Actuators and Sensors Combine Forces in Test and Measurement
An actuator is a device that converts energy into mechanical movement or force. An actuator is responsible for moving and controlling a mechanism or system. It is helpful in systems by generating motion or regulating physical processes. The actuator acts as the driving element, enabling linear and rotary motion, exerting force, and managing various operations.
A load cell, positioned externally or integrated within an actuator, measures force. Additionally, actuators equipped with torque transducers assist in controlling torque during tests such as rotational fatigue or material torsion, ensuring accurate monitoring and adjustment throughout the testing process.
With its precise control over force or motion, the actuator works in tandem with the load cell or torque transducer, which accurately measures the applied mechanical quantity. This interaction ensures the most accurate data collection and analysis in various test and measurement use cases, instilling confidence in the results.
How Actuators are Used in Test and Measurement
In test and measurement, actuators play a pivotal role in simulating real-world conditions, making it possible to apply exact forces or movements to objects under test. This practical application enables engineers and researchers to evaluate different components and systems’ performance, reliability, and durability. Some standard test and measurement uses include:
Material Testing: Actuators apply controlled forces or displacements to materials, enabling the measurement of their mechanical properties, such as strength, stiffness, and fatigue resistance.
Cycle Testing: Actuators input data into a control loop, and the actuator allows you to accurately control how much force you put on a test article. These tests are designed to push the limits on the product so engineers and manufacturers can confirm their designs and ensure safety and durability.
Component Testing: Actuators can simulate the operational loads and stresses experienced by components in their intended applications, allowing engineers to identify potential failure points and optimize their designs.
Environmental Testing: Actuators can simulate vibrations, shocks, and other environmental conditions to evaluate the performance of products in harsh or extreme environments.
Automation: Actuators in automated test systems are instrumental in performing repetitive tasks, significantly improving efficiency and reducing the risk of human error.
Examples of Actuators Using Interface Sensors
Actuators are small components that convert energy into a linear moment. There are various types of actuators, including linear, rotary, hydraulic, pneumatic, and more. Each is designed to create force in different directions and on different axes.
Linear actuators using load cells will apply precise tension or compressive loads to evaluate the strength of materials or components. The load cells are typically placed in series with the linear actuator’s output shaft or integrated into its structure. The load cell measures the force the actuator exerts as it pushes or pulls.
Rotary actuators using torque transducers apply controlled torque to assess the rotational performance of motors, gears, or other rotating components. The transducer is coupled inline between the rotary actuator and the object, and the torque applied is measured. A rotary torque transducer is essential in preventing over-torquing that could damage the actuator or the test subject.
Hydraulic actuators using load cells monitor the hydraulic pressure within the actuator system, which is directly related to the force generated. Pressure control is critical for accurate and safe operation.
Hydraulic Actuator Test Frame Use Case: An Interface customer must monitor the forces applied to their electrohydraulic actuators and conduct a quality test. Their actuators are usually in constrained environments since they are suited for high-force applications, such as hydraulic actuators installed on naval vessels. Interface suggests conducting a quality test using their 1200 High Capacity Standard Precision LowProfile™ Load Cell. The 1200 is installed in the test frame, where the electro-hydraulic cylinder’s rod moves up and down when connected to a motor. The 1200 load cell measures the actuator’s forces in the load frame. Precise force results are captured using the 9840 Calibration Grade Multi-Channel Load Cell Indicator.
Pneumatic actuators help monitor and control the pneumatic pressure, which dictates the force and speed of the actuator. They are essential in robotics and factory automation, mainly in applications such as motor controls.
Pneumatic Actuator Seal Pressure Use Case: A company wants to ensure the pneumatic actuator’s lip seal holds under different pressure loads. Interface suggests conducting a fatigue test using their 1200 Standard Precision LowProfile™ Load Cell. The 1200 is installed externally of the pneumatic actuator, where different pressure loads are measured. The test is conducted until the pneumatic actuator is dismantled. Precise force results are captured using the 9840 Calibration Grade Multi-Channel Load Cell Indicator. Read the use case.
Additional Actuator Applications Across Industries
Actuators equipped with sensors provide the crucial data necessary for feedback control, performance optimization, and safety assurance. They are useful in engineering, test labs, and process controls.
Tensile Testing Machine
A linear actuator applies a controlled tensile force to a material sample until it breaks. Aligning the load cell with the sample accurately measures the applied force throughout the test. This setup determines material properties such as tensile strength, yield strength, and elongation.
Torque Wrench Calibration
A rotary actuator applies a known torque to a torque wrench. A torque transducer is placed between the actuator and the wrench to measure the applied torque precisely. This setup calibrates torque wrenches, ensuring they provide accurate torque readings during use.
Automotive Testing
A hydraulic or electric actuator simulates real-world loads and stresses on automotive components like suspension systems, steering components, or engine mounts. Load cells measure the forces acting on the element, while torque transducers measure the applied rotational forces (torque). This setup helps evaluate automotive components’ performance, durability, and safety under various operating conditions. For instance, load cells measure forces acting on suspension components during testing, aiding design validation and performance optimization. Torque transducers monitor torque applied to engine components, ensuring proper functionality and preventing failures.
Manufacturing Process Control
Robotic arms equipped with actuators precisely position components during assembly. Conveyor belts utilize actuators for controlled material movement. Load cells integrated into robotic grippers ensure optimal gripping force, preventing damage to delicate components. Torque transducers monitor forces exerted by machinery to ensure efficient operation and prevent overloads.
Healthcare Equipment Testing and Monitoring
Linear actuators precisely position surgical robots, enabling minimally invasive procedures with enhanced accuracy. Load cells monitor forces applied by surgical robots, preventing excessive pressure on delicate tissues. Multi-axis sensors track the position and orientation of patient beds, ensuring precise adjustments for various medical needs. Additionally, actuators are used in patient lifts, hospital beds, and other medical equipment to provide accurate and controlled movements.
Construction Equipment Monitoring
Linear actuators control crane booms, enabling precise positioning of heavy loads. Load cells monitor forces exerted by construction equipment, preventing overloads and ensuring safe operation. Torque transducers measure rotational forces in crane mechanisms, providing stability and preventing accidents.
Actuators are essential tools in test and measurement. They allow for the simulation of real-world conditions and the application of precise forces and movements, leading to more accurate and reliable testing results. Interface provides force and torque measurement solutions for actuators, driving innovation and efficiency across numerous sectors.
