Mechatronics Systems Design MPE 301

CHPTER 4
ACTUATORS DEVICES
Actuators take low power signals transmitted from the computer and produce
high power signals which are applied as input to the process.

There are many types of actuating devices, some of the most common ones
include solenoids, electrohydraulic actuators, DC or AC motors, stepper
motors, piezoelectric motors, and pneumatic devices.

Electrical actuators convert electrical command signals into mechanical

motions.

Focusing on DC motors, stepper motors, and fluid power devices

(electrohydraulic) because of their popularity in mechatronics.
It should be noted that AC motors are also widely used for servomechanism.

Dr. M. Atta 1
Mechatronics Systems Design MPE 301

1 Direct Current (DC) Motors

Selection of actuator device for mechatronic applications are affected by;
1- Precision 2- Accuracy and resolution
3- Power required for actuation 4- Cost of the actuation device
DC motors are the most popular actuators in mechatronic systems.
DC motors, which are electromechanical devices, provide precise and
continuous control of speed over a wide range of operations by varying the
voltage applied to the motor.
The desirable features of DC motors are their high torque, speed control ability
over a wide range, speed-torque characteristics, and used in various types of
control applications.
DC motors are suitable for many applications such as; manufacturing
equipment, CNC systems, servo valve actuators, tape transport mechanisms,
and industrial robots.

Dr. M. Atta 2
Mechatronics Systems Design MPE 301

It converts DC electrical energy into rotational mechanical energy. Its working

principle is that wire carrying current in magnetic field experiences a force.

Mathematical Model of a DC Motor

The behaviour of DC motors can be explained by two fundamental equations.

𝑉 = 𝐾𝑒 𝜃ሶ
Where; T motor torque in N-m, V induced voltage in V, i armature current in A
 motor rotational displacement in rad (radians)
kt torque constant in Nm/A, and ke voltage constant in V/(rad/sec)

Dr. M. Atta 3
Mechatronics Systems Design MPE 301

Where; Vm armature voltage in V, Ra armature resistance in ,

La armature inductance in H, and i armature current in A
The primary loads on the motor are inertia and friction.

Where; J the moment of inertia of the rotor, B the damping coefficient, and
TL motor load.

EX.1; A DC gear motor is used to lift a mass.

Develop a mathematical relationship between the
voltage applied to the motor and the rotational
displacement of the motor shaft which is a measure
of the linear displacement of the mass.
Assume; the string is inextensible, and neglect the
friction between the string and the pulleys.

Dr. M. Atta 4
Mechatronics Systems Design MPE 301

load on the motor

Motor angular with gear output displacement

Notes

Dr. M. Atta 5
Mechatronics Systems Design MPE 301

𝐾𝑒 𝜃ሶ

2 Permanent Magnet Stepper Motor

Nowadays, stepper motor has appeared as a cost-effective alternative to DC
motors in motion-control applications.
Stepper motor translates electrical pulses into precise, equally spaced,
angular movements of the rotor in the form of steps.
The rotor is positioned by magnetically aligning the rotor and stator teeth,
which occur when the air gap between the two sets of teeth is minimized and
aligned.

Dr. M. Atta 6
Mechatronics Systems Design MPE 301

Two basic types of stepper motors are;

1. Variable reluctance (VR) stepper motors; step angle is 15°, with torque
ranges up to 14 N-m.
2. Permanent magnet (PM) stepper motors; step angle is 1.8° or 0.9°, with
torque ranges up to 3.5 N-m.
This limits the range of applications for PM motors to a lower torque region
than that of VR motors. PM motors are available in smaller standard sizes
(commercially known as size 23 or size 34).
The four-phase, size 23 motor produces under 0.7 N-m torque with a
speed range of up to 30,000 steps per second (sps),
While size 34 motor produces roughly three times the torque at one
third of the speed.
They are extremely well suited for use in open-loop applications due to their
accuracy and noncumulative position-error characteristics.
Compared to DC servo motors, stepper motors produce less torque, lower
speeds, and higher vibrations.

Dr. M. Atta 7
Mechatronics Systems Design MPE 301

2.1 Motor Equations and Block Diagram Model

The PM motor consists of four identical phases, so the motor model based on
a model of one phase then tripled for the remaining three phases.
The phase model operates as follows;
As a voltage pulse occurs from the drive circuit, the stator winding
produces a current due to the difference between the voltage pulse
and the back emf voltage.
i phase current, amps (A)
R phase resistance, ohms ()
L Phase inductance, Henry (H)
D derivative operator
Vx supply voltage from driver, volts DC (V)
Vbemf back emf voltage, volts (V)

Dr. M. Atta 8
Mechatronics Systems Design MPE 301

Dr. M. Atta 9
Mechatronics Systems Design MPE 301

2.2 Stepper motor positioning system

Step Angle

POSITIONING SYSTEM
Angle of Rotation

Distance Moved

Required number of Pulses Rotational Speed

feed rate (fr)

Dr. M. Atta 10
Mechatronics Systems Design MPE 301

Precision in NC positioning
The precision is measured by;
1)Control resolution
2)Accuracy
3)Repeatability
The control resolution refers to the control system ability to divided the
total range of the axis movement into closely spaced that can be
distinguished by the MCU. It can be defined as the distance separated two
adjacent addressable points.
1- Electromechanical facto.
p
CR1 =
ns rg
2- Number of bits used by the MCU to specify the L
CR2 = B
2 −1
axis coordinates

CR = Max { CR1, CR2}

Dr. M. Atta 11
Mechatronics Systems Design MPE 301

Accuracy is the max. possible error that can be occur between

the desired target point and the actual taken by the system

Accuracy = CR/2 + 3s

Repeatability refers to the capability of the positioning

system to return to a given addressable point that has been
previously programmed.

Repeatability =  s

Dr. M. Atta 12
Mechatronics Systems Design MPE 301

EX; A machine table driven by closed-loop positioning system consists of a

servo motor, lead screw, and an optical encoder. The pitch of lead screw is
0.500 cm and is coupled to the motor shaft with a gear ratio of 4:1. The optical
encoder generates 150 pulses/rev of the lead screw. The table has been
programmed to move a distance of 7.5 cm at a feed rate of 40 cm/min.
Determine ;
Number of pulses (np). 2. Pulse rate (fp).

Lead-screw pitch (p) = 0.5 cm/rev. Motor rpm = 4 * lead screw rpm
Lead screw generates(ns) 150 pulses/rev
Distance (S ) 7.5 cm Feed rate (fr) 40 cm/min.
θ= 360/150 = 2.4
np = 360*7.5/(0.5*2.4) = 2250 pulse

N = 40/0.5 = 80
fp = 150*80/60 = 200 p/sec

Dr. M. Atta 13
Mechatronics Systems Design MPE 301

3 Fluid Power Actuation

Fluid power systems are extensively used for driving high-power machine
tools, such as robots, as they can deliver a higher amount of power while
being relatively small in size.
Control Systems in Fluid Power

F = APd = A(P1 - P2)

Flow rate, q,

q = k1x1 - k2Pd

Dr. M. Atta 14
Mechatronics Systems Design MPE 301

mass, M,
viscous damping constant, f.

Dr. M. Atta 15
Mechatronics Systems Design MPE 301

4 Fluid Power Design Elements

4.1 Fluid Power Energy-Input Devices

The input devices, such as pumps, are the primary source of fluid power
energy creation.
1. General classification

Dr. M. Atta 16
Mechatronics Systems Design MPE 301

Positive-Displacement Pumps; has a small clearance between the

stationary and rotating parts. push a definite volume for each cycle of pump.
piston pumps and gear pumps.
Non-Positive-Displacement Pumps; has a large clearance between the
rotating and stationary parts. The pump volume displaced depends on its
speed and resistance faced at the discharge side of the pump unit. Used for
low-pressure and high-volume flow situation. Centrifugal pumps
Classification by the Design Features

Dr. M. Atta 17
Mechatronics Systems Design MPE 301

Radial Piston Pump

Dr. M. Atta 18
Mechatronics Systems Design MPE 301

4.2 Energy Modulation Devices (Valves)

Dr. M. Atta 19
Mechatronics Systems Design MPE 301

4.3 Energy-Output Devices

Fluid Cylinders

Fluid Motors, reverse of pump

Dr. M. Atta 20
Mechatronics Systems Design MPE 301

5. DIGITAL-TO-ANALOG CONVERSION
It has two steps.
1) Decoding; Digital output is converted into series of analog values at discrete
moment of time signals.

Eo = Eref 0.5B1 + 0.25B2 + 0.125B3 + .......... . + (2− n) B 

n
2) Data holding; Each successive value is changed into a continuous signal
(usually voltage) used to drive the actuator during the sampling interval.
Data holding devices are classified according to the order of extrapolation calculation
used to determine the voltage output during sample intervals.
The most common extrapolation is a zero-order- hold. The voltage function during
the sampling intervals is constant
Ideal envelope
E(t) = Eo Variable
Holding curve

Discrete sample
signal
Time

Dr. M. Atta 21
Mechatronics Systems Design MPE 301

The first-order data hold is less common than zero-order hold,

but it usually approximates the enveloped of the sampled data
values more closely.
E(t) = Eo + a t
a rate of change
t time (sec)
E −E (− )
a= o o

 time interval between sampling (sec).

Ideal envelope
Variable
Holding curve
Discrete sample
signal

Time

Dr. M. Atta 22
Mechatronics Systems Design MPE 301

Good Luck!

Dr. M. Atta 23