High Powerful Linear Actuator

This is a new version of my linear actuator series. This version can hold much power than previous ones. But first, let's start with a brief introduction to what a linear actuator is.

A linear actuator is a mechanical device that converts energy (typically electrical, hydraulic, or pneumatic) into linear motion. It's used in a wide variety of applications to move or control a mechanism or system, such as in robotics, industrial machinery, and consumer electronics.

The basic principle of a linear actuator is relatively straightforward: it uses some form of energy to produce a straight-line movement, which is different from the rotational motion produced by conventional motors. Here are the main types of linear actuators:

1. Electric Linear Actuators: These are powered by electric motors and are known for their precision and control. They are commonly used in applications where accurate positioning is crucial.
2. Hydraulic Linear Actuators: These use hydraulic fluid pressure to create motion and are often found in heavy-duty applications, such as construction equipment and manufacturing machinery, due to their ability to exert large forces.
3. Pneumatic Linear Actuators: These operate on compressed air and are typically used in applications requiring quick, repetitive movements.
4. Mechanical Linear Actuators: These convert rotary motion into linear motion using mechanical components like screws or gears.

Here I am going to make Mechanical linear actuator.

enjoy!

Supplies

Items that we need

1. TT gear motor *2
2. M6 Thread bar *2 ( length of thread bar : 17cm)
3. Aluminum tube ( length : 19.5cm , Outer diameter : 9.3mm)
4. 3mm Acrylic or Plastic tapes * 2 (195mm * 30mm)
5. some wires
6. M6 nut *2

Tools that we need

• Hot glue gun
• Mini grinder
• soldering iron
• 3D printer
• super glue
• Drill
• Digital vernier caliper

3D printed parts

You will also need to 3D print a few parts for this project. You can print them by using PLA with 100% infill rate and 0.1/0.2mm layer height. ( make sure your 3D printer prints to the very correct dimensions.)

Step 1: Prepare the Power Source

1. Cut the excess part of TT gear motor.
2. Cut 3/4 of motor's one side output shaft. Do the same for the other one.
3. paste the both motors together using superglue keeping align them properly.

Step 2: Connect the Threaded Rods

1. Take an M6 threaded rod and cut it into 17-centimeter lengths.
2. Fix the PY4.1 3D printed part with the threaded rod and add superglue to ensure proper attachment.
3. Then fix the above part to the gear motor's outer shaft temporary (don't apply superglue)

Step 3: Fix the Aluminum Rod

1. Take an aluminum rod(Outer Dia.:9.3mm) and cut it into 19.5-centimeter lengths.
2. 3D print the PY4.2 part and fix the M6 nuts with it using superglue. After apply some heat and deform the both end as shown in the figure.
3. Make a 2mm hole at one end of the aluminum rod.
4. Then fix the aluminum rod with the 3D printed part inserting small metal rod through the whole.

Step 4: Prepare the Middle Part

1. First de-attach the threaded rod from the motors.
2. Then insert the both threaded rods to the PY4.2 part (make sure to insert a same length)
3. Now we need to fix above assembly with the motors.

For it, first rotate the motors' output shaft to the same direction. Then rotate the both PY4.1 part to the same direction. Then applying superglue to the PY4.1 holes and fix it with the motor assembly. Here make sure to keep PY4.2 part horizontally. You can refer this video part for proper understand : video

Step 5: Prepare the Top Part

1. 3D print the PY4.3 part.
2. Then insert the PY4.3 to the threaded rod assembly. (make sure to insert it so that the big side is towards the motors)
3. Cut 195mm by 30mm size two rectangles from the acrylic sheets or plastic sheets.
4. Using the cut sheets, connect the motor assemble with the PY4.3 part. (use any suitable gum for this process. here I used hot glue)

You can refer this video part for proper understand : video

Step 6: Fix the Bottom Supporter

1. 3D print the PY4.4 part.
2. Using proper glue type, fix it with the motor assembly's bottom side.

Step 7: Final Part_wire Connection

1. Then solder two wires to motors' terminals so that both motors rotate same direction.
2. Ok ! Our linear actuator is finished.
3. Here you can see the final demonstration : Video
4. If you want to know How much weight this can lift, watch this video part : Video
5. Watch the full video.

Thanks for reading this !

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PHYTION