3 Actuators-Full PDF

BITS Pilani BITS Pilani
Pilani | Dubai | Goa | Hyderabad
Actuators for IoT

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)
Actuators – Introduction
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• These are devices which translates the controller signal into change in a
physical parameter
Actuator
Input: control signal Output: actuation
Main energy signal

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Where do we see them around us !!!

Robotics / Toys
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Industrial setups
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Internet of Things actuator applications
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Actuators: Introduction
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• Usually the output of the actuator is mechanical (e.g., change of

position or velocity)
• Since it converts one physical quantity into an alternative form, it is

also called as transducer.
• Usually, a low-level command signal activates the transducer.

Therefore to drive the actuator, an amplifier is used to provide
sufficient power.
Mechanism
Logical
Signal Final
Signal
Processing & Electric/ Hydraulic / Actuation
Amplification Pneumatic Element
Actuator
Sensor

Classification: based on controlling phenomena
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Actuators
Other (e.g.
Electrical Hydraulic Pneumatic mechanical,
piezoelectric, thermal)

Electrical Actuators
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Converts electrical energy into mechanical energy
DC motor
DC motor rotating a propeller

Electrical actuators - Examples
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➢ Electric motor
❖DC / AC motor
❖Servo motor
❖Stepper motor
➢ Solenoid
➢ Relay
➢ Buzzers

Hydraulic Actuators
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• Hydraulic fluid amplifies the controller command signal
• These have a cylinder or fluid motor which uses

hydraulic power to produce mechanical motion
• Mechanical motion may be in the form of linear or rotary

motion
• The liquid motion is produced by a pump (which is

typically an electric motor)

Hydraulic Power Transmission BITS Pilani
Moving
Motor to pump liquid load
Liquid container

Hydraulic actuators BITS Pilani
Advantages:
• Can cater to high loads

• Have simple design
• High speed
Disadvantages:
• High cost
• May have leakage issues
• Low resolution
• Temperature effects performance

Pneumatic actuators BITS Pilani
• Compressed air provides driving force
• In these potential / kinetic energy of the stream of

compressed gas used to move rod of piston etc.

Pneumatic actuators BITS Pilani
Advantages:
• Compressed air readily available

• Faster operation
• Cheaper than hydraulic systems
• Simple and Reliable
Disadvantages:
• Difficulties in performance at slow speed

• Compressibility of air

Classification: based on operation BITS Pilani
Actuators
Linear Actuators Rotary Actuators

Linear actuator
Linear actuators convert energy into straight line motions BITS Pilani

Rotary actuator
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Rotary actuators convert energy to provide rotary motion

Types of Actuators
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• Electric Linear
• Electric Rotary
• Fluid Power Linear
• Fluid Power Rotary
• Linear Chain Actuators
• Manual Linear
• Manual Rotary
• …… and many more combinations

Electrical actuators: Electric motors (DC motor)

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Electric motors
AC DC

Motor
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1. Device converting electrical energy into mechanical energy

(usually a torque).
2. Conversion → Generation of a magnetic field by means of a
current flowing into one or more coils

Basic principle behind working
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When a current-carrying conductor is placed in a magnetic

field, it experiences a mechanical force.
Fleming’s Left hand rule

An inside view of motor to understand its working
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Wire carrying electric current in a magnetic field

Motor – Speed Control (An Intuitive Idea)
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• The torque is proportional to the current (I) and the magnetic field (B)
• How to further increase torque: by having multiple turns of wire

Animation showing working of DC motor
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• Permanent magnet
• Armature (with multiple windings)
• Commutator (light blue)
• Current source (current shown by

yellow over the black wire).
• Carbon brushes to supply current

through commutator

DC motor: Can even be made at home
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Turns of wires
Loose contact
Magnet
Current source
Making a magnet using current.
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Nail becomes an electromagnet
Magnetic field is proportional

to the current
Magnetic strength ∝ current

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Stator windings (electromagnet)

Rotor windings (the current carrying wires
within the electric field)
Commutator rings
Load
Speed Control – An Intuitive Idea
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Torque ∝ current

Applications of DC motor
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1. Lathe machines
2. Grinders
3. Drilling machine
4. Compressors

Other applications
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Electrical actuators: Servo motors

Servo motor: Definition
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A servomotor is classified as a rotary actuator. It enables precise

control of angular position, velocity & acceleration.
Steering for robot

vehicle
By John Nagle, CC BY-SA 3.0,
https://commons.wikimedia.org/
w/index.php?curid=10268729
Servo motor for hobby kits

Servo motor : Industrial application
Block diagram
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Servomotor comprises of a suitable motor which is coupled to a

sensor to get position feedback.
Amplifier
Error detection
Input Motor Output
signal
Position
Feedback

Types of servo motor
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Servo motors
Continuous Linear
AC DC
rotation servo

Servo feedback: how does it work BITS Pilani
A servomotor has a closed-loop servo-mechanism that uses position

feedback to control its motion and final position.
The input command signal (either analogue or digital) indicates the position
commanded for the output shaft.

Servo rating
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• Servo motors are typically rated in kg/cm (kilogram per centimeter).
• kg/cm rating tells us how much weight it is capable of lifting at a

particular distance. For example:
6kg/cm Servo motor: capable of lifting a load of 6kg suspended at a

distance of 1cm from the motor shaft. As the distance increases the weight
carrying capacity decreases.
• Typical hobby servo motors are rated at 3kg/cm or 6kg/cm or 12kg/cm.

Servo motor mechanism
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A servo comprises a controlling circuit, a motor, gear assembly

and a potentiometer

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Working Principle
DC motor: this is the main component which does the task of rotating BITS Pilani
based on the input signal.
Gear assembly : It is used to reduce RPM (rotations per minute) and increase torque.
Assume that at initial position of motor shaft, the position of the potentiometer knob is
such that there is no electrical signal generated at the output port of the potentiometer.
In that case error signal = input signal. The motor moves and so the gear system.
Potentiometer: As the gears move, the potentiometer position changes and the
voltage changes which is given as feedback to the control circuit.
Control circuit: This circuit compares the feedback and the input signal and based on
that generates an error signal so that the servo can get to the desired state (rotation).
feedback
More precise control
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More accurate position control using encoders which precisely

determine the angular motion

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Electrical Actuators: Stepper – Motor

Stepper Motor
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➢ A stepper Motor is essentially a synchronous Motor. It does not

have any brushes, it does not rotate continuously, but in the form
of discrete steps or pulses. Hence it is a called stepper motor
➢ The principle used in stepper motor is Electro-Magnetism. It

comprises of a permanent magnet rotor and a stator made of
electromagnets.
Stepper Motor
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➢ Since they can move in discrete steps, they are used in robotics
and industrial automation. Stepper motors are used widely in IC
Fabrication plants, x-y plotters and CNC (Computer Numeric
Control) machines.
➢ When no input current is given to the motor, it holds its

position firmly (it does not rotate). These motors can rotate
without limits in both direction depending on the input polarity.
They are easy to use and cheap.
Stepper Motor
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➢ The stator has four coils fixed at 90o angle with each other.
The type of stepper motor is determined by the way in which
the coils are arranged and connected.
➢ These coils are not connected to each other.
➢ This particular motor has a rotation step of 90 degrees in a

cyclic order, the coils are activated one by one.
➢ The order in which the coils are activated is determines the

direction in which the shaft rotates.

Stepper Motor
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1. Brushless, synchronous electric motor

2. Can divide a full rotation into an expansive number of steps
Increased resolution mechanism in

4 pole stepper motor
4 pole stepper motor with rotor magnet in the middle
Image courtesy: https://www.imagesco.com/articles/picstepper/02.html
Many pole stepper motor
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Image courtesy: https://www.imagesco.com/articles/picstepper/02.html
Stepper Motor
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➢ It can be incrementally driven one step at a time, either forward or backward.
➢ Stepper motor is characterized by:

• Number of steps per revolution (e.g. 100 steps per revolution = 3.6° per step)
• Maximum No of steps/second (“stepping rate” = max speed)
Driving a stepper motor
▪ full-step mode: 4 step switching sequence is required
▪half-step mode (higher resolution): 8 step switching sequence is required
▪The final motion appears very smooth if the stepping sequence is very fast.

Stepper motor applications
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Electrical actuators: Relays

What is a Relay?
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A relay is just a switch which is operated electrically. It usually uses an
electromagnet to perform the switching operation.
When the electromagnet is de-energised, current flows through the common line
and through the NC contact. When the electromagnet is energised, the magnetic
contact moves from NC to NO contact and current flows from the common line
though the NO contact.
Normally
Closed
Contact
Common
Line
Normally
Open
Contact
Control signal

Why do we need Relays?
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Relays are used where it is necessary to control a circuit by a

separate low-power signal, or where several circuits must be
controlled by one signal.
Example Application: You want the AC in a house to switch on when

the temperature increases beyond 30 degrees Celsius.
How to go about it:
- Use a temperature sensor and connect it to a microcontroller which is

configured such that it outputs current only when the temperature increases
beyond 30 degrees.
- Connect the microcontroller to a relay which can be fitted inside the AC.
- Now when the temperature increases beyond 30 degrees, the

microcontroller outputs a small current which causes the relay to switch.
While the AC works on the grid supply (high voltage, high current), the relay
is able to switch it on with a small current from the microcontroller.
Nomenclature in Relays
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In any switch, there is a pole and a throw. The pole is the part that
switches the circuit and the throw is the part that makes contact with
the pole.
For example in the SPDT (single pole double throw) relay shown below:
C is the pole whereas A and B are throws. Corresponding to each pole
there are two throws, hence this is a single pole double throw relay.
Electromagnet

Types of Relays
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SPST relay: Here, A is the pole and B is the throw, and

for every pole there is only one throw. Thus this is a
Single Pole Single Throw Relay. In this case, when the
relay is de-energised, the relay is open and there is no
contact and so this is a NO (Normally Open) SPST
Relay.
We can also have a SPST relay where when the relay is

de-energised, the switch is closed (this can be by simply
using a spring mechanism). Such a relay is called a NC
(Normally Closed) SPST Relay.

Types of Relays
BITS Pilani
Next we consider relays with two poles.
DPST relay: for each pole there is only one throw, i.e. A1 can connect to
B1 and A2 can connect to B2.
DPDT relay: there are two throws for each of the two poles, i.e. C1 can
connect to A1 and B1 and C2 can connect to A2 and B2.

Summary: Types of Relays
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Electromagnet
• SPST Relay (Single Pole Single Throw)
o NO (Normally Open)
o NC (Normally Closed)
• SPDT Relay (Single Pole Double Throw)
• DPST Relay (Double Pole Single Throw)
• DPDT Relay (Double Pole Double Throw)

Electrical actuators: Solenoids

What is a Solenoid?
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A solenoid is simply a coil of wire which is tightly wound into a helix.

Understanding what happens when we pass current through a solenoid
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• If electric current is passed through a conducting wire, it generates a

magnetic field (Ampere’s Law).
• Direction of magnetic field is decided by the direction of the current along

the length of the wire.
• Using this principle, when current is passed through a tightly wound coil
of wire, it gives rise to a magnetic field that is similar to that of a bar
magnet !

That’s how solenoid becomes a magnet
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Solenoid Bar magnet

What is a Solenoid?
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Thus we have seen, that a tightly wound coil of wire generates a magnetic field
(when current is passed through it) that makes the coil act like a bar magnet.
It is important to note, that the magnetic field lines are present inside the solenoid
as well, whereas, while there exists magnetic field lines inside the magnet, there
is no way to make use of the same.

The solenoid core
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At times solenoid consists of the wire wrapped around a material with
high magnetic permeability (such as iron, electric steel, perm alloy etc.).
Magnetic permeability (μ) is the ability of a magnetic material to support
magnetic field development.
The magnitude of the magnetic field due to a solenoid depends on the

magnetic permeability of the core.
B is the magnitude of the magnetic field in teslas, μ is the magnetic

permeability of the core, n is the number of turns of the coil and I is the
current in amperes flowing through the coil.
Factors affecting strength of solenoid
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Magnitude of the magnetic field due to a solenoid is given as
So its magnitude depends on:
1. μ (magnetic permeability of the core)

2. n (number of turns of the coil)
3. I (current in amperes flowing through the coil)

Solenoid Valve (or simply Solenoid)
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A solenoid valve is an electromechanical device in which the solenoid

uses an electric current to generate a magnetic field and thereby
operate a mechanism which regulates the opening of fluid flow in a
valve.
A solenoid valve is often simply referred as a solenoid for real life

applications.
Simplified diagram of a solenoid valve

Using solenoid valve to control air flow
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Solenoid Valve
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Application of Solenoids
• Control of water flow in a garden irrigation system BITS Pilani

How to choose an appropriate actuator

Choosing an Actuator
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➢ There are a wide variety of actuators available in market (e.g. dc

motor, servo motor, stepper motor etc.). To choose a right actuator
requires proper understanding of the applications scenario.
➢ It also involves properly understanding things like whether the motion

desired is linear or rotational (or a combination of both).
➢ Also, it is to be kept in mind that as time is advancing, there are

always new products being launched in market so one needs to
keep oneself updated.
➢ Each type of actuator (linear, hydraulic, pneumatic and electric) have

different criteria for selection.

Criteria for Choosing an Actuator
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• Stroke Length
• Speed
• Accuracy
• Repeatability
• Resolution
• Peak Force/Torque
• Mounting
• Temperature Range
• Frequency of Operation
• Operating Environment
• Maintenance
• Safety
Stroke Length
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➢ The distance the actuator needs to move in one direction, known

as the stroke length.

Speed
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➢ Speed is an important factor while choosing an actuator. The

maximum speed for most belt drive actuators is 5 m/s. This limit is
influenced by the guide system, which most commonly employs
recirculating bearings. For applications that require higher speeds, up
to 10 m/s, a belt drive can be used in conjunction with preloaded
wheels or cam rollers rather than recirculating bearings.

Accuracy
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➢ There are 2 aspects of accuracy.
➢ Accuracy of the actuator : This is determined by the moving

element and is the ability to traverse a straight line or an ideal single-
axis path.
➢ Actuator's ability to provide increments of precise motion along

the working axis.
Accuracy is how close an

actuator can consistently
move to the target position

Repeatability
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➢ Repeatability: It is ability of a device to reach a specific location or

position in successive attempts.
➢ Note: An actuator may be highly repeatable without being highly

accurate.
Repeatability is the ability of an

actuator to reach a specific
range in successive attempts

Resolution
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➢ Resolution is the smallest positional increment that can be asked of a

motion system.
➢ Motors, encoders, controllers, and mechanical components act together

to define system resolution.
➢ Better resolution at times becomes challenging due to mechanical

limitations.
Resolution is the smallest increment at which an actuator

can be relied upon to move
Peak Force/Torque
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➢ This refers to the peak force or torque at which the actuator would
stall, i.e. the maximum force the actuator can withstand before it
stops functioning/errors in its functioning. This is dependent on the
force due to the load, the friction force and the acceleration of the
mass.

Mounting
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The way in which a linear motion system is mounted greatly affects the
success or failure of linear motion applications.

Temperature Range
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➢ Electric and pneumatic actuators can typically be used over wide

range of temperature. For pneumatic actuator, the typical range is
-4 to 174°F (-20 to 80°C) but this can be increased to -40 to
250°F (-40 to 121°C) by using optional seals, grease and
bearings.
➢ If these applications use control accessories like solenoid valves

or limit switches, they might not have the same temperature rating
as the actuator and one should carefully consider that during
application development.

Frequency of Operation
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➢ The frequency of operation (or duty) effects the robustness of
controller and durability of the mechanical drive.
➢ Actuators which operate infrequently (such as isolating or regulating

duty actuators) experience less wear and tear on mechanical
components and controls.
➢ Actuators like modulating process valves, operate on continuous basis,

and this require a more durable assembly.
➢ Based on the starts/ operations per hour actuators are categorized as

follows
• Isolation – the actuator operates only a few times per day

• Regulating – 30 to 60 starts per hour
• Modulating – 600 to 1,800 starts per hour

Operating Environment
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➢ While it may seem obvious, many people do not adequately research
their actuator before purchasing it and later find that environmental
factors in their work space require a product with a completely different
specification.
➢ It has been found that in manufacturing plants, two factors most
commonly govern the environmental specifications of actuators:
1. Dusty Environments
2. Wet Environments
➢ These two conditions cover the
majority of working environments
that can be problematic for
actuators. Fortunately, there are
Actuators that are specifically
designed to withstand demanding
working conditions such as IP5X
(dust protected) actuators or IPX5
An IP5X actuator
(water resistant) actuators.
Maintenance
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➢ The primary cause of failure for linear actuators is lack of lubrication.

Both ball screw and belt drive actuators require that the guide system
be lubricated periodically.

Safety
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➢ For hazardous environments / accidents, every actuator comes with some

warnings / safety precautions.
➢ Its best to go for the safest and most reliable option. E.g. an actuator
should be able to maintain the fail-safe position should a fire break out,
for example.
➢ At times additional components are to be added to improve safety and

also to meet regulatory standards. E.g. in electric actuators, there is risk
of damage to motor in case of excessive current and heating due to the
same. Thus to protect it heat/ current sensors and torque switches are
used.

Summary of features of different categories of Actuators
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BITS Pilani BITS Pilani

Pilani | Dubai | Goa | Hyderabad

Actuators for IoT

Main energy signal

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

Where do we see them around us !!!

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Usually the output of the actuator is mechanical (e.g., change of

• Since it converts one physical quantity into an alternative form, it is

• Usually, a low-level command signal activates the transducer.

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

Converts electrical energy into mechanical energy

DC motor rotating a propeller

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Hydraulic fluid amplifies the controller command signal

• These have a cylinder or fluid motor which uses

• Mechanical motion may be in the form of linear or rotary

• The liquid motion is produced by a pump (which is

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Can cater to high loads

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Compressed air provides driving force

• In these potential / kinetic energy of the stream of

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Compressed air readily available

• Difficulties in performance at slow speed

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

Linear Actuators Rotary Actuators

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Fluid Power Linear

• Fluid Power Rotary

• Linear Chain Actuators

• …… and many more combinations

Electrical actuators: Electric motors (DC motor)

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

1. Device converting electrical energy into mechanical energy

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

When a current-carrying conductor is placed in a magnetic

Fleming’s Left hand rule

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

Wire carrying electric current in a magnetic field

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• How to further increase torque: by having multiple turns of wire

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)

• Armature (with multiple windings)

• Commutator (light blue)

• Current source (current shown by

• Carbon brushes to supply current

EEE F411: Internet of Things (Dr. Vinay Chamola, BITS-Pilani)