Synthesis of mechanisms

Freudensteins equation:
This equation is used to compute the length of links of a four bar mechanism.
The equation can be written as
1 4 2 2 3 2 4
cos cos cos( ......( K K K i + =
2 2 2 2
1 2 3
... ! .. ..
2
d d a b c d
where K K and K
a c ac
+ +
= = =
where a!b!c!d are lengths of links of the four bar mechanism with "
2
and "
4
as the input
and output link angles.
The equation (i can be written as for three pairs of #alues ("
21
! "
41
! ("
22
! "
42
and ("
23
!
"
43
as$
1 41 2 21 3 21 41
cos cos cos( ......( K K K ii + =
1 42 2 22 3 22 42
cos cos cos( ......( K K K iii + =
1 43 2 23 3 23 43
cos cos cos( ......( K K K iv + =
Subtracting equation (iii and (i# from (ii! we get
1 41 42 2 21 22 21 41 22 42
(cos cos (cos cos (cos cos (cos cos K K =

1 41 43 2 21 23 21 41 23 43
(cos cos (cos cos (cos cos (cos cos K K =
Sol#ing these two equations for %
1
and %
2
! we get
1 & 2 2
1
1 & ' 2
. .
. .
z x z x
K
x x x x

1 ' 2 1
2
& 1 2 '
. .
. .
z x z x
K
x x x x

(here

1 21 41 22 42
cos( cos( z =

2 21 41 23 43
cos( cos( z =

1 41 42
(cos cos x =

2 21 22
(cos cos x =

' 41 43
(cos cos x =

& 21 23
(cos cos x =
Substituting the #alues of %
1
and %
2
in equation (ii! we get the #alue of %
3.
)*ample$ + four bar mechanism is required such that the input and out angles are
coordinated as gi#en in the table.
Synthesi,e the 4-bar mechanism$
.nput crank angle ("
2
3/
/
'/
/
0/
/
1utput follower angle ("
4
/
/
3/
/
&/
/
Solution$
The displacement equation gi#en by 2reudenstein is written as$
1 4 2 2 3 2 4
cos cos cos( K K K + =
Substituting the #alues of input ("
2
and ("
4
in abo#e equation! we get
/
/ / /
1 2 3
cos / cos3/ cos(3/ / ........( K K K i + =
1 2 3
/.0&& /.0&& K K K + =
/
/ / /
1 2 3
cos3/ cos'/ cos('/ 3/ ........( K K K ii + =
/ /
1 2 3
/.0&& cos'/ cos 2/ K K K + =
/
/ / /
1 2 3
cos &/ cos0/ cos(0/ &/ ........( K K K iii + =
/ /
1 2 3
/.' cos0/ cos(2/ K K K + =
Sol#ing equation (i! (ii and (iii! %
1
31.0321! %
2
31.4244! %
3
3/.2510
+ssuming the length of one link as unity i.e. a 3 1
(e know that
1
1
6
. 1 1.0321 1.0321
K d a
d a K x
=
= = =
2
2
1.0321
6 1.2015
1.4244
d
K d c c
k
= = = =
2 2 2 2
3
2
a b c d
K
ac
+ +
=
2 2 2
3
2 b acK a c d = + + +
2 2 2
27171.20157/.2510 1 (1.2015 (1.0321 = + + +
b3 2.3/34
The length of #arious links are$
a 3 1./
b3 2.3/34
c3 1.2015
d 3 1.0321
Function generation:
.n function generation! the motion of input link is correlated to motion of output link.
2igure shows a four bar mechanism
The input link +8 rotates through an angle "
2
and represents independent #ariable *.
The output link 9: rotates through angle "
4
and indicates independent #ariable y
.
;ere! < is dependent on *.
=et us assume
>
1
and >
2
are initial and final positions of independent #ariable >.
<
1
and <
2
are initial and final positions of dependent #ariable <.
There is linear relationship between "
2
and >
There is linear relationship between "
4
and <
?athematically!

2 2
1
2 1
tan
f i
r cons t
x x

= =

and
4 4
2
2 1
tan
f i
r cons t
y y

= =

where
"
2f
and "
2i
3 final and initial angular positions of input link
"
4f
and "
4i
3 final and initial angular positions of output link
The constants r
1
and r
2
are called scale factors.
.f link ratios are known i.e. a6b! a6c! a6d. ! the mechanism can be designed.
Precision points and structural error
=et us draw a graph between input #ariables and output #ariables as shown in figure$
2igure 4.11
The motion of input is represented by >
/
! >
/
! >
/
@@..>
n
! >
nA1
The motion of input is represented by <
/
! <
/
! <
/
@@..<
n
! <
nA1
:esired function and generated function meet at certain points. These are called
precision points.
The difference between generated function and desire function is called structural
error.
Chebyshev spacing of precision points
9hebyshe# spacing of precision points is useful to minimi,e the structural error.
2or n points in range
/ 1 n
x x x
+

! the precision points *
B
according to chebyshe#
spacing are gi#en as$

cos .
j j
x a b =
where

( )
/ 1
1 /
1
(
2
2 1
2
1
2
1! 2! 3!......!
n
j
n
a x x
j
n
b x x
j n

+
+
= +

=


=
=
)*ample$ Synthesi,e a four bar linkage using 2reudensteinCs equation to generate the
function < 3 >
1.'
for the inter#al 1 4 x . The input crank is to start form "
2
33/
/
and is
to ha#e range of 4/
/
. Take three accuracy points. Take output crank angle from / to 4/
/
.
Solution$
Step1$ 2ind out three accuracy points(n33$
cos .
j j
x a b =
where
/ 1
1 1
( (1 4 2.'
2 2
n
a x x
+
= + = + = ;ere >
/
31 and >
nA1
3 4 (Di#en
( ) ( )
1 /
1 1
4 1 1.'
2 2
n
b x x
+
= = =
1
1
2 1 271 1 1
2 273 &
j
j
j
n

=

= = =


2
2
2 1 272 1 3
2 273 &
j
j
j
n

=

= = =


3
3
2 1 273 1 '
2 273 &
j
j
j
n

=

= = =


Eut the #alue of a! b! "
B
in abo#e equation
1 1
1
cos . 2.' 1.'cos 7 1.2/
&
x a b = = =
2 2
3
cos . 2.' 1.'cos 7 2.'
&
x a b = = =
3 3
'
cos . 2.' 1.'cos 7 3.544
&
x a b = = =
>
S
31
1.' 1.'
(1 y x = =
<
S
31 "
2s
3 3/
/
"
4s
3 /
/
>
1
31.2/
1.'
(1.2/ =
<
1
31.314 "
21
3 3&
/
"
41
3 4./3
/

>
2
3 2.'
1.'
(2.' =
<
2
3 3.4'3 "
22
3F "
42
3F
>
3
33.544
1.'
(3.544 =
<
3
35.4/4 "
23
3F "
43
3F
>
f
3 4
1.'
(4 =
<
f
3 0 "
2f
312/
/
(Di#en "
4f
34/
/
(Di#en
G>34-133 ----- G<30-135 G"
2
34/
/
(Di#en G"
4
3 4/
/
(Di#en
=et the input crank angles corresponding to three accuracy points >
1
! >
2
and >
3
be "
21
!
"
22
! "23 respecti#ely. =et corresponding output crank angles be "
41
! "
42
! and "
43.

(e know that

2 2
2
.......(
s s
x x
i
x

=

and
4 4
4
..........(
s s
y y
ii
y

=

2rom equation (i and (ii
/
/ 21 2 1 21
21
/
2
3/ 1.2 1
3&
3 4/
s s
x x
x

= = =

/
/ 41 4 1 41
41
/
4
/ 1.314 1
4./3
5 4/
s s
y y
y

= = =


/
/ 22 21 2 1 22
22
/
2
3& 2.' 1.2
5'
3 4/
x x
x

= = =


/
/ 42 41 2 1 42
42
/
4
4./3 3.4'3 1.314
35.4&
5 4/
y y
y

= = =


/
/ 23 21 3 1 23
23
/
2
3& 3.544 1.2
113.45
3 4/
x x
x

= = =


/
/ 43 41 3 1 43
43
/
4
4./3 5.4/4 1.314
02.3
5 4/
y y
y

= = =

"
2s
3 3/
/
"
4s
3 /
/

"
21
3 3&
/
"
41
3 4./3
/

"
22
35'
/
"
42
335.4&
/
"
23
3113.45
/
"
43
302.33
/
"
2f
3 12/
/
"
4f
3 4/
/

The displacement equation gi#en by 2reudenstein is written as$
1 4 2 2 3 2 4
cos cos cos( K K K + =
(hen "
2
33&
/
and "
4
3 4./3
/
Substituting the #alues of input ("
2
and ("
4
in abo#e equation! we get
/
/ / /
1 2 3
cos 4./3 cos3& cos(3& 4./3 K K K + =
1 2 3
/.445 /.0/4 /.'1'........( K K K i + =
(hen "
2
35'
/
and "
4
3 35.4&
/
/
/ / /
1 2 3
cos35.4& cos 5' cos(5' 35.4& K K K + =
1 2 3
/.500 /.2'0 /.540........( K K K ii + =
(hen "
2
3113.45
/
and "
4
3 02.3
/
/
/ / /
1 2 3
cos02.33 cos113.45 cos(113.45 02.33 K K K + =
1 2 3
/.133 /.4/& /.0'1........( K K K iii + =
Sol#ing the abo#e equations
%
1
3 /./04&
%
2
3 /.1254
%
3
3 /.52&'
=et us assume d 3 1./
1
1
1./
11.1&
/./04&
11.1&
d
d
K a
K
a
a
= = = =
=
2
2
1./
5.02
/.1254
5.02
d
d
K c
c
K
c
= = = =
=
2 2 2 2
3
2
a b c d
K
ac
+ +
=
2 2 2
3
2 5.5& b acK a c d = + + + =
Thus!
a3 11.1&! b3 5.5&! c3 5.02! d31./
)*ample 2$ + four bar function generator is used to generate the function < 3 (16> for
1 3 x between the input angle of a crank and angle of follower makes with the frame.
2ind the three precision points from 9hebyshe#Cs spacing if the initial #alue of input i.e.
crank angle and output i.e. the follower angle are 3/
/
and 2//
/
respecti#ely. The
difference between the final and initial #alues of the crank and follower angles are each
equal to 4/
/
.
Solution$ Di#en$ >
/
3 1! >
nA1
33! n33(Three precision points
Step1$ 2ind out three accuracy points$
cos .
j j
x a b =
where
/ 1
1 1
( (1 3 2
2 2
n
a x x
+
= + = + = ;ere >
/
31 and >
nA1
3 3 (Di#en
( ) ( )
1 /
1 1
3 1 1./
2 2
n
b x x
+
= = =
1
1
2 1 271 1 1
2 273 &
j
j
j
n

=

= = =


2
2
2 1 272 1 3
2 273 &
j
j
j
n

=

= = =


3
3
2 1 273 1 '
2 273 &
j
j
j
n

=

= = =


Eut the #alue of a! b! "
B
in abo#e equation
/
/
1 1
1 10/
cos . 2 1cos 7 2 1.cos 2 cos3/ 1.134
& &
x a b = = = = =
2 2
3
cos . 2 1.cos 7 2./
&
x a b = = =
3 3
'
cos . 2 1.cos 2.0&&
&
x a b

= = =
=et the input crank angles corresponding to three accuracy points >
1
! >
2
and >
3
be "
21
!
"
22
! "23 respecti#ely. =et corresponding output crank angles be "
41
! "
42
! and "
43.

(e know that

2 2
2
.......(
s s
x x
i
x

=

and
4 4
4
..........(
s s
y y
ii
y

=

2rom equation (i and (ii
/
/ 21 2 1 21
21
/
2
3/ 1.134 1./
3&./3
2 4/
s s
x x
x

= = =

/
/ 41 4 1 41
41
/
4
2// /.001 1
103.42
/.&&& 4/
s s
y y
y

= = =


/
/ 22 21 2 1 22
22
/
2
3&./3 2./ 1.134
5'
2 4/
x x
x

= = =


/
/ 42 41 2 1 42
42
/
4
103.42 /.'/ /.001
132.30
/.&&& 4/
y y
y

= = =


/
/ 23 21 3 1 23
23
/
2
3&./3 2.0&& 1.134
113.45
2 4/
x x
x

= = =

>
S
31 (16 (161 y x = = <
S
31 "
2s
3 3/
/
"
4s
32//
/
>
1
31.134 3161.134 <
1
3/./001 "
21
3 F "
41
3 F
>
2
3 2./ 3162./ <
2
3 /.' "
22
3F "
42
3F
>
3
32.0&& 3162.0&& <
3
3/.344 "
23
3F "
43
3F
>
f
3 3 3163 <
f
3 /.333 "
2f
312/
/
(Di#en "
4f
311/
/
(Di#en
G>33-
132./
---- G<3/.333-13
- /.&&&
G"
2
34/
/
(Di#en G"
4
3 4/
/
(Di#en
<
s
is reducing so angle "
4
will also reduce

/
/ 43 41 3 1 43
43
/
4
103.42 /.344 /.001
112./1
/.&&& 4/
y y
y

= = =

"
2s
3 3/
/
"
4s
3 2//
/

"
21
3 3&./3
/
"
41
3 103.42
/

"
22
35'
/
"
42
3132.30
/
"
23
3113.45
/
"
43
3112./1
/
"
2f
312/
/
"
43
311/
/
The displacement equation gi#en by 2reudenstein is written as$
1 4 2 2 3 2 4
cos cos cos( K K K + =
(hen "
2
33&./3
/
and "
4
3 103.42
/
Substituting the #alues of input ("
2
and ("
4
in abo#e equation! we get
/
/ / /
1 2 3
cos103.42 cos3&./3 cos(3&./3 103.42 ....( K K K i + =
(hen "
2
35'
/
and "
4
3 132.30
/
/
/ / /
1 2 3
cos132.30 cos 5' cos(5' 132.30 .....( K K K ii + =
(hen "
2
3113.45
/
and "
4
3 112./1
/
/
/ / /
1 2 3
cos112./1 cos113.45 cos(113.45 112./1 ...( K K K iii + =
Sol#ing the abo#e equations
%
1
3 '.351
%
2
3 -13.'
%
3
3 0.252
=et us assume d 3 1./
1
1
1./
/.10&
'.351
/.10&
d
d
K a
K
a
a
= = = =
=
2
2
1./
/./54
13.'
/./54
d
d
K c
c
K
c
= = = =

=
(Hegati#e sign indicates that the direction of 9 has re#ersed itself.
2 2 2 2
3
2
a b c d
K
ac
+ +
=
2 2 2
3
2 1./33 b acK a c d = + + + =
Thus!
a3 /.10&! b3 1./33! c3 -/./54! d31./