipped with
position or proximity sensors to monitor the cylinder's position and provide feedback to
the control system.
 LINEAR ACTUATOR OR PNEUMATIC CYLINDERS
Based on the cylinder’s design

Telescopic cylinder Tandem cylinder

Impact cylinder

Duplex cylinders

Cylinders with sensors

Rod less cylinder
 FLUID POWER ACTUATORS

 Fluid power actuators receive fluid from a pump (typically driven by an electric motor).
 After the fluid has been pressure, flow, and directionally controlled, the actuator converts
its energy into rotary or linear motion to do useful work.
 Cylinders account for more than 90% of the actuators used in fluid power systems for
work output.
 Of the approximately 10% of actuators that produce rotary output, more than 90% are
hydraulic motors, while the rest are some form of rotary actuator.
 HYDRAULIC ACTUATORS

 Used in industrial process control, employ hydraulic pressure to drive an output member.
 Used where high speed and large forces are required.
 The fluid used in hydraulic actuator is highly incompressible so that pressure applied can
be transmitted instantaneously to the member attached to it.
 Based upon a principle discovered by the French scientist Pascal, it relates to the use of
confined fluids in transmitting power, multiplying force and modifying motions.
 In the early stages of the industrial revolution, a British mechanic named Joseph Bramah
utilized Pascal’s discovery in developing a hydraulic press.
 Bramah decided that, if a small force on a small area would create a proportionally larger
force on a larger area, the only limit to the force a machine can exert is the area to which
the pressure is applied.
 Hydraulic systems are used to control & transmit power.
 A pump driven by prime mover (electric motor) creates flow of fluid.
HYDRAULIC CIRCUIT SYSTEM COMPONENTS
 HYDRAULIC CIRCUIT SYSTEM COMPONENTS

Electric Motor
 Part which provides drive and motion to the pump, which is the unit which drives the
fluid medium (hydraulic oil) around the hydraulic circuit system.
Oil Reservoir
 The oil is centrally held at this single location & any oil that flows out of components is
generally routed back to return here.
Filter
 Any particulate contamination from the oil reservoir that could damage the more sensitive
hydraulic components are screened out here.
Pressure Regulator
 Part of the hydraulic system that reduces the input pressure of a liquid to a desired value
at its output.
 HYDRAULIC CIRCUIT SYSTEM COMPONENTS

Control Valve
 Within the hydraulic system, a control valve will control the direction of supplied air, so
it can for example allow flow either only in or out.
Cylinder
 Part that plays the most wanted action, in providing actuation in either a lifting or
lowering movement.
 TYPES OF HYDRAULIC ACTUATOR
 Linear Actuator (Hydraulic Cylinder)
 Provides motion in straight line
 Linear displacement depends on stroke length
 Usually referred to as cylinders, rams (single acting cylinders) or jacks
 Rotary Actuators (Hydraulic Motors)
 Produces continuous rotational motion
 Pump shaft is rotated to generate flow
 A motor shaft is caused to rotate by fluid being forced into the driving chambers
 Semi rotary actuators
 Produces non-continuous rotational motion
 Limited to less than one revolution (<360°)
 Used to produce oscillatory motions in mechanisms
 HYDRAULIC CYLINDERS
 The different classification scheme of the hydraulic cylinders are given below:
 Based on application for which fluid cylinders are used
• Light duty fluid cylinders
• Medium duty fluid cylinders
• Heavy duty fluid cylinders
 Based on cylinder’s movement
• Rotating type fluid cylinder
• Non rotating type fluid cylinder
 Based on the cylinder action
• Single acting cylinder
• Double acting cylinder
o Single rod type double acting cylinder
o Double rod type double acting cylinder
 HYDRAULIC CYLINDERS
 Based on the cylinder’s design
• Telescopic cylinder
• Tandem cylinder
• Rod less cylinder
o Cable cylinder,
o Sealing band Cylinder with slotted cylinder barrel
o Cylinder with Magnetically Coupled Slide
• Impact cylinder
• Duplex cylinders
• Cylinders with sensors
 APPLICATIONS OF HYDRAULIC ACTUATOR

 Hydraulic jack
 Hydraulic brake
 Hydraulic ram
 Used as sensor
 Close loop velocity controlling
 Highly precise positioning for heavy loads
PNEUMATIC CIRCUIT SYSTEM COMPONENTS
 PNEUMATIC CIRCUIT SYSTEM COMPONENTS

Aftercooler
 Part that appears directly after the compressor & is designed to cool the air after it has
been pressurised.
Compressor
 Pumps the air though the pneumatic system at a high pressure so it can be used to actuate
certain parts with the pneumatic circuit. This driven by the electric motor.
Filter
 Primary part of the pneumatic system & performs the task of removing any particles from
entering the sensitive compressed air system.
Pressure Regulator
 Part of the pneumatic system that reduces the input pressure of a gas to a desired value at
its output.
 PNEUMATIC CIRCUIT SYSTEM COMPONENTS

Control Valve
 Within the pneumatic system, a control valve will control the direction of supplied air, so
it can for example allow flow either only in or out.
Cylinder
 Part that plays the most wanted action, in providing actuation in either a lifting or
lowering movement.
Air Receiver
 Effect a large storage vessel for the pressurised air in the system & can store air at high
pressure for long periods of time.
Safety Valve
 Essential part of the pneumatic system, providing a safe means of releasing air should the
system become over pressurised.
 ROTARY ACTUATORS

 Some machine actions require rotary motion for only a portion of a turn.
 Using a hydraulic motor to perform a partial-turn function is expensive and it is difficult
to accurately stop a motor at a specified degree of rotation.
 A clevis-mounted cylinder, attached to an arm and keyed to a shaft, produces rotary
action, but is limited to 90° or less.
 At 90° rotation, a cylinder/lever arrangement has half torque or less when it starts and
nears the end of stroke.
 To obtain partial- or multiple-turn rotary action and/or accurate stopping of rotary output,
use one of the rotary actuators shown in this chapter.
 ROTARY ACTUATORS

 Rotary actuators transform pneumatic, hydraulic, or electric energy to mechanical

rotation.
 Pneumatic Rotary Actuators utilize the pressure of compressed air to generate
oscillatory rotary motions.
 The two most common configurations of pneumatic rotary actuators include rack
and pinion and vane configurations.
 Rack-and-pinion Actuators
 Vane-type Actuators
 Screw-type Actuators
 Key advantages of pneumatic rotary actuators are the simplicity of use, durability, high
force output, and ability to be used in hazardous environments.
 ROTARY ACTUATORS

 Hydraulic Rotary Actuators are typically utilized for applications requiring high
torques.
 Common design configurations for hydraulic rotary actuators include piston type, vane
type, or gear type.
 Piston-type actuators
 Vane-type actuators
 Gear-type actuators
 Key advantages of hydraulic rotary actuators include simplicity of design and the ability
to generate high torques and low speeds.
 RACK-AND-PINION ACTUATORS

 Rack and pinion is a type of rotary actuator comprising two parts or two types of gears,
one of which is a rack with a linear gear movement that moves against the pinion with
circular gears.
 The linear movement of the rack, is transferred through teeth to the gears in the pinion,
such that rotary movement in the actuator is transferred to the connected valve through
pinion.
 Rack and pinion actuators work with both hydraulic and air systems, and could be made
both as single-acting and double-acting.

Single-acting single-rack rotary actuator

 RACK-AND-PINION ACTUATORS

 In a single-acting actuator, fluid is only supplied to one side of the piston and is
responsible for the movement of the piston in only one direction.
 The movement of the piston in the opposite direction is performed by a mechanical spring.
 Single-acting actuators conserve fluid, but perform work in only one direction.
 A downside of single-acting cylinders is the inconsistent output force through a full stroke
due to the opposing spring force.

Single-acting double-rack rotary actuator

 RACK-AND-PINION ACTUATORS

 In a double-acting actuator, fluid is supplied to chambers on both sides of the piston(s).

 Higher air pressure on one side can drive the piston(s) to the other side.
 Double-acting actuators are used when work needs to be performed in both directions.
One of the advantages of double-acting cylinders is the constant output force through a
full rotation range.
 The drawbacks of double-acting cylinders are their need for compressed air for movement
in both directions and a lack of a defined position in case of a power or pressure failure.

Double-acting double-rack rotary actuator

 VANE TYPE ACTUATORS

 A vane actuator consists of a vane mounted on a

central shaft enclosed in a cylindrical chamber.
 The vane rotates upon pressurization and
continues to rotate until it reaches the end of the
stroke.
 Air pressure applied to the other side of the vane
causes it to rotate the shaft in the opposite
direction.
 Vane actuators employ a rigid vane inside a sealed
chamber that is connected directly to the drive
shaft at one end with no gears.
 The result is much smoother rotary movement
and greater cycle life.
 VANE TYPE ACTUATORS

 Vane actuators operate by introducing a fluid or gas to either side of it's enclosure through
inlet/outlet ports, creating the force required for movement.
 Advanced vane actuators utilize double sided vanes that allow for pressurization of both
sides, allowing for bi-directional movement.
 When vane actuators use only gas or fluid as their source for movement in both directions,
they are referred to as “double acting”.
 When an optional spring is used to provide the power in one direction (open or close) they
are referred to as “spring return”.
 GEAR TYPE ACTUATORS

 In a gear-type configuration, pressurized fluid moves meshed gears to generate rotary

motion of the shaft connected to the gears.
 When a gear pair is used to obtain rotary motion by utilising fluid energy, it is known as
gear motor
 It works on the principle of imbalance of oil pressure to act on the gear tooth and push the
tooth for development of torque.
 When pressurised oil enters through the inlet port it exerts oil pressure on the gear teeths.
 As the casing inside surface and gear pair are closely fitted, the oil pressure acts on the
one side of one tooth on the gear located near the inlet port.
 This will cause hydraulic imbalance and it push the gear tooth to develop torque.
 The larger the gear tooth or higher the pressure, more is the torque developed.
 This action continued to produce rotary motion of the shaft.
 The oil used has low pressure and of no use hence drained through the outlet port.
 GEAR TYPE ACTUATORS

 Gear motors construction is similar to gear pump mainly consists of

 Gear pair: Two meshing gears are mounted with one gear on the driving shaft while
meshing gear is mounted on driven shaft.
 Casing: It is the outer body of the motor which encloses gear pair and passages for
inlet and outlet ports.
 Inlet and outlet ports: The oil is allowed to enter through inlet port and drain out
through the outlet port.
 PISTON TYPE ACTUATORS

 In piston-type actuators, pressurized hydraulic fluid is used to displace a piston and

generate rotational motion.
 An example of a piston-type actuator is a swash plate motor.
 In a swash plate motor, pressurized oil is used to push a piston back and forth and generate
rotation of a swash plate.
 The swash plate is connected to a shaft which rotates as the plate rotates.
 When pressurised oil enters in the cylinder, it pushes the piston out of the cylinder barrel
and slides over the swash plate.
 As the swash plate has angular surface, piston movement causes the twisting movement of
the barrel and rotation of the shaft is created.
 The single piston develops only half rotation of the full circle of rotation of the cylinder
barrel.
 The number of pistons should be 5 to 7.
 PISTON TYPE ACTUATORS

 Swash plate: It is positioned at an angle and acts as a surface on which the shoe side of
the piston travel.
 Cylinder barrel: Cylinder barrel contains number of axially placed pistons. Minimum
three pistons are necessary.
 Shaft: The rotating shaft is connected to the cylinder barrel.
 Piston and piston shoes: The pistons are provided to move in the cylinder bore provided
in the cylinder barrel. Piston shoes are provided at the end of piston rods and held in
contact with the swash plate by the shoe plate.
 SCREW TYPE ACTUATORS

 Helical spline actuators are a type of screw type rotary actuators that can be used for
quarter turn valves such as the ball valve.
 One of the reasons why helical spline actuators could be preferred over rack and pinion or
scotch yoke actuators is that helical splines stand vertically over the valve, which is
connected to a horizontal line.
 Therefore using helical spline actuators saves a lot of horizontal space that is taken up by
both rack and pinion and scotch yoke actuators.
 In addition, the weight of a helical spline actuator is less than that of two other rotary
actuator types.
 The housing of the actuator has internal gears connected to the external section of the
spline.
 Hydraulic fluid enters from the top and pushes the spline down, while the helical
gearing causes the spline and the shaft to rotate at the same time.
 SCREW TYPE ACTUATORS

 There are two helical gears:

 One is between the external part of the spline and the internal section of the actuator
body or casing, and
 The other is between the external section of the shaft and the internal section of the
spline.
 Rotation of the bottom of the shaft will be transferred to the valve.
 SYSTEM SAFETY CONSIDERATIONS

Pneumatics System
 Should the pneumatic system ever have maintenance performed on it, the system should
be depressurised.
 The supply of the air needs to be isolated correctly so no part of the circuit can be become
unwantedly pressurised.
 The same isolation procedure should also be applied to any electrical parts during
maintenance.
 SYSTEM SAFETY CONSIDERATIONS

Hydraulics System
 Should the hydraulic system ever have maintenance performed on it, the system should
be depressurised.
 The supply of the oil needs to be isolated correctly so no part of the circuit can be become
unwantedly pressurised.
 The same isolation procedure should also be applied to any electrical parts during
maintenance.
 Any oil leaks require immediate cleaning as these could pose a health hazard to the
engineers maintaining the system and/or danger to the surrounding environment.
 PNEUMATICS SYSTEM MAINTENANCE CHECKS
 The safety valve would require checking for correct functioning under pressure and that
there is no physical damage to it.
 The air filter would require checking for its condition, possibly changing for a new one if
it has been in the system for some time.
 The compressor would be checked for mechanical and electrical integrity.
 The pressure gauge would require checking for correct functioning under pressure and no
physical damage is visible.
 The air receiver would require checking for its physical integrity, working at the correct
pressures & any air leaks.
 The cylinder would require checking for correct directional operation.
 The entire system of pipework would require checking for air leaks & its physical
condition.
 HYDRAULICS SYSTEM MAINTENANCE CHECKS
 If fitted with a safety valve would require checking for correct functioning under pressure
and that there is no physical damage to it.
 The oil filter would require checking or its condition, possibly changing for a new one if
it has been in the system for some time.
 The pump would be checked for mechanical and electrical integrity.
 The pressure gauge would require checking for correct functioning under pressure and
physical damage presence.
 The oil reservoir would require checking for its physical integrity, working at the correct
pressures & any oil leaks.
 The cylinder would require checking for correct directional operation.
 The entire system of pipework would require checking for oil leaks & its physical
condition.
 CONTROL VALVES

 One of the most important considerations in any fluid power system is control.
 If control components are not properly selected, the entire system will not function as
required.
 Fluid power is controlled primarily through the use of control devices called valves.
 The selection of these valves involves not only the type but also the size, actuating
technique, and remote-control capability.
 There are three basic types of valves:
 Directional Control Valves
 Pressure Control Valves
 Flow Control Valves
 CONTROL VALVES

Directional Control Valves

 Determine the path through which a fluid traverses a given circuit.
 For example, they establish the direction of motion of a hydraulic cylinder or motor.
 Control of the fluid path is accomplished primarily by check valves; shuttle valves; and
two-way, three-way, and four-way directional control valves.

Pressure Control Valves

 Protect the system against overpressure, which may occur due to excessive actuator loads
or due to the closing of a valve.
 In general pressure control is accomplished by pressure relief, pressure reducing,
sequence, unloading, and counterbalance valves.
 CONTROL VALVES

Flow Control Valves

 Fluid flow rate must be controlled in various lines of a hydraulic circuit and the type of
control is accomplished through the use of flow control valves.
 For example, the control of actuator speeds depends on flow rates.
 Non-compensated flow control valves are used where precise speed control is not required
since flow rate varies with pressure drop across a flow control valve.
 Pressure-compensated flow control valves automatically adjust to changes in pressure
drop to produce a constant flow rate.
 CONTROL VALVES
 A welding machine application in which a directional control valve, a check valve, and a
sequence valve are used as components of a hydraulic circuit for positioning and holding
parts during a welding operation.

Welding machine application Hydraulic circuit showing control valves used for
using hydraulic control valves. welding application.
 CONTROL VALVES
 Welding application requires a sequencing system for fast and positive holding of these
parts.
 Accomplished by placing a sequence valve in the line leading to the second of the two
hydraulic cylinders.
 When the four-way directional control valve is actuated, the first cylinder extends to the
end of its stroke to complete the “positioning” cycle.
 Oil pressure then builds up, overcoming the sequence valve setting.
 This opens the sequence valve to allow oil to flow to the second cylinder so that it can
extend to complete the “hold” cycle.
 The check valve allows the second cylinder to retract, along with the first cylinder, when
the four-way valve is shifted to allow oil to flow to the rod end of both cylinders.
 DIRECTIONAL CONTROL VALVES

 Used to control the direction of flow in a hydraulic circuit.

 Any valve (regardless of its design) contains ports that are external openings through
which fluid can enter and leave via connecting pipelines.
 The number of ports on a directional control valve (DCV) is identified using the term
way.
 For example, a valve with four ports is a four-way valve.
 DIRECTIONAL CONTROL VALVES

Check Valves
 The simplest type of direction control valve is a check valve, which is a two-way valve
because it contains two ports.
 The purpose of a check valve is to permit free flow in one direction and prevent any flow
in the opposite direction.
 DIRECTIONAL CONTROL VALVES

Pilot-Operated Check Valve

 Type of check valve always permits free flow in one direction but permits flow in the
normally blocked opposite direction only if pilot pressure is applied at the pilot pressure
port of the valve.
 Pilot check valves are frequently used for locking hydraulic cylinders in position.
 DIRECTIONAL CONTROL VALVES

Three-Way Valves
 Contain three ports, are typically of the spool design rather than poppet design.
 The flow paths through a three-way valve uses two positions of the spool and such a
valve is called a three-way, two-position directional control valve.
 Typically used to control the flow directions to and from single-acting cylinders.

P – Pump Port connected to the pump discharge pipe

A - Outlet Port
T – Tank Port connected to the pipe leading to the oil tank
 DIRECTIONAL CONTROL VALVES

Four-Way Valves
 Contain four ports and flow paths through a four-way, two-position directional control
valve.
 Typically used to control the flow directions to and from double-acting cylinders.
 DIRECTIONAL CONTROL VALVES

Manually Actuated Valves

 The directional control valves are manually actuated by the use of a lever.
 Four-way valve and a spring-centered, three-position and two-position directional control
valve.

Manually actuated,
Manually actuated, spring-centered, three-position, four-way two-position, spring-offset, four-way
valve. valve.
 DIRECTIONAL CONTROL VALVES

Mechanically Actuated Valves

 A two-position, four-way, spring-offset valve that is mechanically rather than manually
actuated.
 The graphic symbol is the same except that actuation is depicted as being mechanical (the
circle represents the cam-driven roller) rather than manual.
 DIRECTIONAL CONTROL VALVES

Pilot-Actuated Valves
 Directional control valves can also be shifted by applying air pressure against a piston at
either end of the valve spool.
 A four-way, three-position, spring-centered, air pilot–actuated directional control valve.
 In the graphic symbol, the dashed lines represent pilot pressure lines.
 DIRECTIONAL CONTROL VALVES

Solenoid-Actuated Valves
 A very common way to actuate a spool valve is by using a solenoid
 When the electric coil (solenoid) is energized, it creates a magnetic force that pulls the
armature into the coil which causes the armature to push on the push pin to move the
spool of the valve.
 Solenoids are actuators that are bolted to the valve housing.
 Like mechanical or pilot actuators, solenoids work against a push pin, which is sealed to
prevent external leakage of oil.

Solenoid-actuated, three-position, spring-centered,

four-way directional control valve.
 DIRECTIONAL CONTROL VALVES
Solenoid-Actuated Valves
 There are two types of solenoid designs used to dissipate the heat created by the electric
current flowing in the wire of the coil.
 Air Gap Solenoid – Simply dissipates the heat to the surrounding air.
 Wet Pin Solenoid – The push pin contains an internal passageway that allows tank
port oil to communicate between the housing of the valve and the housing of the
solenoid.

Single solenoid-actuated, four-way, Solenoid-controlled, pilot

two-position, spring offset operated directional control
directional control valve. valve.
 DIRECTIONAL CONTROL VALVES
Center Flow Path Configurations for Three-Position, Four-Way Valves
 Most three-position valves have a variety of possible flow path configurations.
 Each four-way valve has an identical flow path configuration in the actuated position but
a different spring-centered flow path.
 The open-center-type connects all ports together.
 The tandem design results in a locked actuator.

Various center flow

paths for three-position,
four-way valves.
 DIRECTIONAL CONTROL VALVES
Shuttle Valves
 Type of directional control valve.
 Permits a system to operate from either of two fluid power sources.
 A shuttle valve consists of a floating piston that can be shuttled to one side or the other of
the valve depending on which side of the piston has the greater pressure.
 Shuttle valves may be spring-loaded in one direction to favor one of the supply sources or
unbiased so that direction of flow through the valve is determined by circuit conditions.
 A shuttle valve is essentially a direct-acting double-check valve with a cross-bleed.
 The double arrows on the graphic symbol, reverse flow is permitted.
 PRESSURE CONTROL VALVES
Simple Pressure Relief Valves
 The most widely used type of pressure control valve and is found in practically every
hydraulic system.
 Normally a closed valve whose function is to limit the pressure to a specified maximum
value by diverting pump flow back to the tank.

Pressure versus flow curve for

simple relief valve.

Simple pressure relief valve.

 PRESSURE CONTROL VALVES
Simple Pressure Relief Valves
 If the hydraulic system does not accept any flow, then all the pump flow must return to
the tank via the relief valve.
 The pressure relief valve provides protection against any overloads experienced by the
actuators in the hydraulic system.
 Obviously one important function of a pressure relief valve is to limit the force or torque
produced by hydraulic cylinders and motors.

Symbolic representation of partial

hydraulic circuit.
 PRESSURE CONTROL VALVES
Compound Pressure Relief Valves
 Operates in two stages.
 The pilot stage is located in the upper valve body and contains a pressure-limiting poppet
that is held against a seat by an adjustable spring.
 The lower body contains the port connections.
 Diversion of the full pump flow is accomplished by the balanced piston in the lower body.

External and cutaway views of an

actual compound relief valve.
 PRESSURE CONTROL VALVES
Compound Pressure Relief Valves

Compound pressure relief valve

with integral solenoid-actuated,
two-way vent valve having remote
operation capability.
Operation of compound pressure relief valve.
 PRESSURE CONTROL VALVES
Pressure-Reducing Valves
 Valve (which is normally open) is used to maintain reduced pressures in specified
locations of hydraulic systems.
 Actuated by downstream pressure & tends to close as the pressure reaches valve setting.
 Uses a spring-loaded spool to control the downstream pressure.

Operation of a pressure-reducing valve.

 PRESSURE CONTROL VALVES
Unloading Valves
 Valve is used to permit a pump to build pressure to an adjustable pressure setting and then
allow it to discharge oil to the tank at essentially zero pressure as long as pilot pressure is
maintained on the valve from a remote source.
 Hence, the pump has essentially no load and is therefore developing a minimum amount
of power.
 PRESSURE CONTROL VALVES
Sequence Valves
 Designed to cause a hydraulic system to operate in a pressure sequence.
 PRESSURE CONTROL VALVES
Counterbalance Valves
 The purpose of a counterbalance valve is to maintain control of a vertical hydraulic
cylinder to prevent it from descending due to the weight of its external load.
 FLOW CONTROL VALVES
Orifice as a Flow Meter or Flow Control Device
 An orifice (a disk with a hole through which fluid flows) installed in a pipe is a device
used as a flowmeter by measuring the pressure drop across the orifice.
 Greater the flow rate, the greater will be the pressure drop and vice versa for a given
orifice.
 An orifice can also be used as a flow control device.
 Smaller the orifice area, the smaller will be the flow rate and vice versa for a given
pressure drop.
 FLOW CONTROL VALVES
Needle Valves
 Designed to give fine control of flow in small-diameter piping.
 Name is derived from their sharp, pointed conical disk and matching seat.
 For a given opening position, a needle valve behaves as an orifice.
 However, unlike an orifice, the flow area (A) in a needle valve can be varied.
 FLOW CONTROL VALVES
Non-Pressure-Compensated Valves
 Used where system pressures are relatively constant and motoring speeds are not too
critical.
 Work on the principle that the flow through an orifice will be constant if the pressure drop
remains constant.
 FLOW CONTROL VALVES
Pressure-Compensated Valves
 If the load on an actuator changes significantly, system pressure will change appreciably.
 Thus, the flow-rate through a non-pressure-compensated valve will change for the same
flow-rate setting.
 ELECTRIC MOTORS

 Motor converts electrical power into mechanical power.

 Most electric motors are rotational.
 Available in many different styles and sizes.
 The motor consists of two basic components, a stator and a rotor.
 The stator is the ring-shaped stationary component, and the rotor is the cylindrical part
that rotates inside the stator.
 The rotor is assembled around a shaft that is supported by bearings, and the shaft can be
coupled to machinery components such as gears, pulleys, leadscrews, or spindles.
 ELECTRIC MOTORS
 Electric current supplied to the motor generates a continuously switching magnetic field
that causes the rotor to develop torque and rotate in its attempt to align its poles with the
opposite poles of the stator.
 The details relating to type of current (alternating or direct), how the continuously
switching magnetic field is created, and other aspects of the motor’s construction give
rise to a great variety of electric motors.
 The simplest and most common classification is between direct current (DC) motors and
alternating current (AC) motors.
 Within each category, there are several subcategories.
 Four types that are used in automation and industrial control are
 DC Motors
 AC Motors
 Stepper Motors
 Linear Motors
 ELECTRIC - DC MOTORS
 DC motors are widely used for the convenience of using direct current as the power
source.
 For example, the small electric motors in automobiles are DC because the car’s battery
supplies direct current.
 The popularity of DC motors is that their torque–speed relationships are attractive in
many applications compared to AC motors.
 DC servomotors are a common type of DC motor used in mechanized and automated
systems, and it will be used to represent this class of electric motors.
 The term servomotor simply means that a feedback loop is used to regulate speed.
 In a DC servomotor, the stator typically consists of two permanent magnets on opposite
sides of the rotor.
 The rotor, called the armature in a DC motor, consists of copper wire windings around a
ferrous metal core.
 ELECTRIC - DC MOTORS
 Input current is provided to the windings through the commutator and interacts with the
magnetic field of the stator to produce the torque that drives the rotor.
 Although DC motors have several attractive features, they have two important
disadvantages:
 The commutator and brushes used to conduct current from the stator assembly to the
rotor result in maintenance problems with these motors
 The most common electrical power source in industry is alternating current, not
direct current
 ELECTRIC - AC MOTORS
 In order to use AC power to drive a DC motor, a rectifier must be added to convert the
alternating current to direct current.
 For these reasons, AC motors are widely used in many industrial applications.
 AC motors do not use brushes, and they are compatible with the predominant type of
electrical power.
 Alternating current motors operate by generating a rotating magnetic field in the stator,
and the rotational speed of the rotor depends on the frequency of the input electrical
power.
 The rotor is forced to turn at a speed that depends on the rotating magnetic field.
 AC motors can be classified into two broad categories:
 Synchronous Motors
 Induction Motors
 ELECTRIC - AC MOTORS
Synchronous Motors
 Operate by energizing the rotor with alternating current, which generates a magnetic field
in the gap separating the rotor and the stator.
 The magnetic field creates a torque that turns the rotor at the same rotational speed as the
magnetic forces in the stator.
 The term synchronous derives from the fact that the rotor rotation is synchronized with
the AC frequency in steady-state operation.
 Synchronous motors cannot start by themselves from zero speed; they require a device,
sometimes called an exciter, to initiate rotation of the rotor when power is first supplied
to the motor.
 The exciter, which may be an electric motor itself, accelerates the rotational speed of the
rotor so that it can be synchronized with that of the stator’s rotating magnetic field.
 ELECTRIC - AC MOTORS
Induction Motors
 Probably the most widely used motors in the world, due to their relatively simple
construction and low manufacturing cost.
 A magnetic field is induced in the rotor from the stator.
 The rotor in most induction motors does not need electrical current from an external
power supply.
 No brushes or other means of connection are required for the rotating component of an
induction motor.
 Unlike synchronous motors, induction motors operate at speeds that are slower than the
synchronous speed.
 The steady-state rotational speed depends on the load that the motor is driving.
 If the rotor speed were equal to the synchronous speed of the stator magnetic field, then
no induced voltage and no torque would be generated in the rotor.
 ELECTRIC - AC MOTORS
 When AC power is first applied to an induction motor, the induced magnetic field and
torque are maximum, so no exciter is needed to start the motor turning.
 Both synchronous motors and induction motors operate at constant speeds.
 Most of their applications are those in which running at a fixed speed is required.
 This is a disadvantage in many automation applications because frequent speed changes
are often necessary with much starting and stopping.
 The speed issue is sometimes addressed by using adjustable-frequency drives (called
inverters) that control the cycle rate of the AC power to the motor.
 Motor speed is proportional to frequency, so changing the frequency changes the motor
speed.
 Advances in solid-state electronics have also improved speed control for AC motors, and
they are now competitive in some applications traditionally reserved for DC motors.
 ELECTRIC – STEPPER MOTORS
 Also called step motors and stepping motors, provides rotation in the form of discrete
angular displacements, called step angles.
 Each angular step is actuated by a discrete electrical pulse.
 The total angular rotation is controlled by the number of pulses received by the motor,
and rotational speed is controlled by the frequency of the pulses.
 The step angle is related to the number of steps for the motor according to the relationship

where, α = the step angle, degrees, °;

ns = the number of steps for the stepper motor, which must be an integer value
 Typical values for the step angle in commercially available stepper motors are 7.5°, 3.6°,
and 1.8°, corresponding to 48, 100, and 200 steps (pulses) per revolution of the motor.
 ELECTRIC – STEPPER MOTORS
 Used in open-loop control systems for applications in which torque and power
requirements are low to modest.
 Widely used in machine tools and other production machines, industrial robots, x–y
plotters, medical and scientific instruments, and computer peripherals.
 Probably the most common application is to drive the hands of analog quartz watches.
 ROTARY-TO-LINEAR MOTION CONVERSION

 Many actuator applications require linear motion and the application of force.
 A rotating motor can be used by converting its rotary motion into linear or translational
motion.
 The following are some of the common conversion mechanisms used:
 Leadscrews and Ball Screws - The motor shaft is connected to a leadscrew or ball
screw, which have helical threads throughout their lengths.
 Pulley Systems - The motor shaft is connected to the driver wheel in a pulley
system, around which a belt, chain, or other flexible material forms a loop with an
idler wheel.
 Rack and Pinion - The motor shaft is connected to a pinion gear that is mated with
a rack, which is a straight gear with tooth spacings that match those of the gear.
 ROTARY-TO-LINEAR MOTION CONVERSION
 The use of leadscrews and ball screws is most common in machine tools, industrial
robots, and other automation applications.
 A gear reduction box is often inserted between the motor shaft and the screw to reduce
speed and increase torque and precision.
 Ball screws are to leadscrews as ball bearings are to conventional sliding bearings.
 ROTARY-TO-LINEAR MOTION CONVERSION
 Pulley systems are common in material transport equipment such as belt and chain
conveyors and hoists.
 Belt-driven pulley systems can also be used for positioning.

 Rack-and-pinion mechanisms are found in gear systems, for example, rack-and-pinion

steering in automobiles.
 LINEAR MOTORS
 A linear electric motor provides a linear motion directly; it does not require a rotary-to-
linear conversion.
 Operation is similar to that of rotary electric motors, except that the ring-shaped stator
and cylindrical-shaped rotor are straight rather than circular.
 The rotor, known as the forcer in linear motor terminology, consists of wire windings
encased in a non-conducting material such as epoxy, and the magnetic field that drives
the forcer consists of a series of magnets contained in a straight track, which corresponds
to the stator.
 Just as a rotary motor requires bearings to align the rotor inside the stator, creating a
small air gap between them, a linear motor requires straight guideways that support the
forcer and maintain a gap between it and the magnetic track.
 Linear encoders can be used to indicate the position & speed of the forcer along the track,
just as rotary encoders are used to determine angular position and speed of a rotary motor.
 LINEAR MOTORS
 Applications include mechanical and electronic assembly, metrology and laser
positioning.
 One limitation is that they should not be used where vertical lifting is required, because if
power to the motor is lost, gravity would cause any load that had been lifted to fall.
 Linear motors are available in three styles:
a) Flat
b) U-channel
c) Cylindrical
 ELECTRIC ACTUATORS
There are other types of electrical actuators in addition to motors which include solenoids
and relays, which are electromagnetic devices like electric motors, but they operate
differently.
 Electromechanical Relay
 An on–off electrical switch consisting of two main components, a stationary coil and
a movable arm that can be made to open or close an electrical contact by means of a
magnetic field that is generated when current is passed through the coil.
 The reason for using a relay is that it can be operated with relatively low current
levels, but it opens and closes circuits that carry high currents and/or voltages.
 Relays are a safe way to remotely switch on and off equipment that requires high
electrical power.
 ELECTRIC ACTUATORS

 Solenoids
 Consists of a movable plunger inside a stationary wire
coil.
 When a current is applied to the coil, it acts as a magnet,
drawing the plunger into the coil.
 When current is switched off, a spring returns the plunger
to its previous position.
 Linear solenoids are often used to open and close valves in
fluid flow systems, such as chemical processing equipment
where, the solenoid provides a linear push or pull action.
 Rotary solenoids are also available to provide rotary
motion, usually over a limited angular range (e.g., neutral
position to between 25° and 90°).
 SIZING OF ACTUATORS

 Sizing of actuators for industrial applications is a crucial step to ensure optimal

performance, energy efficiency, and reliability in automation systems.
 Selecting the right size ensures that the actuator can handle the required loads, operate
efficiently, and function within the system's desired parameters (e.g., speed, force, stroke
length).
 If an actuator is too small, it can be overloaded and fail prematurely; if too large, it can be
inefficient, cost more, and create unnecessary complexity.
 Key factors in sizing of actuators for industrial applications are
 Load Requirements  Environmental Conditions
 Motion and Stroke Length  Inertia and Load Balancing
 Power Requirements  Safety Factors
 Duty Cycle  Control and Feedback
 Friction and Efficiency
 KEY FACTORS IN SIZING ACTUATORS

Load Requirements
 Force/Load: The force required to move, lift, or rotate the load is a primary factor in
selecting actuator size. For linear actuators, the force is often expressed in pounds (lbs),
Newtons (N), or kilograms (kg). For rotary actuators, the torque (Nm or lb-ft) is the main
consideration.
 Formula for Force: F = m ⋅ a (where, F is force, m is mass, and a is acceleration).
 Static and Dynamic Load: It's essential to differentiate between static (non-moving) and
dynamic (moving) loads, as dynamic loads often require more force due to friction,
acceleration, and inertia.
 KEY FACTORS IN SIZING ACTUATORS

Motion and Stroke Length

 Linear Motion: For linear actuators, stroke length refers to the total distance the actuator
will move. Stroke length must match or slightly exceed the required movement range.
 Rotary Motion: For rotary actuators, the rotation angle (e.g., 90°, 180°, 360°) must be
considered. Some rotary actuators may need multiple revolutions to achieve the desired
motion.
 Speed: The speed at which the actuator operates also influences its sizing. Higher speeds
may require more power or a larger actuator, especially if load inertia is a concern.
Control and Feedback
 Positioning accuracy: Some applications require precise positioning, which influences
actuator sizing, particularly for electric actuators with servo control systems.
 Feedback systems: If precise control is necessary, actuators may need to incorporate
position or speed sensors, which add to the actuator’s complexity and affect its sizing.
 KEY FACTORS IN SIZING ACTUATORS

Power Requirements
 Actuators are powered by pneumatic, hydraulic, or electric energy, and the energy source
directly impacts the sizing process.
 Pneumatic: Requires sufficient air pressure (measured in psi or bar) to generate the
necessary force.
 Hydraulic: Hydraulic actuators rely on fluid pressure (measured in psi or bar). They
are used for high-force applications.
 Electric: Electric actuators are sized based on motor power, current, and voltage
requirements.
 KEY FACTORS IN SIZING ACTUATORS

Duty Cycle
 The duty cycle describes how frequently the actuator operates compared to the time it
remains idle. For example, if an actuator is required to operate 80% of the time and rest for
20%, it has a duty cycle of 80%.
 High-duty-cycle actuators must be robust and capable of continuous operation.
 Actuators in low-duty-cycle applications can be smaller and optimized for intermittent
use.
Friction and Efficiency
 Friction affects how much force or torque is needed to move a load. It is crucial to account
for friction in mechanisms such as gears, guides, and bearings, as well as in the actuator
itself.
 Efficiency losses must be considered, especially for pneumatic and hydraulic actuators,
where mechanical losses and pressure drops reduce output force.
 KEY FACTORS IN SIZING ACTUATORS

Environmental Conditions
 Actuators must be sized for the environment they operate in, including:
 Temperature: Extreme temperatures (hot or cold) can impact the performance and
sizing of actuators, particularly for electric and pneumatic types.
 Corrosion and Dust: Harsh or corrosive environments require actuators with suitable
protection (IP rating for electric actuators or corrosion-resistant materials for hydraulic
and pneumatic actuators).
 Shock and Vibration: Industrial environments may expose actuators to high vibration
or shock loads, requiring them to be more robust or oversized.
 KEY FACTORS IN SIZING ACTUATORS

Inertia and Load Balancing

 When moving loads with significant mass, the actuator needs to overcome the inertia of the
object. This is particularly important for applications involving rotary motion, where large
loads can create high inertia and require more torque.
 Rotational inertia can be calculated using I = m ⋅ r2 (where, I is inertia, m is mass, and
r is the distance from the axis of rotation).
Safety Factors
 A safety factor should be applied to ensure the actuator can handle unexpected loads, wear,
or environmental variations.
 For critical applications, a safety factor of 1.5 to 2.5 times the calculated force or
torque is typically used.
 Overload protection is another consideration, especially in applications that involve
sudden load changes or impacts.
 STEPS TO SIZE AN ACTUATOR
Define the Application
 Identify the required motion (linear or rotary) and specify load conditions, motion range
(stroke or rotation angle), and operational environment.
Calculate the Load
 Determine the static and dynamic forces or torques required to move the load. Include
friction, gravity, and acceleration.
Determine Speed and Duty Cycle
 Define how fast the actuator needs to move the load and how often the actuator will cycle.
Select Power Type
 Choose between pneumatic, hydraulic, or electric actuators based on available power
sources and required force output.
Factor in Safety
 Apply safety margins to the calculated force/torque to ensure reliability.
Environmental Adjustments
 Consider environmental factors such as temperature, humidity, dust, and exposure to
chemicals when choosing materials and protective enclosures.
 SIZING OF AN ACTUATOR

Example: Sizing a Linear Electric Actuator for Industrial Use

Let’s consider an application where a linear actuator is needed to lift a load of 200 kg over a
500 mm stroke in a factory setting.

 Load Calculation
 Force needed: F = m ⋅ g = 200 kg ⋅ 9.81 m/s2 = 1962 N.
 Speed and Stroke
 Required speed: 50 mm/s (user requirement).
 Stroke length: 500 mm.
 Duty Cycle
 Expected operation: 20 times per hour, with each cycle lasting 10 seconds. This
implies a moderate-duty cycle.
 SIZING OF AN ACTUATOR

 Power Type:
 Electric actuator selected based on the availability of power and the need for precise
control.
 Safety Factor
 Apply a safety factor of 1.5. The total required force is: 1962 N × 1.5 = 2943 N.
 Environmental Adjustments
 The factory has high humidity, so an IP65-rated actuator with corrosion-resistant
materials is selected.
 Final Actuator
 A 2943 N capacity electric linear actuator, with a 500 mm stroke and 50 mm/s speed,
would be chosen with appropriate feedback control for precision.