Linear Actuator Research Articles

Design and Performance Analysis of A Linear Switched Reluctance Motor Considering End Effects

Introduction: In recent years, linear actuators have gained significant attention due to their ability to provide direct linear movement without the need for motion transformation devices. One significant challenge in the design and modeling of linear actuators is the occurrence of longitudinal end-effects. The finite length of the translator stack in linear actuators causes an unbalanced phase force, leading to discrepancies between the phases at the end and center of the actuator. Neglecting these end-effects can lead to inaccuracies in the actuator's performance and control. Methods: The objective of this study is to develop a comprehensive approach for the design, sizing, and modeling of the actuator to ensure optimal performance. An energy conversion procedure calculates the thrust force and determines the actuator's geometrical parameters. A numerical model based on the finite element method is developed to analyze the actuator's magnetic behavior and establish its characteristics. Furthermore, a thorough analysis of the end effect is conducted using two-dimensional finite element analysis. Results: To accurately capture the actuator's dynamic response and enable precise control, a mathematical model is formulated, incorporating the nonlinear behavior of inductance and incorporating the end effect factor. The proposed model demonstrates high accuracy and provides a solid foundation for the control of the linear switched reluctance actuator. Conclusion: Overall, this study contributes to the advancement of direct drive systems for industrial applications by providing a detailed design procedure and an accurate modeling approach for the linear actuator, enabling more efficient and precise control strategies.

Design and Optimization of a Custom-Made Six-Bar Exoskeleton for Pulp Pinch Grasp Rehabilitation in Stroke Patients.

Stroke often causes neuromotor disabilities, impacting index finger function in daily activities. Due to the role of repetitive, even passive, finger movements in neuromuscular re-education and spasticity control, this study aims to design a rehabilitation exoskeleton based on the pulp pinch movement. The exoskeleton uses an underactuated RML topology with a single degree of mobility, customized from 3D scans of the patient's hand. It consists of eight links, incorporating two consecutive four-bar mechanisms and the third inversion of a crank-slider. A two-stage genetic optimization was applied, first to the location of the intermediate joint between the two four-bar mechanisms and later to the remaining dimensions. A targeted genetic optimization process monitored two quality metrics: average mechanical advantage from extension to flexion, and its variability. By analyzing the relationship between these metrics and key parameters at different synthesis stages, the population evaluated is reduced by up to 96.2%, compared to previous studies for the same problem. This custom-fit exoskeleton uses a small linear actuator to deliver a stable 12.45 N force to the fingertip with near-constant mechanical advantage during flexion. It enables repetitive pulp pinch movements in a flaccid finger, improving rehabilitation consistency and facilitating home-based therapy.

Scalable, compact and easy-to-control linear electromagnetic actuator

Scalable, compact and easy-to-control linear electromagnetic actuator

Design and performance evaluation of a stick–slip actuator with Z-shaped beam and two-stage amplification system

Abstract In the domain of piezoelectric driving, actuators that utilize the stick–slip effect at high speeds and low frequency have garnered significant interest. This study presents an innovative linear piezoelectric actuator that integrates a two-stage amplification system with a Z-shaped beam mechanism. The designed actuator has good driving speed at low frequency while overcoming the disadvantage of such actuators requiring two flexible mechanisms to achieve reverse motion and poor reverse performance. The structure and scale of the actuator are explained and designed through theory and simulation. The experimental results demonstrate the prototype’s capability for bidirectional motion. Subjected to a 400 Hz and 140 V excitation, the maximum speed of the actuator is 12.88 mm s−1. The maximum load capacity is tested to be of 0.35 N. This research introduces a new approach for the design of high-speed bidirectional motion stick–slip piezoelectric actuators.

High-Transparency Linear Actuator Using an Electromagnetic Brake for Damping Modulation in Physical Human–Robot Interaction

High-Transparency Linear Actuator Using an Electromagnetic Brake for Damping Modulation in Physical Human–Robot Interaction

Modeling and numerical analysis of Kangaroo lower body based on constrained dynamics of hybrid serial–parallel floating-base systems

This paper presents the modeling and numerical analysis of the Kangaroo lower body prototype, a novel bipedal humanoid robot developed and manufactured by PAL Robotics. Kangaroo features high-power linear electric actuators combined with unique serial–parallel hybrid chains, which allow for the positioning of all the leg actuators near the base of the robot to improve the overall mass distribution. To model and analyze such complex nonlinear mechanisms, we employ a constrained formulation that is extended to account for floating-base systems in contact with the environment. A comparison is made to demonstrate the significant improvements achieved with TALOS, another humanoid bipedal robot designed by PAL Robotics, in terms of equivalent Cartesian inertia at the feet and centroidal angular momentum. Finally, the paper includes numerical experiments conducted through simulation and preliminary tests performed on the actual Kangaroo platform.

In-field performance evaluation of robotic arm developed for harvesting cotton bolls

Robotic harvesting of cotton bolls combines the advantages of manual picking and mechanical harvesting, including selective picking and reduced labor dependency. Thus, we designed, developed, and tested a cotton-picking robotic arm equipped with a depth camera, a 4-DoF manipulator, and a vacuum-type end-effector. Convolutional neural networks were implemented for cotton boll recognition, while an artificial neural network-assisted particle swarm optimization-based model was utilized for solving inverse kinematics. Linear actuators, controlled by a microcontroller and relays, positioned the end-effector for cotton boll harvesting. Laboratory testing resulted in picking 44–49 cotton bolls per hour, taking approximately 73.0 s per boll. During field testing, the robotic arm picked 40–42 bolls per hour with an average time of 86.0 s per boll. Picking efficiency ranged from 76.19% to 85.71% in the lab and 66.32% to 72.04% in the field. The complex structure of cotton plants sometimes hindered the end-effector’s path, resulting in lower picking efficiency during field testing. As observed in present study, manual pickers achieved a significantly higher picking rate, harvesting 1.381 kg of cotton per hour, nearly 4.7 times more than the robotic arm. Manual pickers achieved 98.04% picking efficiency, significantly higher than the robotic arm’s 68.25%. This significant difference in efficiency is due to the agility, adaptability, and decision-making abilities of human pickers. The developed robotic arm demonstrates competitive efficiency in the domain of harvesting robots, contributing to advancements in robotic agriculture. Future research and development efforts in this field hold the potential to enhance the efficiency and productivity of robotic cotton harvesters.

Pressing Mechanism Design and Performance Analysis for Brake Pedal System at Low-Speed Driving

This article focuses on the modelling and analysis of an automatic braking mechanism for low-speed driving scenarios. The study aims to replicate the force exerted by a driver on the brake and accelerator pedals by strategically placing the suitable actuator within the pedal subsystem assembly. The primary objective is to model the pedal pressing mechanism for the braking subsystem and gain insights into driver ‘s behaviour during traffic congestion, thereby ensuring the effective operation of the automatic braking system. The actuator was modelled using 3D virtual environment, while the car body or dynamics was modelled using SimScape in MATLAB environment, and the simulation performance analysis was employed to evaluate the performance outcomes. It has shown that the mechanism designed mimics the actual manual pedal pressing mechanism of driver’s leg where the results show that the actuator managed to produce 150 N to reach speed at 8.5 km/h at 48 mm linear actuator stroke. Therefore, the research findings are anticipated to contribute significantly to the advancement of automatic braking systems, particularly during low speed in road traffic delay, which may help in reducing the fatigue among drivers, enhancing vehicle safety, and providing valuable insights for the development of more reliable and efficient systems within the automotive industry.

A Study on the Usefulness of Effective Stiffness for Robust Design of Unified Linear Actuators

A Study on the Usefulness of Effective Stiffness for Robust Design of Unified Linear Actuators

Synchronous Cation-Driven and Anion-Driven Polypyrrole-Based Yarns toward In-Air Linear Actuators.

Conducting polymers (CP) have shown great features in building textile actuators. To date, most of the yarn-based or CP-yarn actuators have been operated in liquid electrolytes in a three-electrode-cell configuration, comprising an external counter and a reference electrode. For integration in textiles, a two-electrode system is needed, where both electrodes are in a yarn format. This can be achieved by having two CP-yarns, where one acts as the anode and the other as the cathode. For these two CP-yarns to operate synchronically, they both need to expand (or contract) during opposite reactions. This can be achieved by doping one CP-yarn with mobile anions that will expand during oxidation, while the other CP-yarn should be doped with immobile anions expanding during reduction. As a result, the same movement is created upon opposite redox reactions, both collaborating with the actuation in the same direction without the need for an external passive electrode to close the electrical circuit, which could oppose or hinder the movement. Most of the studies on textile actuators are based on cation-driven CP-yarn actuators, while little is known about anion-driven systems in CP-yarn actuators. Here, we first present a study of the effect of the dopants, solvents, and polymer layer combinations on the mechanism and strain of CP-yarns. The CP-yarns are coated with two layers: an inner poly(3,4-ethylenedioxythiophene) (PEDOT) layer and the outer and active polypyrrole (PPy) layer. According to our results, the dopant of the inner PEDOT layer seems to affect the actuation mechanism of the outer PPy layer and, thereby, of the whole CP-yarn actuator, influencing the direction of the movement and enhancing or hindering the total strain of the actuator. We show that a CP-yarn coated with PEDOT(Tos)/PPy(ClO4) and actuated in LiClO4 aqueous solution showed a pure anion-driven actuation. Next, based on the latter results, we demonstrate for the first time the dual actuation of two CP-yarns, doped with two different dopants, ClO4 - and DBS-, actuating simultaneously driven by opposite redox reactions and exhibiting an average of 0.5% of strain, an important step toward in-air actuating yarns.

Design and validation of an In Vitro test bench for the investigation of cardiopulmonary resuscitation procedure

Despite recent clinical and technological advancements, the cardiac arrest survival rate remains as low as 10%. To enhance patient outcomes, it is crucial to deepen the understanding of cardiopulmonary resuscitation (CPR) at a fundamental level. Currently, there is a lack of knowledge on the physiological effects of CPR, in particular on the hemodynamics in the heart and the great vessels. The design and validation of a dedicated in vitro heart simulator, capable of replicating the physiological response to CPR, holds the potential to provide valuable insights into the fluid dynamics in the heart during CPR but also to be used as a platform for the development and testing of mechanical CPR machines. The main objective of this study is to design and validate the first in vitro heart simulator that can replicate the physiological response during CPR. For that, a custom-made heart simulator is designed consisting of an elastic model of the complete heart and a controllable linear actuator. The heart model is positioned in an anatomical position, and the linear actuator compresses the model at specific rates and depths. Flow and pressure waveforms are recorded on the newly developed simulator at 60 contractions per minute and results are validated against reported in vivo data in the literature. Finally, the system’s capabilities are evaluated by considering several combinations of compression rates and depths.

A Pneumatic Flexible Linear Actuator Inspired by Snake Swallowing.

Soft robots spark a revolution in human-machine interaction. However, developing high-performance soft actuators remains challenging due to trade-offs among output force, driving distance, control precision, safety, and compliance. Here, addressing the lack of long-distance, high-precision flexible linear actuators, an innovative pneumatic flexible linear actuator (PFLA) is introduced, inspired by the smooth and controlled process observed in snakes ingesting sizable food, such as eggs. This PFLA combines a soft tube, emulating the snake's body cavity, with a pneumatically driven piston. Through the joint modulation of moving resistance and driving force by pneumatic pressure, the PFLA exhibits exceptional motion control capabilities, including self-holding without pressure supply, smooth low-speed motion (down to 0.004 m s-1), high-speed motion (up to 5.6 m s-1) with low air pressure demand, and a self-protection mechanism. Highlighting its adaptability and versatility, the PFLA finds applications in various settings, including a wearable assistive devices, a manipulator capable of precise path tracking and positioning, and rapid transportation in diverse environments for pipeline inspection and firefighting. This PFLA combines biomimetic principles with sophisticated fluidic actuation to achieve long-distance, flexible, precise, and safe actuation, offering a more adaptive solution for force/motion transmission, particularly in challengingenvironments.

Development of a Novel Retinal Surgery Robot Based on Spatial Variable Remote Center-of-Motion Mechanism

Abstract This article reports the design, modeling, and experiments of a novel retinal surgery robot based on spatial variable remote center-of-motion (RCM) mechanism. The general design criteria for parallel mechanisms are proposed, and the planar five-bar mechanisms are evaluated and selected. The planar-spatial evolution process, including the parallel connection of the planar mechanism and the equivalent substitution of joints, is adopted to develop a spatial variable RCM mechanism and then the robot. The mobility and singularity of the robot are analyzed, and the forward/inverse kinematics and workspace are modeled. Dimension optimization is conducted based on a comprehensive performance indicator that characterizes the motion range of linear actuators and the global dexterity performance index of robot. The prototyped robot is fabricated and assembled, and the kinematic calibration is performed. The position error of end-effector is within 34 μm, and both the position error and deviation of the RCM point are within 23 μm. The robot is demonstrated to reach the desired position and execute the RCM motion with high precision simultaneously.

Formation of interfaces responsive and adaptive to environment via the sol-gel method

Smart devices, such as soft robots, artificial organs, and soft actuators, require materials that adapt their morphologies and properties in response to their environment. These materials can be obtained through the composition of different types of materials that exhibit different responses to environmental stimuli, arranged in a rational spatial configuration. We achieved unique responsive materials by forming interfaces and surfaces of appropriate materials using the sol–gel method. In recent decades, we have proposed the use of wrinkles and nano-brushes on sol–gel-derived materials for various sophisticated applications, such as micropattern fabrication, wettability control, and linear actuators for size-selective transportation. This account introduces environment-responsive materials with rational interfaces via the sol–gel method, particularly those characterized by surface morphology.Graphical Materials with unique environmental responsiveness such as micropattern fabrication, wettability control, and linear actuating can be achieved by forming interfaces and surfaces using the sol–gel method.

A novel linear piezoelectric inchworm actuator based on a ratchet mechanism

Abstract A new working principle of inchworm actuator, which converts vibrations of a single piezo actuator into unidirectional step movement of a mover via a ratchet mechanism, was proposed. The proposed working principle has the following priorities: (1) it requires only one piezoelectric actuator which greatly simplifies its driving signals and driving circuits; (2) it can achieve a large driving speed with little compromise of a large force output while maintaining a high positioning precision of piezoelectric actuator and a theoretically unlimited motion range, although it can only achieve unidirectional movement with unidirectional self-locking capability; (3) it could be open-loop controlled with no accumulated step errors. The proposed actuator was designed with compliant mechanism and an analytical model of the design was developed, validated by finite element simulations carried out in Commercial Software ANSYS and used to guide the selection of design parameters. A prototype was fabricated and tested. Experiments show that the proposed actuator achieved a speed larger than 12 mm s−1, a driving load larger than 60 N in the moving direction, a reliable open-loop controllability with no step accumulated errors even under driving load variations of 60 N, and a working range larger than 1 mm with a high positioning precision around 320 nm under closed-loop control, which validated the superiorities of the proposed actuator.

On-load magnetic field calculation for linear permanent-magnet actuators using hybrid 2-D finite-element method and Maxwell–Fourier analysis

PurposeThe purpose of this study is to present a novel extended hybrid analytical method (HAM) that leverages a two-dimensional (2-D) coupling between the semi-analytical Maxwell–Fourier analysis and the finite element method (FEM) in Cartesian coordinates.Design/methodology/approachThe proposed model is applied to flat permanent-magnet linear electrical machines with rotor-dual. The magnetic field solution across the entire machine is established by coupling an exact analytical model (AM), designed for regions with relative magnetic permeability equal to unity, with a FEM in ferromagnetic regions. The coupling between AM and FEM occurs bidirectionally (x, y) along the edges separating teeth regions and their adjacent regions through applied boundary conditions.FindingsThe developed HAM yields accurate results concerning the magnetic flux density distribution, cogging force and induced voltage under various operating conditions, including magnetic or geometric parameters. A comparison with hybrid finite-difference and hybrid reluctance network methods demonstrates very satisfactory agreement with 2-D FEM.Originality/valueThe original contribution of this paper lies in establishing a direct coupling between the semi-analytical Maxwell–Fourier analysis and the FEM, particularly at the interface between adjacent regions with differing magnetic parameters.

Reversible Electrochemical Swelling of Straight Carbon Nanotube Yarns for High-Performance Linear Actuation.

Coiled artificial muscle yarns outperform their straight counterparts in contractile strokes. However, challenges persist in the fabrication complexity and the susceptibility of the coiled yarns to becoming stuck by surrounding objects during contraction and recovery. Additionally, torsional stability remains a concern. In this study, it is reported that straight carbon nanotube (CNT) yarns when driven by a low-voltage electrochemical approach, can achieve a contractile stroke that surpasses even NiTi shape memory alloy fibers. The key lies in the suitable match between a yarn consisting of randomly aligned CNTs and the reversible and substantial electrochemical swelling induced by solvated ions. Wrinkled structures are formed on the surface of the CNT yarn to adapt to the swelling process. This not only assures torsional stability but also enhances the surface area for improved electrode-electrolyte interaction during electrochemical actuation. Remarkably, the CNT artificial muscle yarn generates a contractile stroke of 8.8% and an isometric stress of 7.5 MPa under 2.5 V actuation voltages, demonstrating its potential for applications requiring low energy consumption while maintaining high operational efficiency. This study highlights the crucial impact of CNT orientation on the effectiveness of electrochemically-driven artificial muscles, signaling new possibilities in smart material and biomechanical system development.

Conversion of a Coaxial Rotorcraft to a UAV—Lessons Learned

A coaxial helicopter with a maximum take-off weight of 600 kg was converted to an unmanned aerial vehicle. A minimally invasive robotic actuator system was developed, which can be retrofitted onto the copilot seat of the rotorcraft in a short period of time to enable automatic flight. The automatic flight control robot includes electromechanical actuators, which are connected to the cockpit inceptors and control the helicopter. Most of the sensors and avionic components were integrated into the modular robotic system for faster integration into the rotorcraft. The mechanical design of the control system, the development of the robot control software, and the control system architecture are described in this paper. Furthermore, the multi-body simulation of the robotic system and the estimation of the linear low-order actuator models from hover-frame flight test data are discussed. The developed technologies in this study are not specific to a coaxial helicopter and can be applied to the conversion of any crewed flight vehicle with mechanical controls to unmanned or fly-by-wire. This agile development of a full-size flying test-bed can accelerate the testing of advanced flight control laws, as well as advanced air mobility-related functions.

Linear Actuators Based on Polyvinyl Alcohol/Lithium Chloride Hydrogels Activated by Low AC Voltage

Linear Actuators Based on Polyvinyl Alcohol/Lithium Chloride Hydrogels Activated by Low AC Voltage

Hand Teleoperation with Combined Kinaesthetic and Tactile Feedback: A Full Upper Limb Exoskeleton Interface Enhanced by Tactile Linear Actuators

Hand Teleoperation with Combined Kinaesthetic and Tactile Feedback: A Full Upper Limb Exoskeleton Interface Enhanced by Tactile Linear Actuators