linear actuator

52 Articles

Carbon Fiber And Kevlar Make This Linear Actuator Fast And Strong

May 3, 2023 by 9 Comments

When it comes to the “build versus buy” question, “buy” almost always wins. The amount of time you have to put into building something is rarely justified, especially with a world of options available at the click of a mouse.

That’s not always the case, of course. These custom-made linear actuators are a perfect example of when building your own wins. For a planned ball-juggling robot, [Harrison Low] found himself in need of linear actuators with long throw distance, high speed, and stiff construction. Nothing commercially available checked all the boxes, so he set out to design his own.

A few design iterations later, [Harrison] arrived at the actuators you see in the video below. Built mainly from carbon fiber tubing and 3D-printed parts, the actuators have about 30 centimeters of throw, and thanks to their cable-drive design, they’re pretty fast — much faster than his earlier lead screw designs. The stiffness of the actuator comes by way of six bearings to guide the arm, arranged in two tiers of three, each offset by 60 degrees. Along with some clever eccentric spacers to fine-tune positioning, this design provides six points of contact that really lock the tube into place.

The cable drive system [Harrison] used is pretty neat too. A Kevlar kite string is attached to each end of the central tube and then through PTFE tubes to a pulley on an ODrive BLDC, which extends and retracts the actuator. It’s a clever design in that it keeps the weight of the motor away from the actuator, but it does have its problems, as [Harrison] admits. Still, the actuator works great, and it looks pretty cool while doing it. CAD and code are available if you want to roll your own.

These actuators are cool enough, but the real treat here will be the ball juggler [Harrison] is building. We’ve seen a few of those before, but this one looks like it’s going to be mighty impressive.

Continue reading “Carbon Fiber And Kevlar Make This Linear Actuator Fast And Strong” →

A Fast Linear Actuator Entirely In One PCB

August 10, 2022 by 18 Comments

There are many ways to make a linear actuator, a device for moving something is a straight line. Most of the easier to make ones use a conventional motor and a mechanical linkage such as a rack and pinion or a lead screw, but [Ben Wang] has gone for something far more elegant. His linear actuator uses a linear motor, a linear array of coils for the motor phases, working against a line of magnets. Even better than that, he’s managed to make the whole motor out of a single PCB. And it’s fast!

This represents something of an engineering challenge, because achieving the required magnetic field from the relatively few turns possible on a PCB is no easy task. He’s done it by using a four-layer board to gather enough turns for the required magnetic field, and a simple view of the board doesn’t quite convey what lies beneath.

PCB motors are perhaps one of those areas where the state of the art is still evolving, and the exciting part is that their limits are being pushed right there in our community. And this isn’t the only linear motor we’ve seen recently either, here’s one used in a model train.

Pikul Servo Powered Falling Dominoes Pushing a Cube

Domino Row Goes With The Flow

May 30, 2022 by 1 Comment

Around here, we’re always excited about a new actuator design. Linear actuators are particularly hard to make cheap, fast, and good, so it’s even better when something new that we can build ourselves slides onto the scene.

Researchers at U Penn’s Pikul Research Group took inspiration from the cascade of falling dominoes for an innovative take on linear motion. This article on IEEE Spectrum describes the similarity of the sequential tipping-over with the peristaltic motion of biological systems, including you, swallowing right now.

The motion propagation in falling dominoes, called a Soliton Wave, can be harnessed to push an object at the front of the wave, just like a surfer. See the videos after the break for examples of simple setups that any of us could recreate with laser-cut or 3D printed parts. Maybe you won’t be using them to help a robot swallow (a terrifying idea that the article suggests), but you might need a conveyor or a novel way to help a device crawl like a shrimp. The paper is behind a paywall on IEEE, though you readers likely see enough in the videos to get started, and we can’t wait to see where your dominoes will lead us next.

 

Sisyphean Ball Race Robot Toils Gracefully, Magnetically

May 20, 2022 by 5 Comments

Aren’t ball races and marble runs fun? Wouldn’t they be so much more enjoyable if you didn’t have to climb back up the ladder each time, as it were, and reset the thing? [Johannes] wrote in to tell us about a wee robot with the Sisyphean task of setting a ball bearing on a simple but fun course, collecting it from the end, and airlifting it back to the start of the track.

[Johannes] built this ‘bot to test small-scale resin printing strength as well as the longevity of some tiny linear actuators from Ali that may or may not be available at a moment’s notice. The point was to see how these little guys fared when connected directly to an Arduino or other microcontroller, rather than going the safer route with a motor driver of some kind.

Some things worked well, like the c-clips that keep the axles together, and using quick pulses to release the magnetically-linked ball from the gripper. Other aspects didn’t work out so well. Tiny resin parts do not respond well to force, for starters. And then there’s the actuators themselves. The connections are fragile and the motors are weak, but they vary wildly in quality from piece to piece, so YMMV. Some lose steps, and others occasionally seize. But you wouldn’t know any of that from the graceful movement capture in the video below. Although it appears to be automated, the bot is under remote control because of the motor issues.

Not into ball runs? There are other Sisyphean tasks available, such as moving sand around in the name of meditation.

Continue reading “Sisyphean Ball Race Robot Toils Gracefully, Magnetically” →

3D Printed Linear Actuator Is Cheap And Strong

May 18, 2022 by 29 Comments

Motors are all well and good for moving things, but they’re all about the round-and-round. Sometimes, you need to move something back and forth, and for that a linear actuator will do the trick. While they can be readily sourced for under $50 online, [Michael Rechtin] genuinely felt like reinventing the wheel, and managed to whip up a 3D-printed design that costs under 20 bucks.

The basic design is simple, consisting of a small motor which is geared down through several stages using simple spur gears. The last gear in the train is tasked with turning a lead screw which drives the arm of the linear actuator back and forward.

For simplicity, [Michael] used a 24V brushed DC gearmotor for its low cost and the fact it already has a step-down gearbox integrated into the design. It’s paired with a couple more 3D-printed spur gears to provide even more torque. Instead of a fancy lead screw, the build instead just uses a quarter-inch bolt sourced from Home Depot, which can be had much cheaper. This pushes a 3D-printed arm back and forth thanks to a nut stuck in the arm. It’s all wrapped up in a neat-and-tidy 3D-printed housing. The design is able to push with a force of roughly 220 lbs. For a more practical idea of its strength, it can readily crush an empty soda can.

The video on the design is great, showing how important features like limit switches are added, and how the wiring can be neatly hidden away inside the housing. We’ve seen [Michael’s] work before, too, like strength testing various types of 3D printed gears. Video after the break.

Continue reading “3D Printed Linear Actuator Is Cheap And Strong” →

The end result - motorized window in a silver stainless steel frame, with the linear actuators and gas struts, shown from the outside half-open.

Swing Gate Motors Come To Help For Opening A Giant Servery Window

April 11, 2022 by 34 Comments

[Martin Roberts] wrote to us, telling us about a build that his company, [Ocean View Workshop], was tasked with. Creating a four meter wide window able to open vertically is no small feat, and it had to be custom-built because the local company building such windows wasn’t comfortable working with anything other than aluminum — insufficient for the window’s scale. With massive weight of the glass alone, structural requirements for supporting it, and the mechanical loads to be applied, some careful planning was in order.

To start with, this window had to be motorized, as an average person wouldn’t be capable of pulling it upwards. Not satisfied with the linear actuator choice available, they went to a hardware store and found some swing gate actuators that, in workshop tests, proved themselves to be more than capable of handling way over the weight required. In fact, they were capable of lifting [Martin] himself off the ground without much hassle.

Continue reading “Swing Gate Motors Come To Help For Opening A Giant Servery Window” →

Building A High-Capacity Linear Servo Actuator

February 17, 2022 by 19 Comments

Linear actuators are useful things, moving things in straight lines rather than annoying circles like so many motors. [Retsetman] recently built a linear servo actuator of his own design with accurate positional control.

The design relies on a carriage that moves along a threaded rod, perhaps the most rudimentary design of linear actuator. A large brushed DC motor is used to turn the threaded rod through a 3D-printed 9:1 herringbone geartrain, shifting the actuator back and forth. End stop switches are used to disengage the motor to avoid damage to the mechanism. Feedback is via a ten-turn potentiometer driven off the output geartrain to match the range of the actuator to the rotational range of the pot.

The final build has a stroke of approximately 100 mm, and can lift and hold a 15 kg weight with ease. In a pull test, the actuator failed at a load just shy of 100 kg. If you’re looking for something smaller, though, you can try building a linear actuator out of old DVD drive parts instead. Video after the break.

Continue reading “Building A High-Capacity Linear Servo Actuator” →