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Actuator List | Basic Pneumatics | Pneumatic Connections | Basic Electronics | Electrical Connections
This page contains the basic information that every 2.007 student should know about the how the actuators
work, and how to connect them.
Students who are interested in more advanced information on the how the actuators work should read the
Advanced Actuator Handout* after understanding the contents of this one.
Students who are interested in more advanced information on wiring and plumbing the electrical and pneumatic
actuators should read the Advanced Connecting and Control Handout after understanding the contents of this
one.
Double-Acting Air Cyclinder
Vane Type Rotary Air Actuator
The Ford Motor
The Bosch Motor
The Green Maxon Motor
The Siver Maxon Motor
The Polaroid Motor (& Drive Assembly)
The Decco Solenoid
Basic Pneumatics
Pneumatic systems use a difference in pressure to move a piston or vane. A simple cylinder is constructed as
shown below in cross-section.
It consists of an opening into which air is allowed to enter. The pressurized air pushes against the piston inside
the cylinder. This force is dependent on two things: the pressure of the air and the area of the piston. (For this
contest, it is impossible to change either of these values.) The air pressure is set at 60 psi or pounds per square
inch. The diameter of the piston is 10mm, thus it has an effective surface area of 78mm2 or 0.1217in2. With a
pressure of 60 psi this means the force can be calculated. Force = (Pressure)*(Area). Thus the pushing force
equals 7.3 lbf or 32.5 N.
Because the piston rod reduces the effective area on one side of the piston, the pull force is not as great as the
push force. For the pull force, the effective area = (Piston area) - (rod area). The rod is 4mm in diameter, so
the rod area is 12.5mm2. Thus the effective area is 65.5mm2 and the pull force is therefore 27.1 N or 6.09 lbf.
A more detailed look at your pneumatic pistons reveals two ports with a two part thumb screw on each. These
are flow controls, and as their name implies, they regulate the speed at which a volume of air enters the
cylinder by changing the size of the inlet hole. Thus if one were to adjust the screw all the way down, no air
would be able to enter the cylinder from that side. These ports can be adjusted independently and thus, the
speed at which the cylinder extends and retracts can be changed independently.
The connectors on the Y-connectors, the flow controls and the connections at the umbilical all work on the
same principle. You simply insert the pneumatic tube (4mm O.D.) into the connector and then pull back gently.
To remove, DO NOT JUST YANK HARD!!. Push the small collar down into the connector (usually blue
or green) and while holding the collar down, pull tube out. It is much easier this way!
Basic Electronics
Electrical systems are analytically remarkably similar to pneumatic systems which were explained above.
Instead of pressure, there is voltage, and instead of flow there is current (or the measure of current which is
amps.) The power supply outputs 13.8 volts. This is like placing the two wires on your motor between nine
batteries (such as C cells.)
The DC motors you have in your kit are permanent magnet DC motors. Each motor requires that both wires be
hooked to the umbilical or to either side of a battery.
To reverse the direction of the motor, simply flip the wires at either the motor or the connector to the umbilical.
(It is usually much easier to switch at the motor connections.)
Flipping the wires has no effect on the solenoid. It is simply on or off. The solenoid will only pull. It cannot
push, it needs some other force to pull the plunger out so it can be used again (i.e. spring, gravity, etc.)
Each contestant has four electrical lines, and therefore can control four motors independently. To control more
motors you could do so, but not independently. To control more motors you must hook up two motors to the
same line. This would mean that when you flipped the switch to on, both motors would turn on. You could
make one motor turn one way while the other turned in the opposite direction and then flipping the switch
would cause them to both change direction. When you hook up multiple motors to one line you may use either
a series or parallel connection. A series connection will make each motor "see" about 6.9 volts, while a parallel
connection will make each motor "see" 13.8 volts. Both are shown below. Note that if you use either of the
Polaroid motors, you should connect a second one in series so they each see 6.9 volts as they are not rated to
13.8 volts. The Polaroid motors can, however, be run at the higher voltage for short periods of time.
The maximum torque a motor can produce is called the stall torque. This is the point when the shaft speed is
zero. The maximum speed of a motor is called the no load speed. This is the point when there is no opposing
load on the shaft. For permanent magnet motors the torque vs. speed curve is a straight line that connects the
no load speed (where torque is zero) and the stall torque (where speed is zero). The motors in the kit are not
designed to be operated near the stall torque limit for extended periods of time.
When calculating the speed your motor will turn at you should not use the no load speed. The torque applied to
the motor will determine the speed of the motor. You should try to run your motors at half of the stall torque
for maximum power output. A typical torque vs. speed curve is shown below.
Soldering:
Soldering uses a hot probe called a soldering iron to heat solder (usually a mix of tin and lead in roughly equal
proportions.) The hot solder flows around other metal parts and when allowed to cool bonds the parts together
mechanically and electrically.
To solder two wires (or two metal objects) together you should:
Strip (Remove the insulating material from) both wires roughly 1/4" - 1/2" from the ends to be soldered.
1. If the wire is made up of many smaller wires, twist them tightly with your fingers.
2. Using a soldering iron with a clean tip, (if not clean see instructions below) apply a small amount of
solder directly to the tip of the soldering iron. Bring the soldering iron to the underside of the wire
while placing the solder on the side or top of the wire. The wire will heat up and the solder will start to
melt. Apply enough to coat the wire fully but not so much as to form globs. Do this to both wires (this
is called tinning the wires.)
3. Bring both wires in contact after they have been tinned. Wrap wires together and apply the soldering
iron to the wires. The solder should flow and form a connection. You may have to apply a small
amount of additional solder but this is usually not necessary if the wires have been tinned correctly.
4. Wrap the exposed wire with electrical tape.
To clean the soldering iron:
1. A wet sponge may also be used to clean off small amounts of solder.
2. Apply a small amount of solder directly to the tip and then wet tip with sponge to clean off excess.
Crimping involves using a crimping tool (or a pliers if a crimpnig tool cannot be found) to deform metal
prongs around a wire.
Interference:
Interference fits are used in the AMP connector and simply involve forcing two parts together that deform
slightly and make surface contact thus providing an electrical connection
All contents copyright © 1997 MIT
Keith Breinlinger or Roger Cortesi
SMC Double-Acting Air Cylinder
For optional advanced information on how a pneumatic piston works, read the pneumatic section of the
Advanced Actuator Handout*.
Specs:
Manufacturer: SMC
Part Number: NCJ2D10-45
Metric English
Theoretical Pull 27.1 N 6.09 lbf
Force @ 60 psi:
Force @ 60 psi:
Nose mount thread: M8 x 1.00
Rod thread: M4 x 0.7
Piston weight: 57 g 0.125 lbs
Clevis weight: 20 g 0.044 lbs
1. Typically linear actuators of this type are mounted in one of two ways: a nose mount or a clevis (pivot)
mount.
2. To use a nose mount, one would thread the body into a matching part and thus clamp the body at the
"nose" of the cylinder. This would typically be used in pushing applications when the cylinder
provides both the "guidance" and the force.
3. To use a pivot or clevis mount, one simply needs to place a rod through the hole at the end of the
(opposite the nose) of the cylinder. This mounting is used for most linkages (where the other links
pivot and provide the "guidance".)
4. Do not clamp around the body of the cylinder in any way. The clamping force tends to deform the
cylinder slightly and then the piston does not slide as well or gets stuck at the deformed area.
5. No bending moments should be placed on the cylinder or rod otherwise the piston will bind.
6. Use #4-40 bolts or welding rod as pivots inserted into the clevis holes.
Mounting:
SMC Vane Type Rotary Air Actuator
For optional advanced information on how a pneumatic rotary actuator works, read the pneumatic rotary
actuator section of the Advanced Actuator Handout*.
Specs:
Manufacturer: SMC
Part Number: NCRB1BW15-270SE
Metric English
Theoretical Torque @ 60 psi: 24.9 N-cm 2.2 in-lbf
Max. Operating Freq:
2 Hz
Rotation Angle:
270 degrees
Body diameter:
34 mm 1.34 in
Body Height:
20 mm 0.79 in
Top Shaft Diameter:
5.0 mm 0.197 in
Top Shaft Length:
13 mm 0.51 in
Bottom Shaft Diameter:
5.0 mm 0.197 in
Bottom Shaft Length:
7.2 mm 0.28 in
Mounting Holes (6)
M3 x 0.5
Actuator Weight:
48 g 0.10 lbs
1. The actuator has built in bearings and thus can be used to directly support small loads, however, if
moving a heavy load, you should use additional support. The actuator can support static loads up to a
15 N (3.37 lbf.) radial load and a 10 N (2.24 lbf.) axial load. Dynamic loading should be
limited to even less.
2. You should adjust the rotation speeds to the slowest possible speed so as not to exceed the kinetic
energy limit (0.024 N-cm). The maximum rotation speed (with no load and flow controls fully open)
is 0.03 sec./90 degrees. Speeds slower than 0.03 sec./90 degrees may result in some sticking or jerky
movement.
3. The speed of any pnuematic actuator should be adjusted by restricting the outflow air and NOT the
inflow air. This way, stick and slip effects can be avoided.
Mounting:
When pressure is applied to the A side, the shaft will
rotate clockwise. When pressure is applied to B
side, the shaft will rotate counter-clockwise.
All contents copyright © 1997 MIT
Keith Breinlinger or Roger Cortesi
Ford Windshield Wiper Motor
For optional advanced information on how a DC motor works, read the DC motor section of the Advanced
Actuator Handout*.
Specs:
Ford Motor Company
Manufacturer:
Part Number:
Clockwise
No Load High
Speed @ 13.8 volts 47 rpm
3.02 26.7
Stall Torque (hi) N-m in-lbf
No Load Low Speed 38 rpm
@ 13.8 volts
Stall Torque (low) 5.03 44.5
N-m in-lbf
Counter Clockwise
No Load High
Speed @ 13.8 volts 28 rpm
2.01 17.8
Stall Torque (hi) N-m in-lbf
No Load Low Speed 30 rpm
@ 13.8 volts
Stall Torque (low) 5.03 44.5
N-m in-lbf
13.8
Nominal Voltage Volts
197
Overall Length 7.75 in
mm
101
Overall Height 4.0 in
mm
M6 x
Shaft Mounting 1.0
Body Diameter 61 mm 2.4 in
Mounting Holes (3) M6 x
1.0
Overall Weight 1417 g 3.13 lbs
Notes on usage:
1. The speed and torque of the motor are rotation dependent. Looking at the shaft, clockwise rotations
tend to have higher torque and speed, and the speed increases with time (time const. approx. 2
seconds). Counter-clockwise rotations slow down with time and typically have less torque.
2. Use an M6 bolt and aluminum flanges to mount to a load.
3. Use the 5 color connector and carefully insert it into the receptacle on the motor until the tap engages.
When removing the connector, first release the locking tab, do not just yank it out.
4. The connector has 5 wires, of which only 2 are needed to operate the motor. You can choose either the
high speed (yellow & white) or low speed (black & white). The blue and green wires are used for
wiper control in Ford cars. Also, note there is one other speed (yellow & black), but this is not a
connection that Ford recommends and it has a very low torque (approx.. 1.7 in-lbf. CW and 1.7 in-lbf
CCW).
5. You can uses the large size Tygon tubing to make flexible couplings to a bearing supported drive
shaft.
6. To fix the base of the motor to a flat plate, you may use the M6 screws to tap the 3 holes around the
output shaft. Then, use the flat head M6 bolts with countersunk holes to mount to a plate. Or you can
bend two U shaped pieces of welding rod and thread the ends to make a clamp. Both are shown
below. (Note: Your holes may already be tapped in which case they are probably not M6 but 1/4"-20.)
Mounting:
Torque Speed Data:
Bosch Motor
For optional advanced information on how a DC motor works, read the DC motor section of the Advanced
Actuator Handout*.
Specs:
Manufacturer: Bosch Automotive
Part Number:
No Load Speed @ 95 rpm
13.8 volts
0.60 5.38
Stall Torque N-m in-lbf
13.8
Nominal Voltage Volts
1. Use 4mm x 4mm steel square shaft. (Rounding the tip of the shaft slightly with a file will ease
insertion into the motor).
2. Use female spade connectors to make electrical connections. Do not solder directly to electrical
contacts.
3. You can use Tygon tubing to make flexible coupling to a bearing supported drive shaft.
4. To fix the base of the motor to a flat plate, use #10-32 screws from opposite side. No nuts are needed.
5. To limit translational motion of the steel shaft, thread the shaft with a #10-32 die. Do not use cotter
pins as it is difficult to get a good fit. You should use two nylon washers on each side to limit rubbing
friction.
Mounting:
Torque Speed Data:
All contents copyright © 1997 MIT
Keith Breinlinger or Roger Cortesi
Green Maxon Motor
For optional advanced information on how a DC motor works, read the DC motor section of the Advanced
Actuator Handout*.
Specs:
Manufacturer: Maxon Motor Co.
Part Number:
No Load Speed 8350 rpm
@ 13.8 volts
0.0041 0.0036
Stall Torque N-m in-lbf
No Load Speed 610 rpm
(gearbox)
Stall Torque 0.053 0.47
(gearbox) N-m in-lbf
Nominal Voltage 13.8
Volts
111.8
Overall Length 4.4 in
mm
Body Diameter 22 mm 0.87 in
Small Shaft 2 mm 0.079 in
Diameter
Large (gearbox) 4 mm 0.157 in
Shaft Diameter
Mounting Holes M2 x
(gearbox) 0.4
0.313
Overall Weight 142 g lbs
Notes on Usage:
1. To mount to either shaft, use Tygon tubing to make flexible coupling to a bearing supported drive
shaft. You may also use a clamp collar made from Delrin or aluminum.
2. There should be no radial loads on the shaft. They will hurt the bearings in the gearbox.
3. Use female spade connectors to make electrical connections. DO NOT solder directly to the electrical
contacts.
4. To fix base of motor to a flat plate, use M2 machine screws in three bolt pattern on the gearbox side.
DO NOT support the motor from the black flange on the motor side. Unless you're using the small
output shaft.
5. The motor is green and the gearbox is a metallic color. The smaller shaft rotates faster with less torque
than the large shaft exiting the gearbox.
6. The gearbox has a ratio of 14:1
7. If the black plate falls off the motor bring it to a TA to get it fixed.
8. The smaller shaft is prone to bending and should be protected from any forces that might damage it. If
the shaft does get bend, it will ruin the motor. This shaft is normally used to drive an encoder.
Mounting:
Silver Maxon Motor
For optional advanced information on how a DC motor works, read the DC motor section of the Advanced
Actuator Handout*.
Specs:
Manufacturer:
Maxon Motor Co.
Part Number:
No Load Speed @ 13.8 volts
3750 rpm
Stall Torque
0.00722 N-m 0.163 in-lbf
Nominal Voltage
13.8 Volts
Overall Length
54 mm 2.125 in
Body Diameter
40 mm 1.575 in
Shaft Diameter
3 mm 0.118 in
Mounting Holes (2)
M2.5 x 0.45
Overall Weight
??? g ??? lbs
1. To mount to shaft, use Tygon tubing to make a flexible coupling to a bearing supported drive shaft.
You may also use a clamp collar made from Delrin or aluminum.
2. There should be no radial loads on the shaft.
3. Use female spade connectors to make electrical connection. Do not solder directly to electrical
contacts.
4. To fix the base of the motor on a flat plate use M2.5 machine screws in the two holes on the same side
as the output shaft.
Mounting:
Torque Speed Data:
Polaroid Motor and Gear Box
For optional advanced information on how a DC motor works, read the DC motor section of the Advanced
Actuator Handout*.
Specs:
Manufacturer:
Polaroid Co.
Part Number:
No Load Speed @ 13.8 volts:
19,000 rpm
Stall Torque:
0.049 N-m 0.043 in-lbf
Nominal Voltage:
6.9 Volts
Overall Length:
35.8 mm 1.41 in
Body Width:
22.3 mm 0.878 in
Body Height:
15.0 mm 0.590 in
Shaft Diameter:
2 mm 0.079 in
Overall Weight:
28 g 0.062 lbs
Weight with Transmission:
57 g 0.125 lbs
1. These are 6 volt motors and the electrical system will only output 13.8 volts. Therefore, to prevent
burning the motors out, you should hook up both motors in series so that each motor will "see" only 6
volts.
2. The drive assembly is quite intricate and you can use it intact by attaching it to one of the output gears.
The timing gear reduction is 367:1. The spread gear train has a reduction of 25:1. All gears are 64
pitch except for one of the gears on Gear 3 and the spread gear which are 48 pitch.
3. Gearing is as follows
Motor Pinion Gear - 20 Teeth, 64 Pitch Gear 4 - 9 Teeth & 37 Teeth, 64 Pitch
Gear 1 - 14 Teeth & 32 Teeth, 64 Pitch Timing Gear - 96 Teeth, 64 Pitch
Gear 2 - 14 Teeth & 32 Teeth, 64 Pitch Spread Gear - 36 Teeth, 48 Pitch
Gear 3 - 9 Teeth 64 Pitch, 12 Teeth 48 Pitch Pick travels 0.0052" / 1 degree motor rotation
4. To hook up electrically, carefully solder on wires to the two leads of the motor. You should use a fine
tip solder iron or this will be very difficult.
5. You can pop the gear off the motor by using a straight blade screwdriver and prying between the gear
and the motor body. You can then attach a Tygon tubing flexible coupling or a clamp collar. There
should be no radial load on the shaft.
Mounting:
Torque Speed Data:
Decco Solenoid
For optional advanced information on how a Solenoid works, read the solenoid section of the Advanced
Actuator Handout*.
Specs:
Manufacturer: Decco Co.
Part Number:
Pull @ 1.5 mm & 33 N 7.4 lbf
13.8 volts:
Pull @ 6.3 mm & 10.7 N 2.4 lbf
13.8 volts:
Pull @ 12.7 mm & 4.4 N 1.0 lbf
13.8 volts:
12.3
Maximum Stroke: 0.5 in
mm
13.8
Nominal Voltage: Volts
73.1 2.881
Overall Length: mm in
28.7
Body Diameter: 1.13 in
mm
54.1
Body Length: 2.13 in
mm
Nose Mount 3/4-16
Threading:
12.7
Plunger Diameter: 0.5 in
mm
Overall Weight: 227 g 0.5 lbs
Notes on Usage:
1. This is a tubular DC pull-type solenoid. When a field is applied the plunger is pulled in. To release the
plunger, the field must be turned off and an external force (e.g. a spring) applied.
2. Reversing the field will not push the plunger out.
3. This is an intermittent duty solenoid so it cannot be turned on continuously for more then
one minute. If it is left on for more then one minute it will burn out and be useless. This should not
be a problem as the contest only lasts 30 seconds, but be careful in practice!
4. The E-clip (snap-ring) prevents the plunger from bottoming out and damaging the housing. Do not
remove when in use.
5. The non-magnetic disc absorbs shock and greatly reduces residual magnetism. If removed it will be
hard to remove the plunger even after the power is turned off.
6. Note that the maximum stroke is 12.7 mm (0.5 in). Although the plunger can be pulled out further
than this, the solenoid will not be able to pull it in at longer strokes.
7. Note the pull force vs. stroke length curve is not linear.
Mounting: