Actuator
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2.007 Actuator Information & Index
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.
The List of Actuators 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.
Making Pneumatic Connections The pneumatic connectors are labeled with four colors: red, yellow, green and blue. You should color code your connectors to match so that you will not mix up the connections at the contest. 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.
Making Electrical Connections There are three basic ways to make electrical connections in 2.70: soldering, crimping and interference fits. (There are many other ways discussed briefly in the Advanced Wiring section.)
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: Part Number:
SMC NCJ2D10-45 Metric English
Theoretical Pull Force @ 60 psi:
Theoretical Push Force @ 60 psi:
27.1 N 6.09 lbf
Stroke length: Body diameter: Piston diameter:
45 mm 1.77 in
11 mm 0.43 in
10 mm 0.39 in
32.5 N 7.31 lbf
Nose mount thread: M8 x 1.00
Rod diameter: Rod thread: Rear clevis hole: Rear clevis slot: Piston weight:
4 mm 0.157 in
M4 x 0.7
3.2 mm 0.125 in
3.3 mm 0.130
57 g 0.125 lbs
Clevis hole diameter: 3.2 mm 0.125 in
Clevis slot: 3.3 mm 0.130 in
Clevis weight: 20 g 0.044 lbs
Notes on Usage: 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: Part Number:
SMC
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
Notes on Usage: 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: Manufacturer:
Ford Motor Company
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 44.5 Stall Torque (low) 5.03 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 44.5 Stall Torque (low) 5.03 N-m in-lbf 13.8 Volts 197 Overall Length mm 101 Overall Height mm M6 x Shaft Mounting 1.0 Body Diameter 61 mm Mounting Holes (3) M6 x 1.0 Overall Weight 1417 g Nominal Voltage
Notes on usage:
7.75 in 4.0 in
2.4 in
3.13 lbs
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 @ 13.8 volts
95 rpm
Stall Torque
0.60 N-m
Nominal Voltage
13.8 Volts
Overall Length
125 mm 4.92 in
Overall Height
54.5 mm 2.14 in
Body Diameter
42 mm
Base to Shaft Height
15.5 mm 0.61 in
Shaft Mounting
4mm x 4mm
5.38 in-lbf
1.65 in
Mounting Holes (2) #10-32 Overall Weight
400 g
0.881 lbs
Notes on Usage: 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 @ 13.8 volts
8350 rpm
Stall Torque
0.0041 N-m
No Load Speed (gearbox)
610 rpm
Stall Torque (gearbox)
0.053 N-m
0.0036 in-lbf
0.47 in-lbf
Nominal Voltage 13.8 Volts Overall Length
111.8 mm
4.4 in
Body Diameter
22 mm
0.87 in
Small Shaft Diameter
2 mm
0.079 in
Large (gearbox) Shaft Diameter
4 mm
0.157 in
Mounting Holes (gearbox)
M2 x 0.4
Overall Weight
142 g
0.313 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
Notes on Usage: 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
Notes on Usage: 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 & 13.8 volts:
33 N
7.4 lbf
Pull @ 6.3 mm & 13.8 volts:
10.7 N
2.4 lbf
Pull @ 12.7 mm & 13.8 volts:
4.4 N
1.0 lbf
Maximum Stroke:
12.3 mm
0.5 in
Nominal Voltage:
13.8 Volts
Overall Length:
73.1 mm
2.881 in
Body Diameter:
28.7 mm
1.13 in
Body Length:
54.1 mm
2.13 in
Nose Mount Threading:
3/4-16
Plunger Diameter:
12.7 mm
0.5 in
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:
Force vs. Stroke Data:
All contents copyright © 1997 MIT Keith Breinlinger or Roger Cortesi
* See the Section Page for the Linked Resources
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.
The List of Actuators 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.
Making Pneumatic Connections The pneumatic connectors are labeled with four colors: red, yellow, green and blue. You should color code your connectors to match so that you will not mix up the connections at the contest. 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.
Making Electrical Connections There are three basic ways to make electrical connections in 2.70: soldering, crimping and interference fits. (There are many other ways discussed briefly in the Advanced Wiring section.)
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: Part Number:
SMC NCJ2D10-45 Metric English
Theoretical Pull Force @ 60 psi:
Theoretical Push Force @ 60 psi:
27.1 N 6.09 lbf
Stroke length: Body diameter: Piston diameter:
45 mm 1.77 in
11 mm 0.43 in
10 mm 0.39 in
32.5 N 7.31 lbf
Nose mount thread: M8 x 1.00
Rod diameter: Rod thread: Rear clevis hole: Rear clevis slot: Piston weight:
4 mm 0.157 in
M4 x 0.7
3.2 mm 0.125 in
3.3 mm 0.130
57 g 0.125 lbs
Clevis hole diameter: 3.2 mm 0.125 in
Clevis slot: 3.3 mm 0.130 in
Clevis weight: 20 g 0.044 lbs
Notes on Usage: 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: Part Number:
SMC
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
Notes on Usage: 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: Manufacturer:
Ford Motor Company
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 44.5 Stall Torque (low) 5.03 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 44.5 Stall Torque (low) 5.03 N-m in-lbf 13.8 Volts 197 Overall Length mm 101 Overall Height mm M6 x Shaft Mounting 1.0 Body Diameter 61 mm Mounting Holes (3) M6 x 1.0 Overall Weight 1417 g Nominal Voltage
Notes on usage:
7.75 in 4.0 in
2.4 in
3.13 lbs
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 @ 13.8 volts
95 rpm
Stall Torque
0.60 N-m
Nominal Voltage
13.8 Volts
Overall Length
125 mm 4.92 in
Overall Height
54.5 mm 2.14 in
Body Diameter
42 mm
Base to Shaft Height
15.5 mm 0.61 in
Shaft Mounting
4mm x 4mm
5.38 in-lbf
1.65 in
Mounting Holes (2) #10-32 Overall Weight
400 g
0.881 lbs
Notes on Usage: 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 @ 13.8 volts
8350 rpm
Stall Torque
0.0041 N-m
No Load Speed (gearbox)
610 rpm
Stall Torque (gearbox)
0.053 N-m
0.0036 in-lbf
0.47 in-lbf
Nominal Voltage 13.8 Volts Overall Length
111.8 mm
4.4 in
Body Diameter
22 mm
0.87 in
Small Shaft Diameter
2 mm
0.079 in
Large (gearbox) Shaft Diameter
4 mm
0.157 in
Mounting Holes (gearbox)
M2 x 0.4
Overall Weight
142 g
0.313 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
Notes on Usage: 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
Notes on Usage: 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 & 13.8 volts:
33 N
7.4 lbf
Pull @ 6.3 mm & 13.8 volts:
10.7 N
2.4 lbf
Pull @ 12.7 mm & 13.8 volts:
4.4 N
1.0 lbf
Maximum Stroke:
12.3 mm
0.5 in
Nominal Voltage:
13.8 Volts
Overall Length:
73.1 mm
2.881 in
Body Diameter:
28.7 mm
1.13 in
Body Length:
54.1 mm
2.13 in
Nose Mount Threading:
3/4-16
Plunger Diameter:
12.7 mm
0.5 in
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:
Force vs. Stroke Data:
All contents copyright © 1997 MIT Keith Breinlinger or Roger Cortesi
* See the Section Page for the Linked Resources
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