TopicISynthesisPartI Detail

ME 3610 Course Notes - Outline
Part II -1
Part I: Mechanism Synthesis

Mechanism synthesis in kinematics consists of formalized techniques used in design of
mechanisms. We call these techniques dimensional synthesis to determine the critical
dimensions of the mechanism. The following table names some of the more common
techniques:

Mechanism class Name Application Comments Ref.
Linkages Planar Graphical 2
position
Driving dyad
Quick return
N. pg 93
Graphical
Body guidance
3 position N. pg 99
Graphical
Path generation
3 positions, w/ or
w/o prescribed
timing
S&E, Ch. 2
Graphical
Function generation
3 positions S&E, Ch. 2
Freudensteins
equation technique
Analytical
technique, initially
for function
generation
Initial application of
solutions at precision
positions - Loop Closure
equations
N. pg 176
Loop closure
equation technique

Part II -2
Dyadic synthesis Analytical, dyads Forms equations
for up to n
positions
N. Ch. 5
Chebyshev spacing Theory for error
limiting at precision
positions
M&R
Cognate linkages
Roberts-Chevyshev
theorem -Three different
linkages generate the
same coupler point
curve
N. pg 123
Hrones & Nelson
atlas of coupler
curves
Path generation N. pg 113
Burmester theory 4 position body
guidance
S&E, Ch. 3
Five position with
Sylvesters dyalitic
eliminant
Analytical 5 position
body guidance
S&E, Ch. 3
Order synthesis
Synthesis applied to
infinitely separated
positions (to match
velocity and acc.
specifications
S&E, Ch. 3
Linkages Spatial Dyadic synthesis
equations

Up to seven positions
can be met with SS
dyad (compare to 5 RR)
M&R, S&E

Part II -3
Cams Graphical M&R
Conjugate geometry course notes

Gears

References:
N. - Norton , R. L., 2004, Design of Machinery: An Introduction to the Synthesis and Analysis of
Mechanisms and Machines, 3
rd
Ed., McGraw-Hill.
S&E - Sandor, G.N. and Erdman, A. Advanced Mechanism Design: Analysis and Synthesis, Vol.
II, Prentice Hall.
M&R - Mabie, H. H., and C. F. Reinholtz, 1987, Mechanisms and Dynamics of Machinery,
Fourth Edition, Wiley.

Part II -4
Linkage Synthesis:
This section will review some of the most common and techniques for synthesizing linkages.
These section will cover the following topics: 1) review basic graphical and analytical synthesis
techniques. 2) center/circle point curves for choosing free choices (3 position), 3) ground-pivot
specified methods (3 position). 4) Burmester theory for the 4 position problem and 5) basic
optimization techniques for linkages and synthesis in commercial software.

Review basics of linkage synthesis

1. Definitions:
a. Synthesis: To create a mechanism given desired task

b. Analysis: To determine the motion characteristics (task) given a mechanism.

c. Grashof mechanism

d. Toggle position

e. Types of sixbars

Part II -5
2. Forms of synthesis:
a. Type synthesis:
Choosing the type of mechanism best suited to the task
a. Ex: Gear trains, linkages, cams, actuation methods, and #of links/joints the
mechanism should have.
b. Degrees of freedom.

b. Dimensional synthesis:
Determine the significant dimensions of the mechanism

c. Classical Synthesis problems:
Motion generation

Path generation

Part II -6

Function generation

d. Defects that may occur:

Branch defect

Grashof defect

Order defect

Part II -7
2. Graphical Synthesis Techniques: 2 positions
Toggle positions
Equal forward/reverse drive times:
Locate the driving dyad ground pivot along the chord line
Quick return-type mechanisms
Driving dyad ground pivot not located along the chord line

Part II -8
3. Graphical Synthesis Techniques: 3 positions
a. Introduction:

b. why three positions?
The graphical approach for linkage synthesis is based on the geometric construction of a
circle from three points (i.e., finding the center of a circle defined by three positions).
Interestingly, four positions (and even five) can define a unique circle. However, simple
geometric construction techniques for these cases do not exist, therefore three positions are the
problems we solve.

c. How many positions total could be solved?
Five, (three link-lengths and two off-sets). This can be seen in considering

d. What are Precision Positions
Positions which will be met exactly (precisely) during linkage motion

e. How are Precision Positions selected?
Precision positions should be selected to best represent the overall desired motion. If some exact
points are required (for example a pick-up or drop-off point), then these can be used as precision

Part II -9
positions. Note that no other desired position (other than precision positions) will be necessarily
met by linkage motion.
One formal method for choosing precision points is Chebyshev spacing

Four different three-position techniques will be discussed: motion generation, path generation,
function generation, and motion generation with prescribed ground pivots.

Part II -10
B.1. Motion Generation:
Motion generation is the workhorse of the linkage synthesis problems. In motion generation, the
position and orientation of a body are to be guided (hence the other name, body guidance).

The procedure proceeds as follows:
1) Specify 3 positions of the body (the precision positions)
2) Choose 2 moving pivots on the body (coupler or circle points), A& B. Locate A1, A2, A3 and
B1, B2, B3.
3) Find the center of points Ai and Bi:
1. create lines A1A2, A2A3, B1B2, and B2B3
2. Draw perpendicular bisectors
3 Find the intersection of these bisectors to give OA and OB.
4) Construct the linkage, check for defects
5) iterate as necessary, choosing new coupler points

Notes:
1. there are 4 infinities of solutions corresponding to choosing the circle points, A & B.
2. Choosing the 3 body positions to represent the task presents an iteration
3. A & B do not need to be on the body.
4. Once OA and OB are chosen, check for defects.

Part II -11

B.2. Path Generation:
Path generation is a subset of motion generation (only body positions, not orientations are
specific). Two approaches are used to solve a path generation problem.
One approach would define an additional set of angles as prescribed input timing and
then proceed in a manner somewhat like motion generation.
A second approach is to look at coupler curves: Curves defined by points on a coupler
link (non-grounded link in a four-bar). An infinite number of coupler curves exist for one
four-bar, and there are infinite possibilities of fourbars (the coupler curve in general is a
6
th
order curve).
The Hrones and Nelson Atlas of fourbar coupler curves can be used to choose curves, or
select a suitable software program.

Part II -12
B.3. Function Generation:
The function generation problem relates creates a functional relationship between the rotations of
the input and output links of a fourbar.

Part II -13
B. 4. Motion Generation with Specified Ground Pivots:
Given a motion generation task and two ground pivots specified, create a 4-bar linkage
Process uses inversion: to consider the motion of a device with different links considered
as the reference or ground

Part II -14
Procedure:
1. Specify 3 precision positions of the body
2. Choose 2 ground pivots, OA and OB. Now, using inversion, locate OA2, OA3 and OB2,
OB3. i.e., consider the body fixed and the pivots moving around the body.
2.1 First, measure the position of OA relative to the body in the second position, and
then draw OA (call it OA2) relative to the body in the first position using these
measurement. Do the same to locate OA3 (measure relative to the body in the third
position, draw it relative to the body in the first position).
2.2 Repeat for OB
3. Find the center of points OA and OB in the usual manner.
4. Draw the linkage in the first position

Part II -15

Locate three precision positions and grd pivots Locate OA2

Part II -16

Locate OA3 Locate Coupler point A

Part II -17

Repeat for coupler points B Draw in the linkage

Part II -18
4. Analytical Synthesis Techniques:
Analytical synthesis techniques lend themselves to computer solution can automate the synthesis
process and present much better tools for linkage synthesis. (The trade-off is that the techniques
are somewhat less-intuitive initially to a beininning mechanism designer).
The analytical techniques began with Freudenstien, who essentially solved the geometric
synthesis equations in an analytical fashion.
The techniques we will use are called dyadic synthesis and developed out of Sandors
work (extended by Erdman).

Analytical Dyadic Synthesis of Linkage or Dyadic Linkage Synthesis:
The key idea behind dyadic linkage synthesis is to consider a linkage as composed of a set of
dyads. Each dyad must perform the motion desired of the linkage. Therefore, the synthesis
process can be reduced to synthesizing the motion of a set of dyads independently and then
combining them to create entire linkage.

Dyad: Two-link pair

Consider for example a four-bar:

Part II -19

Part II -20
Notation
1. Point P on the coupler traces the output position while gives the orientation of coupler
(and body)
2. W and Z are vectors representing the dyad in position 1.
3. W rotated by angle j is given by We^(i*j)
4. Zl and Zr must have the same rotation ()
5. j gives left-hand input timing
6. j gives right-hand input timing

Part II -21
Procedure: (From here on, we will consider the body-guidance problem, with body position and
orientation given)
1. Represent the four-bar as 2 coupled dyads
2. Synthesize one dyad at a time
3. Move one dyad from the first precision position to the next
4. Write a vector loop equation to represent the unknown dyad vector at known positions (In
the standard form solution, each loop equation will include the dyad in the first and j
th

position)
5. For each single loop equation, there are 5 u.k. parameters (Wl, Zl,
j
)
6. Make appropriate free choices
7. Solve the system equations for the unknowns
8. This results in 1 dyad that satisfies the precisions points. Solve for second to complete
the four bar (with the requirement that the coupler rotation is consistent)

Part II -22

Part II -23
1. Write a vector-loop equation:
n j e e
l l j
i
l
i
l
j j
= = + + 2 , 0
1
W Z P P Z W

Or:
( ) ( ) ( )
1
1 1 P P Z W = +
j
i
l
i
l
j j
e e

This is called the Standard-form equation
2. For three positions (n=3), there are 2 vector equations for the left dyad:
( ) ( ) ( )
2 1 2
1 1
2 2

= = + P P Z W
i
l
i
l
e e
( ) ( ) ( )
3 1 3
1 1
3 3

= = + P P Z W
i
l
i
l
e e
Note the number of unknowns in the above equations:
Knowns: P
1
, P
2
, P
3
,
2
,
3
Unknowns: W
l
, Z
l
,
2
,
3
6
Number of equations: 4

Part II -24
3. For four positions (n=4), there are 3 vector equations for the left dyad:
(above 2 plus):
( ) ( ) ( )
1 4
1 1
4 4
P P Z W = +
i
l
i
l
e e

Note the number of unknowns in the above equations:
Knowns: P
1
, P
2
, P
3
,
2
,
3
Unknowns: W
l
, Z
l
,
2
,
3
,
4
7
Number of equations: 6

4. This process can be repeated. Look at all possibilities in the following table:

Part II -25
Table I: Number of positions Vs. number of solutions for the Std Form Equation on a Body
Guidance Problem
#of
positions
(j)
#of
scalar
equations
#of Scalar
unknowns
#of
Free
Choices
#of
Solutions
Solution
Technique
2 2 5 (W,Z,
b2)
3 O(infinity)^3 So Easy!
3 4 6 (W,Z,
b2, b3)
2 O(infinity)^2 Straight
forward
(Linear
equations in
general)
4 6 7 (W,Z,
b2, b3)
1 O(infinity) Medium-
difficulty
(Burmester)
5 8 8 (W,Z,
b2, b3, b4)
0 Finite Hard
Analytically
(but not
impossible)

Part II -26
Free Choices, a few more comments:

1. Proper selection of free choices leads to a set of linear equations in the unknowns.
2. Consider other sets of free choices, discuss their merits and disadvantages.

Part II -27
Solving the Standard Form Equation for 3 positions:

1. Recall the two loop closure equations for 1 dyad:
( ) ( ) ( )
2 1 2
1 1
2 2

= = + P P Z W
i
l
i
l
e e Eq. 2a
( ) ( ) ( )
3 1 3
1 1
3 3

= = + P P Z W
i
l
i
l
e e Eq. 2b

2. Make free choices such that only W and Z are unknown. The equations are known linear and
can be solved as:

( )
(
1 2
1 3
P P dZ cW
P P bZ aW
= + )
= +
l l
l l
Eq. 3
where:
( ) ( )
( ) ( 1 , 1
, 1 , 1
3 3
2 2
= =
= =

i i
i i
e e
e e
d c
b a
)

3. Cast in matrix form:
Eq. 4 rhs
Z
W
A =
l
l

Part II -28
where
( )
( )
=
1 3
1 2
,
P P
P P
rhs
d c
b a
A

Note that matrix A and vector b are complex. How would you expand (Eq. 4) such that A and b
are not complex?
4. Now solve for the unknown dyad vectors, W
l
and Z
l
Eq. 5 rhs A
Z
W
1
=
l
l

5. Methods to do this (matrix inverse)
Cramers Rule
Gauss-J ordan Elimination
Matlab

Part II -29
Using Matlab to solve the Std. Form Equation:

Assigning complex vectors:
>>a=exp(beta2*i)-1
>>b=exp(alpha2*i)-1
Creating matrix and vector
>>A=[a,b;c,d]
>>rhs=[(P2x-P1x)+i*(P2y-P1y); (P3x-P1x)+i*(P3y-P1y)];
Invert and multiply
>>x=inv(A)*b
Extract results
>>W=x(1)
>>Wx=real(W);Wy=imag(W)

Part II -30
Complete the Fourbar:
Now solve for the right hand dyad
For a body-guidance problem, s are the same, the s are the free choices
What are free choices for a path-generation problem?
Reconstruct the four-bar using the two dyads
Check for defects, performance, etc.

Part II -31
Analytical Dyadic Synthesis: Thought-Provoking Questions
1) Generate the standard form equation,
W(eibj - 1) +Z(eiaj - 1) =dj
for a body guidance problem (draw a figure). List the knowns and unknowns. Given three
positions, describe a closed-form solution technique.
2) Create a table for the body guidance problem that demonstrates the maximum number of
positions that can be solved with a four-bar, and list the unknowns, free-choices, and
solutions for all smaller positions.
3) Given a path generation problem w/o prescribed input timing (the only givens are the Pj's,
determine the maximum number of positions that can be synthesized with a four-bar linkage.
Support/prove your result.
4) Derive the standard form equation for a function generation problem. List the knowns and
unknowns. Also, list the number of free-choices to solve for three positions.
5) Create a table for the function generation problem that demonstrates the number of
positions possible along with knowns, unknowns, free choices, and number of solutions.
6) For a body guidance problem, given the three positions and thus two free-choices, list all
possible combinations of two free choices. Discuss the merits of these various choices.
7) Show how to set up the equations to solve three position body-guidance problem if the
ground pivots are to be made as free-choices.
8) Given a function generation problem, determine the maximum number of precision pairs
that can be synthesized with a four-bar linkage.

Part II -32

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ME 3610 Course Notes - Outline

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