New approach for optimum synthesis of six-bar dwell
mechanisms by adaptive curve fitting*
Huimin Dong
Dalian University of Technology
Dalian China
∗
Abstract—A new approach for optimum synthesis of six-bar
dwell mechanisms is presented in this paper. At first, a new
approach of adaptive segment curve fitting is presented in terms
of invariants of circle or line. Meanwhile, an approximate
segment circle point and an approximate segment slide point are
defined. Based on these definitions and the adaptive curve fitting
approache, the unified mathematical model is established for the
synthesis of circular-arc and straight-line dwell mechanisms.
Particularly, the non-dwell portion is also considered in the
approach. The co-operation of global searching and local
searching is adopted to satisfy the prospective accuracy.
Examples under various given conditions illustrated show that
the technique is simple, efficient and accurate.
Key words ： Six-bar dwell mechanism, Adaptive curve
fitting, Function generation
I. Introduction
Dwell mechanisms have applications in many industries,
especially for automation. Linkage-type dwell mechanisms
are less expensive to manufacture and maintain, and can be
superior to cams at high speed. Commonly used linkage-
type dwell mechanisms, as Fig.1 shows, are composed of a
basic four-bar mechanism that generates either the
circular-arc or straight-line portion of the coupler curve
and adding an output dyad with rocker output option or
slider output option to convert uniform motion of the input
link into periodic and intermittent motion of the output
link. However linkage-type dwell mechanisms only give
"approximate dwells". Since exact dwells are often not
necessary and are rarely obtained in practice due to
vibration, manufacturing errors and backlash, this makes
the use of approximate dwells acceptable. Several
researchers have made contribution to studying on linkage-
type dwell mechanisms in the past [1-12]. Sandgren[1] led
to an optimum method with constraint equations into a
class of six-bar linkages to produce single- and multiple-
dwell mechanisms, in which the objective function was the
length l5 of the link shown in fig.1b with invariable and the
optimal parameters were all dimensions in the mechanism.
For Stephenson’s six-bar inversion three with pin jointed,
Shimojima and Jizai [2] presented the conditions for
dwelling at edge points of rocking, the relationships
between the dwell periods and mechanisms parameters
∗
E-mail : donghm@dlut.edu.cn
E-mail : dlunwang@dlut.edu.cn
*Supported by National Natural Science Foundation of China under grant
No. 50475154
Delun Wang
Dalian University of Technology
Dalian China
were approximated by polynomials in the order of less
than five, and the existing domains of parameters. Both
methods mentioned [1, 2] have more optimal parameters.
With computer technique rapidly developing, the atlas
method based on path curvature theory was more
employed for designing linkage-type dwell mechanisms.
Kota et al. [3, 4] presented several "rules of thumb" based
on path curvature theory, which includs systematic
analysis and classification of straight-line, circular-arc and
symmetrical coupler curve generating mechanisms. Based
on those research, Kota et al.[5] developed MINN-
DWELL, transforming design experience into design
catalogues--preprogrammed building blocks for the
intelligent and efficient design of dwell linkages. And
more in 1991 Kota [6], taking Stirling Engines as an
example, presented the generic design models, as well as a
new concept in which single-input control the multiple-
dwell-output. Venkatesh[7] developed RECDWELL
helping to design both circular-arc and straight-line dwell
mechanisms which is simple, efficient and accurate.
Beier[8], according to the axiom, for any curve if
curvature center invariable the curvature radii is constant,
presented a method looking for circular-arc or straight-line
portion of the coupler curve, which reducing the design
time. Cao Qinglin et al[9] studied the atlas with
symmetrical path carefully, and applied their research to
design twice dwell mechanisms. Yu Hongying[10], using
the methods of “linear scanning “and “tangent envelop”,
separately synthesized the basic four-bar linkage and the
output dyad, set up four-bar linkages database with
circular-arc segment coupler curve, carried out synthesis of
six-bar dwell linkages with pin jointed. For improving the
design efficiency and reducing the randomicity of initial
selecting, several researchers have turned to study on the
method and system of the conceptual design in computer
aided design dwell mechanisms[11], [12]. All above
researches’ work pushed the development of six-bar dwell
mechanisms in different aspect.
Ref.[13] presented an adaptive curve fitting method for
four-bar planar mechanism synthesis based on the
theoretics of curvature, by means of searching a invariants
of curve, and established the unified mathematic model,
and solved such problems as selecting initial point,
capturing global optimal solution.
We modify the adaptive curve fitting method [13] in this
paper according to the structural characteristic of
Stephenson’s six-bar inversion three, and give the
definitions of an approximate segment circle point and an
approximate segment slide point. Based on these
definitions and the approach, establish the unified of basic four-bar linkages can be expressed as nonlinear
mathematical model for the synthesis of circular-arc and functions about input angle ϕ , whose properties depend on
straight-line dwell mechanisms. Particularly, consider the the position on the coupler plane.
non-dwell portion in the approach. Adopt the co-operation
of global searching and local searching to satisfy the E
prospective accuracy. Examples under various given
β C
conditions illustrate that the technique is simple, efficient le
and accurate. B γ
yf
E φ
E G E D
G of(A) xf
F l5 l6
C le
F C Fig.2 Coupler curve of planar four-bar linkage
l2
B B l3
l1

A l4 D III. The approach of adaptive segment curve fitting

A D
The first step of synthesis of dwell mechanisms with the
(a) type of Stephenson’s III six-bar is for searching coupler
point E in a basic four-bar linkage, which generates
approximate straight-line or circler-arc portion. Based on
E the approach of adaptive curve fitting to search
E E approximate characteristic point presented in Ref.[13], this
G
l5 paper presents an adaptive segment curve fitting method to
G le C find approximate local characteristic point.
C l2

B l3
B l1 A. Adaptive segment circle fitting
A l4 D As shown in Fig.3, there is the set of discrete points Ei
A D
of any coupler point in the basic four-bar linkage, a circle
(b)
is chosen to fit the segment curve E k1 E k 2 . Based on the
adaptive fitting circle[13], the optimal mathematical model
E of a local adaptive fitting circle can be written as
E E min max f i (z )
z k1 ≤ k ≤ k 2

F
( )
le
f k ( z ) = (x E − x0 ) + ( y E − y0 )
1
C (2)
−r
2 2 2
C l2
F k k

B B l3

z = [x0 , y0 , r ] , z ∈ RZ
l1 T

A A
D where f k ( z ) is the fitting error between a discrete point Ei
(c)
Fig 1 Constructions of Stephenson Ш six-bar dwell linkages
II. Representation of coupler curve
As shown in Fig.1, the dwell motion condition of six-
bar linkages is either the straight-line or circular-arc
portion of the path traced by the coupler point E in a basic
four-bar linkage. According to the geometry characteristic
of four-bar linkages, in coordinate system (of, xf, yf ) shown
in Fig.2, the point E( le, β ) can be easily expressed as
⎧ x E = l1 cos ϕ + l e ⋅ cos(γ + β )
⎨ (1)
⎩ y E = l1 sin ϕ + l e ⋅ sin (γ + β )
Obviously, the trace of point E x E , y E ( ) is
functions about ϕ . That is, any point on the coupler plane
l4 D
and the adaptive fitting circle, and z = [ x 0 , y 0 , r ]T are the
optimal parameters, in witch ( x 0 , y 0 ) is the coordinates of
the circle center and r is the radius of the fitting circle.
It is necessary to indicate that, the length of segment
curve fitted lies on the intermission angle ∆ϕ m , the
position depends on the k1and k2, select a different segment
get a different fitting circle and different fitting error. Here,
we give the definition of the local adaptive fitting circle.
Definition A.1 Based on the properties of the set of
discrete points Ei in the given path and the given
intermission angle ∆ϕ m , a circle is adaptively located by
nonlinear the circle fitting in the principle of minimum maximum
fitting error in all segments, witch is called a local adaptive
fitting circle.
 A local adaptive fitting circle have the same properties
with an adaptive fitting circle in Ref [13]. For a basic four-
bar linkage, every tracing point of a moving body is
corresponding to a local adaptive fitting circle, whose
difference of those is only the maximum error. Therefore,
we can define the approximate segment circle point.
Definition A.2 For a basic four-bar linkage, a tracing
point of a moving body is corresponding to a local
adaptive fitting circle, whose maximum fitting error in
normal direction reaches the minimum with respect to
other tracing points in its neighborhood, within the range
of the intermission angle ∆ϕm , called approximate
adaptive segment circle point, or an approximate segment
circle point for short.
An approximate segment circle point has three
meanings about minimum maximum: one is the adaptive
segment fitting circle, which leads to the maximum fitting
error with a circle get minimum, the second one is to
search for a best segment in the given path, and the third
one is to search for a best approximate segment circle
point on the moving body, which traces a segment of a
curve closest to a circle-arc, or the maximum fitting error
gets minimum in its neighborhood.
The minimum maximum fitting error of adaptive
segment fitting circle is a nonlinear function of the
coordinates of the tracing point on the moving body.
Therefore, there must exist extreme values of the
minimum maximum fitting error for all adaptive fitting
circles with respect to their tracing points of moving body.
Theorem A.1 There must exist several approximate
segment circle points on the moving body in
nondegenerated planar motion.
Ek2
Ek
Ek1
(x0,y0)
yF
r adaptive segment slide point.
xF
of
Fig.3 Local adaptive fitting circle of coupler curve
As shown in Fig.1a and 1b six-bar dwell mechanisms,
the point E is an approximate segment circle point on the
coupler plane of a basic four-bar linkage. The center
coordinate ( x0 , y0 ) and radius r of that are the coordinate
(
of the point F x F , y F 0 0
) in dwell period and the length l
of the link EF.
B. Adaptive segment straight-line fitting
As shown in Fig.4, there is the set of discrete points Ei
of any coupler point in the given intermission angle ∆ϕm of
a basic four-bar linkage. Fitting the segment
curve E k1 Ek 2 needs to employ an adaptive fitting line,
which is similar to an adaptive segment fitting circle.
Hence, we can also give the definition of a local adaptive
fitting line.
Ek2
Ek
yf
fk(z)
E k1
of xf
Fig.4 Local adaptive fitting line of coupler curve
Definition B.1 Based on the properties of the set of
discrete points Ei in the given path and the given
intermission angle ∆ϕ m , a straight-line is adaptively
located by the line fitting in the principle of minimum
maximum fitting error in all segments, which is called a
local adaptive fitting line.
The optimal mathematical model of an adaptive line can
be written as
min max f j (z )
z j1 ≤ j ≤ j2
f j (z ) = y E − kxE − b / (1 + k 2 )2
1
(3)
j j
z = [k , b] , z ∈ RZ
T
fk(z)
where f j ( z ) is the fitting error between a discrete point of
the given path, the adaptive fitting line: k and b are the
optimal parameters.
The properties of adaptive segment fitting line are
similar to those of adaptive segment fitting circle. In the
same way, we can give the definition of an approximate
Definition B.2 For a basic four-bar linkage, a tracing
point of a moving body is corresponding to the adaptive
segment fitting line, whose maximum fitting error in
normal direction reaches the minimum with respect to
other tracing points in its neighborhood, within the range
of the intermission angle ∆ϕm , called approximate
adaptive segment slide point, or an approximate segment
slide point for short.
The minimum maximum fitting error of adaptive
segment fitting line is also a nonlinear function, which
5 solving process is same with that of the approximate
segment circle point and solutions must be existent.
 Theorem B.1 There must exist several approximate ⎧ 2 2
(a 3 + l 5 − l 6 )
segment slide points on the moving body in ⎪ p =
⎪ 2a 3
nondegenerated planar motion. ⎨ (9)
2
The point E in Fig.1c is an approximate segment slide ⎪q = M ⋅ 5 l
− p2
point on the coupler plane of a basic four-bar linkage, ⎪⎩ a3
which is corresponding to dwell position of the output link. Equation (9) has two solutions, obtained from
the ± condition of the coefficient M, which depends on the
C. the synthesis of output dyads ( )
initial position of x F , y F . If y F >= y G , then
0 0
After finding the segment characteristic point E on the
coupler plane of a basic four-bar linkage in the dwell x F − xG
ψ Ⅱj = arccos( ) (10a)
period angle ∆ϕ m , the next step is the synthesis of output ( x F − xG ) 2 + ( y F − y G ) 2
dyads to satisfy non-dwell function requirement, such as otherwise
having RRR, RPR as well as RRP dyadic configuration. x F − xG
ψ Ⅱj = 2π − arccos( ) (10b)
C. 1 Rocker output option ( x F − xG ) 2 + ( y F − y G ) 2
Fig.1a and 1c show the most commonly used six-bar For the dyad RPR shown in Fig.1c, the point E is the
type dwell mechanism with rocker output. Based on segment slide point on the coupler plane of the basic four-
getting the approximate segment characteristic point E, bar linkage, whose line segment is corresponding to the
circle point or slide point, on the coupler plane of a basic rocker position with dwell. According to the geometry
four-bar linkage, the synthesis of the output dyad RRR and properties of the output dyad RPR, the output angle ψ Ⅱj ,
RPR is to search the fixed pivot.
can be found as follow equation
According to the given transmission function in the non-
dwell section, under the precondition of all parameters in y F = kx F + b (11)
the basic four-bar linkage known, the object function of where (x F , y F ) are the coordinates of fixed pivot F; k and
the optimal mathematical model can be expressed as b are the parameters of point E at the position of the
f jⅡ (z ) = max ψ Ⅱj − ψ Ⅱ
j (4) adaptive segment fitting line. If y E >= kx F + b , then
where ψ Ⅱ
is the output angle (output function of the xE − xF
j ψ Ⅱj = arccos( ) (12a)
rocker), ψ Ⅱ
is the desired output function of the rocker, ( x E − x F ) 2 + ( x E − kx F − b) 2
j
otherwise
the optimal parameters are z = (x G , y G ) which are the
T
xE − xF
ψ Ⅱj = 2π − arccos( ) (12b)
coordinate (x G , y G ) of fixed pivot. ( x E − x F ) 2 + ( x E − kx F − b) 2
For the dyad RRR shown in Fig.1a, the output angleψ Ⅱj ,
according to the principle of the distance between the two C. 2 Slider output option
pivots of the link keeping constant, can be found as follow The output link is a slider in the six-bar type dwell
equations mechanism shown in Fig.1b which transforms the rotating
l6 = (x G − xF
0
) + (y
2
G − yF0 )
2
(5) input motion to the translating output and dwell. After
selecting an approximate segment circle point on the
and coupler plane as pivot E, the synthesis of the output dyad
⎧⎪ x − xE）2 +（y − yE）2 = l5 2
（ with slider output is to search the tilted angle θ of the
(6)
⎨ guideway according to the given transmission function in
⎪⎩ x − xG）2 +（y − yG）2 = l6
2
（ the non-dwell section. As with the section C. 1 the object
substituting equation (5) into equations (6) and rearranging function of the optimal mathematical model in the non-
them yields dwell portion can be constructed as
⎧ x F = x E + pa1 − qa 2
(7)
f jⅡ (θ ) = max sⅡj − s Ⅱj (13)
⎨
⎩ y F = x F + pa 2 − qa1 where sⅡj is the output displacement of the slider F, s Ⅱ
j is
Where
2 2 the desired output displacement, θ is the optimal
a1 = xG − x E , a 2 = y G − y E , a 3 = a1 + a 2 (8) parameter which is the tilted angle of the guideway with
respect to the xf. axis. The output displacement of the slider
F can be found as follow equations
 ⎧⎪( x F − x E ) 2 + ( y F − y E ) 2 = l 5 2 approach, the results of different synthesis examples are
⎨ (14) given.
⎪⎩ y F = ( x F − x F )tgθ + y F
0 0 Example 1, design a six-bar dwell linkage with rocker
the solutions are output option for 400 rocker motion over 240 crank
⎧ degrees with dwell for the remaining 1200, which function
⎪ x F = (−b + M b − 4ac )
2
between the input crank angle and output rocker angle is
⎨ 2a (15)
listed in table 1. The result of the synthesis with those of
⎪ y F = ( x F − x F )tgθ 2 + y F
⎩ 0 0 the minimum transmission angle γ min = 15 o , maximum
where common link ratio Tmax = 10 , weight number λ = 0.8 , and
⎧a = 1 + tg 2θ 2 the dimension of the basic for-bar linkages selected in
⎪
⎪b = 2dtgθ 2 − 2 x E (16)
table 2, shows in table 3. Fig 5 illustrates the result of the
⎨ 2 2 synthesis with high precision has been carried out.
⎪c = x E + d − l 5
2

⎪d = y − x tgθ − y
⎩ F 0 F 0 2 E ϕ (o ) ψ (o ) ϕ (o ) ψ (o )
As with the equation (9), this also has two solutions, obtain 0 0.0 180 40.0
from the M ± condition on the radical, which also depends 20 2.68 200 40.0
( )
on the initial position of x F , y F . If set the point F0 as
0 0
40 10.0 220 40.0
60 20.0 240 40.0
the fixed point on the guideway line, then
( ) (
sⅡj = x F j − x F0 ⋅ cos θ + y F j − y F0 ⋅ sin θ ) (17)
80
100
30.0
37.3
260
280
37.3
30.0
120 40.0 300 20.0
IV. Unified mathematical model of the synthesis 140 40.0 320 10.0
160 40.0 340 2.68
A similar process to that used for finding the output TABLE 1 Desired function (Example 1)
function of the output dyad can be applied to the problem
of dwell portion, since it is easy to convert the fitting error
in the formula (2) and (3) to the function error. For the l1 (mm) l 2 (mm) l3 (mm) l 4 (mm)
desired output function of in the dwell and non-dwell 100 150 220 220
portion, the object functions can be established TABLE 2 Dimensions of the basic four-bar linkage
respectively. let
F1 ( X ) = maxψⅠi −ψ Ⅰ
i (18a) le(mm) β(°) e1(°)
RR 236.0391 203.0333 0.2274
F2 ( X ) = max ψ Ⅱ
i −ψ i
Ⅱ
RP 272.0157 350.137 0.440
xG(mm) yG(mm) e2(°)
(18b)
RR 269.8405 223.1493 7.2667
where F1 ( X ) ， F2 ( X ) are the output function errors in the
RP 347.6064 -0.8521 3.148
dwell and non-dwell portion, which express angular TABLE 3 Optimum result
displacement error or linear displacemen error depending e1 , e 2 express the maximum error in dwell and non-dwell portion.
on the type of the mechanisms in Fig.1.
Generally, it is need to take both output function errors
in dwell and non-dwell potion into account in the practical
application of dwell mechanisms. Therefore, we employ
linear weighted method to construct the evaluating
function as follow
F (U ) = λF1 ( X ) + (1 − λ )F2 ( X ) (19)
where λ is weight number with λ ∈ [0,1.0] . The formula
(19) describes the optimal problem with single objective.
The solving process of that in detail can refer to Ref.[13].

V. Examples Fig. 5 Desired and resulting function

According to the approach above introduced, the
software, which carries out the approximate function
synthesis for planar six-bar dwell mechanisms, is
programmed. For illustrating the effectiveness of the
Example 2, design a six-bar dwell linkage with slider
output option used in the industrial sawing machine to
enlace button neck with thread, which require that
maximum stroke is 80mm, slider motion over 320 crank
degrees with dwell for the remaining 400, which the
function between the input crank angle and output slider VI. Conclusion
displacement is listed in table 4. The result of the synthesis This paper presents a new optimization approach of
with those of the minimum transmission angle γ min = 40 o , six-bar dwell mechanism synthesis by adaptive segment
maximum link ratio Tmax = 6 , weight number λ = 0.8 , and curve fitting, in which the definitions of approximate
the dimension of the basic for-bar linkage selected in table segment circle points and approximate segment slide
5, shows in table 6. Fig 6 illustrates that the result of the points are given. Here, we introduce the approximate
synthesis with high precision has been carried out. properties and optimization process of the six-bar dwell
mechanisms, and prove the existence of the best solution
ϕ (°) S ϕ (°) S ϕ (°) S and the convergence of the proposed optimization
0 0 127 46.61 250 80 algorithm. In addition, we establish the unified
7 0.82 134 50.57 255 80 mathematical model, which can describe the approximate
14 1.54 140 53.99 260 80 segment circle point and the approximate segment slide
20 2.26 147 57.58 268 79.23 point, and develop the “saddle-point planning”
27 2.98 154 61.18 283 76.35 programming.
33 4.06 160 64.06 292 72.39 By employing the approach, the approximate function
40 5.14 168 67.67 300 66.64 synthesis of six-bar dwell mechanisms can be optimized in
47 6.75 188 74.85 315 49.85 the unified mathematical model and algorithm. Numerical
54 8.73 199 77.00 320 41.22 examples show that the approach can ensure the desired
66 13.23 206 78.33 326 30.4 precision of the output function in dwell and non-dwell
73 15.93 213 79.05 332 18.56 period.
80 19.52 220 79.76 340 7.77
87 23.12 225 80 348 3.27 References
100 30.85 230 80 356 0.93 [1] SANDGREN E. Design of single- and multiple-dwell six-link
108 35.35 235 80 mechanisms through design optimization[J]. Mechanisms and
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Fig. 6 Desired and resulting function