MCB3043 Mechanics of Machines

Semester May 2014

SLIDER-ROCKER MECHANISM DESIGN PROJECT

GROUP 8
1. TAN HUAT CHAI

15886

2. TAN KE WEI

16330

3. LEE WEN CHING

16222

4. HEA YIH TORNG

16251

5. KAM CHONG PING

16474

Lecturer: Azman Bin Zainuddin

1.0 Introduction
1.1 Aim
To design a slider rocker mechanism driven by an electric motor turning at constant speed and direction
with the given parameters and requirements.
To obtain 2 output motions from this mechanism which are:
A linear reciprocating motion of a slider along the horizontal axis with a stroke of S. The expected
tolerance is 0.5 mm.
A rocking motion with a throw angle of degrees. The expected tolerance is 1.
To obtain the velocity of the slider with the maximum velocity between the given VMIN and VMAX mm/s.
1.2 Description
Crank Slider Mechanism
The Slider-crank mechanism is used to transform rotational motion into translational motion by means of
a rotating driving beam, a connection rod and a sliding body. The sliding mass is not allowed to rotate and
three revolute joints are used to connect the bodies. While each body has six degrees of freedom in space,
the kinematical conditions lead to one degree of freedom for the whole system.
A slider crank mechanism converts circular motion of the crank into linear motion of the slider. In order
for the crank to rotate fully the condition L> R+E must be satisfied where R is the crank length ,L is the
length of the link connecting crank and slider and E is the offset of slider . A slider crank is a RRRP type of
mechanism i.e. It has three revolute joints and 1 prismatic joint. The total distance covered by the slider
between its two extreme positions is called the path length. Kinematic inversion of the slider crank
mechanisms produce ordinary a white work quick return mechanism.

Figure 1.1 represents illustration of crank slider mechanism. Does not relate to text.
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Crank Rocker Mechanism

In a four bar mechanism the link on which input motion is applied is known as driver. The output motion
link is follower and the middle link connecting these two links is coupler link. The fourth link is grounded.
A four bar mechanism has 1 degree of freedom.
If the input link can rotate fully it is called as crank. A link that can't rotate fully is known as rocker.
Grashof's Theorem :
If S is the smallest link, L is the largest link and P,Q are the intermediate links ,then there will be at least
one link which will be able to revolve/rotate if S+ L< P+Q. The four bar mechanisms that satisfy this criteria
is known as Grashofian mechanism.

Figure 1.2 represents illustration of crank rocker mechanism. Does not relate to text.

The Slider Rocker Mechanism

A slider rocker mechanism is a 6 linkage mechanism on which input motion is applied by the crank. This
system is a combination of both the crank slider mechanism and the crank rocker mechanism. The crank
is placed in the middle with one end the rocker and the other end is placed the s lider with both having a
coupler of their own to link them to the crank. The crank then powers the movement of both these moving
parts, the rocker and slider, to move simultaneously at the same direction located opposite to one another.
This combined mechanism satisfies both criteria which are the:
1. Grashof's Theorem :
If S is the smallest link, L is the largest link and P,Q are the intermediate links ,then there will be
at least one link which will be able to revolve/rotate if S+ L< P+Q. The four bar mechanisms that
satisfy this criteria is known as Grashofian mechanism.
2. Crank slider mechanism lengths ratio
In order for the crank to rotate fully the condition L> R+E must be satisfied where R is the crank
length ,L is the length of the link connecting crank and slider and E is the offset of slider .
3

1.3 Requirement
To sum up the requirement given by our lecturer, we formed a table as shown below. Kindly note that we
separate all the requirements into slider-crank mechanism and crank-rocker mechanism so that we can
obtain a clearer picture of what our lecturer wants.
Slider-Crank Mechanism
Stroke, S = 120mm +- 0.5mm
1300mm/s Max Velocity of Slider 1500mm/s
3.5 < Coupler Ratio < 6
Time Ratio 1.1

Crank-Rocker Mechanism
Throw Angle, = 30 +- 1
45o Transmission Angle, 135o

2.0 Methodology
In this project, the mechanism was separated into two parts, which are slider-crank mechanism and crankrocker mechanism. The objective of this separation was to ease the calculation and design of our
mechanism.
Crank-rocker
In designing crank-rocker mechanism L1 and L4 were randomly selected to be used in drawing. Then the
limiting positions of the mechanism were drawn using graphical method. After the drawing was done,
simultaneous equation was applied to obtained length links of L 2 and L3. In assuring the transmission angle
is between 45 and 135, they were calculated by using equation as stated bel ow.
Minimum transmission angle, min =
Maximum transmission angle, max

cos -1

= cos -1

23 + 24 (1 2 ) 2
23 4

23 + 24 (1 + 2 )2

23 4

(Eq 2.1)

(Eq 2.2)

With the value of link lengths obtained from the drawing and transmission angles obtained from the
calculation, designing process was proceeded to crank-slider mechanism.

Slider-crank
In designing crank-slider mechanism, there were a few constraints that need to be followed. There are as
stated below.
1.
2.
3.
4.

Stroke must be 120mm

Maximum slider speed must be between 1300mm/s and 1500mm/s
Coupler ratio must be between 3.5 and 6
Time ratio must be larger than 1.1

First of all, a suitable coupler ratio based on the specification was selected to be used in the designing
process. By using the selected coupler ratio, a calculation by using formula as stated below was used to
obtained value of link length, L3 .
Coupler Ratio =

L3

(Eq 2.3)

L2

Link length, L2 that was obtained previously in crank-rocker drawing was used in above calculation to get
value of L3. After that, both limiting positions were used to solve the mechanism by using trigonometric
equation and simultaneous equation. At the end of the calculation, the value for length L1 was obtained.
Last but not least, in order to clarify whether the design fits the specifications given or not, it was tested
by using time ratio equation as stated below.
Time Ratio =

180+

(Eq 2.4)

180

The imbalanced angle of was calculated by using trigonometric equation.

Following from that, the link lengths and all the calculated data were then tabulated into excel to further
calculate the angles, displacements, velocities and accelerations. The equations used for such working are
displayed below:

3 = sin1 [

L1 + L2 sin 2
L3

(Eq 2.5)

L4 = L2 cos 2 + L3 sin 3

(Eq 2.6)

= 180 (2 + 3 )

(Eq 2.7)

BD = L21 + L22 2(L1 )(L2 ) cos( 2 )

(Eq 2.8)

2
2
2
1 L3 +L4 BD
cos [ 2(L3 )(L4 ) ]

3 = 2 tan1 [L

L2 sin 2 +L4 sin

1 +L3 L2 cos 2 L4 cos

4 = 2 tan1 [

(Eq 2.9)

L2 sin 2 +L3 sin

L1 +L4 +L2 cos 2 L3 cos

(Eq 2.10)

(Eq 2.11)

Including Eq 2.1 and Eq 2.2 as stated previously

3.0 Result
3.1 Link Lengths Calculations
Knowing that we are given full freedom in the length of links, we made our choice to set L 1 = 300mm and
the rocker length, L4 = 180mm. Then we draw the limiting positions of the mechanism using graphical
method as shown below.

Then, by measurement, we got to know that L3+L2 = 19.3cm and L3-L2 = 15.2cm. Using simultaneous
equation,
L2 = 41mm
L3 = 345mm

Next, to ensure that the transmission angle is between 45 and 135, we calculate them in both limiting
position as shown below:

2
2
2
3 + 4 (1 2 )

min = cos -1 [

23 4

= 47.23

max =

cos -1

2
2
2
3 + 4 (1 + 2 )

23 4

= 73.56

After getting a set of link lengths and angles, we moved on to the crank-slider section. Based on the given
requirement:
1.
2.
3.
4.

Stroke must be 120mm

Maximum slider speed must be between 1300mm/s and 1500mm/s
Coupler ratio must be between 3.5 and 6
Time ratio must be larger than 1.1

Taking these into account, we first took the crank length, L 2 from crank rocker design which is 41mm. Then
we set our coupler ratio to be 3.6. The reason is that we want our mechanism to be as mobile as we can
and besides, avoid all the joints from experiencing additional joint forces which will shorten the lifespan
of our model.
Coupler Ratio =

3.6 =

L3
L2
L3
41mm

L3 = 147.6mm
Next, we solve the mechanism by listing out the equation formed by both limiting positions:

Substituting Eqn.3 into Eqn. 1:

L1 2 = 21169.96 240X2 (X2) 2

(Eqn. 4)

Substituting Eqn. 4 into Eqn. 2:

(106.6) 2 = 21169.96 240X2 (X2) 2 + (X2) 2
X2 = 40.86mm

(Eqn. 5)

Substituting Eqn. 5 into Eqn. 2:

(106.6mm) 2 = L1 2 + (40.86mm) 2
L1 = 98.458mm

Next, we need to check if the results we calculated are able to generate a time ratio of more than 1.1.
Thus, we need to first find the imbalance angle, and then use the time ratio formula as shown below:
Time Ratio =

180+
180

(120mm) 2 = (106.6mm) 2 + (188.6mm) 2 - 2(106.6mm)(188.6mm) cos

= 35.99

Time Ratio = 1.5 > 1.1

8

Following from that, the link lengths and all the calculated data are then tabulated into excel to further
calculate the angles, displacements, velocities and accelerations.
Kindly refer to Microsoft Excel and MSC Adams for full details.

3.2 Diagrams
3.2.1 The scaled kinematic diagram of the mechanism showing the position when the slider is at the
middle of its stroke.

Figure 3.1 showing the 1cm: 30mm scaled kinematic diagram of rocker-slider mechanism drawn using
graphical method.

3.2.2

The slider displacement curve for a single cycle.

displacement (mm) versus crank angle

20.00

0.00
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
-20.00
-40.00
displacement
-60.00
-80.00

-100.00
-120.00

3.2.3

The slider velocity curve for a single cycle.

velocity (mm/s) versus crank angle

1000.00

500.00

0.00

0
-500.00

20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340
velocity (mm/s)

-1000.00

-1500.00

-2000.00

10

3.2.4

The slider acceleration curve for a single cycle

acceleration (mm/(s^2)) versus crank angle

50000.00
40000.00

30000.00
20000.00
10000.00

acceleration (mm/(s^2))

0.00
0 20 40 60 80 100120140160180200220240260280300320

-10000.00
-20000.00
-30000.00

3.2.5

The rocker angular displacement curve for a single cycle.

angular displacement (rad) versus crank angle

30.00
25.00

20.00
15.00

angular displacement
10.00
5.00

0.00
0 20 40 60 80 100120140160180200220240260280300320340360
-5.00

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3.2.6

The rocker angular velocity curve for a single cycle.

angular velocity (rad/s) versus crank angle

300.00
200.00
100.00
0.00
10 30 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330 350

angular velocity

-100.00
-200.00
-300.00
-400.00

3.2.7

The rocker angular acceleration curve for a single cycle.

angular acceleration (rad/s^2) versus crank angle

8000.00
6000.00

4000.00
2000.00
angular acceleration
0.00
10 30 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330
-2000.00
-4000.00

-6000.00

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4.0 Conclusion
4.1 The lengths of all links, the slider offset

Figure 4.1 showing the 1cm: 30mm scaled kinematic diagram of rocker-slider mechanism drawn using
graphical method.

Figure 4.2 To reconfirm accuracy, we use AutoCAD to redraw our kinematic diagram.
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Figure 4.3 Drawing taken from Adams software during simulation of mechanism. The slider is in the
middle of its range of motion.

Based on calculation and measurement, we obtained the following results:

Links
L2 (Crank)
Crank-Rocker

Slider-Crank

L1
L3, coupler
L4, rocker
L1, offset
L3, coupler

Length (mm)
41
300
345
180
98.458
147.6

4.2 The stroke of the slider and the rocker

For the slider, we managed to make its stroke, S= 119.9mm, which satisfied the requirement. Meanwhile,
our rocker is able to generate an angular stroke (throw angle) of 30.31.
4.3 The crankshaft speed in rpm
After trying different crankshaft speed in the multiplication of 10rpm, we finally decided to use 180rpm
as it is able to push the sliding mechanism to achieve a V max of 1497.95mm/s. This achieved the objective
of the design.
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4.4 The time ratios of the slider and the rockers

For the slider mechanism,
To find the time ratio, we need to first find the imbalance angle, . Figure below shows 2 lines produced
when the coupler and crank forms a straight line at both limiting positions. The third line (120mm) is the
path of sliding which is also known as the stroke of the slider.

Using Cosine Rule:

(120mm) 2 = (106.6mm) 2 + (188.6mm) 2 2(106.6mm)(188.6mm) cos
= 35.99
36
Time Ratio =

180+
180

= 1.5
For the crank-rocker mechanism,
The imbalance angle, can be obtained as shown below:

15

Time Ratio =

180+
180

= 1.091

Thus, time ratio of slider-crank mechanism is 1.5 while time ratio of crank-rocker mechanism is 1.091.

4.5 The coupler ratio of the slider

Coupler ratio =

L3 (coupler length)
L2 (crank length)

147.6mm
41mm

= 3.6
Thus, the coupler ratio is 3.6 and it meets the requirement. This will ensure that no excessive force will be
experienced in the joints, therefore enhancing the lifespan of our mechanism.

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4.6 The range of transmission angles of the rocker

Based on the transmission angle calculated in Excel, the related table is shown below:

Transmission Angle vs Crank Angle

80.00

70.00
60.00

50.00
40.00

30.00
20.00

10.00
0.00

20

40

60

80 100 120 140 160 180 200 220 240 260 280 300 320 340 360

Thus, it can be clearly seen that our transmission angle is:

45o Transmission Angle, 135o

4.7 The working area required by the mechanism (in terms of L x W)

To calculate the working area needed by our slider-rocker mechanism, we have to first calculate the
maximum possible expansion of our mechanism vertically and horizontally.
In terms of vertical length, which is the height,
We can calculate it simply by adding the L4, rocker and L1, offset. This is because when the rocker is in the vertical
position, it expand the most vertically. Besides that, for the vertical length below the rocket pivot, we
chose L1, offset because its the fixed length from the pivot of rocker to the ground where the slider moves.
Thus:
Vertical Length = L4, rocker + L1, offset
= 180mm + 98.458mm
= 278.458mm
17

Then speaking about the horizontal expansion, we can actually divide the mechanism into three portion
to analyze. This division can be shown below:

The left part is the horizontal length between the rocker pivot to the point where rocker can stretch the
most horizontally.
Hence, L4,rocker cos (4 min) = 180mm cos (75.76)
= 44.28mm
The middle part is the horizontal length between the rocker pivot to crank pivot. It is L1 , which is 300mm.
The right part is the horizontal length where the slider can stretch out the most to the right from the crank
pivot. Thus, we take the maximum value of L4, slider which is 160.84mm
Thus:
Horizontal Length = 44.28mm + 300mm + 160.84mm
= 505.12mm
Therefore, the size of the mechanism in terms of L x W is 505.12mm x 278.458mm. However, if this value
is to be used for casing design, we will strongly recommend it to be 10% larger which is approximately
550mm x 310mm because the slight increment in area will prevent our mechanism from knocking our
casing due to tolerance. Besides that, slight increment of area will also not occupy much space and
increase much initial cost.

4.8 The maximum speed of the slider and the rocker

By installing a motor which has an operating speed of 180rpm, we are able to make the rocker to rock at
a maximum angular speed of 307.79rad/s. On the other hand, the maximum speed of the slider is
1497.95mm/s. Hence, the requirement of maximum slider velocity between 1300mm/s to 1500mm/s is
fulfilled.

Therefore, all the requirements are fulfilled.

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