A Seminar II Report On

SYNTHESIS OF GEARED FOUR BAR MECHANISM

Submitted In Partial Fulfillment of the Requirement For The Award of Degree of Master of Engineering In Mechanical Design Engineering of North Maharashtra University, Jalgaon

Submitted By

Patil Yogesh Balu

Under The Guidance of

Prof. R B Barjibhe

Department of Mechanical Engineering Shri Sant Gadge Baba College of Engineering and Technology, Bhusawal North Maharashtra University, Jalgaon 2011-2012

Shri Sant Gadge Baba College of Engineering and Technology, Bhusawal 425201

Certificate
This is to certify that Mr. Patil Yogesh Balu has successfully completed his seminar II on Synthesis of Geared Four Bar Mechanism for the partial fulfillment of the Masters Degree in the Mechanical- Design Engineering as prescribed by the North Maharashtra University, Jalgaon during academic year 2011-12.

Prof. R. B. Barjibhe
[Guide]

Prof. R. B. Barjibhe
[P.G.Co-Ordinator]

Prof. A. V. Patil
(H.O.D.)

Prof. R. P. Singh
(Principal)

ABSTRACT
This paper presents an analysis and synthesis method for a certain type of geared four-bar mechanism (GFBM) for which the input and output shafts are collinear. A novel analysis method is devised, expressions for the transmission angle are derived and charts are prepared for the design of such mechanisms. It is observed that the GFBM considered is inherently a quick-return mechanism. During the working stroke, approximately constant angular velocity at the output link is observed. For the type of GFBM analyzed, direction of rotation of the input link affects the force transmission characteristics.

INDEX
Sr. No. Name of Topic Abbreviations List Of Figures List of Graphs 1 2 3 Introduction Literature review Synthesis of mechanism 3.1 Type synthesis 3.2 Number synthesis 3.3 Dimensional synthesis 3.3.1 Function generation 3.3.2 Path generation 3.3.3 Motion generation 4 Transmission angle 4.1 Maximum and Minimum transmissions angle 4.2 Optimum transmission angle 5 6 7 8 9 N Enumeration of the GFBM Motion analysis of the GFBM Transmission angle of the GFBM Synthesis of the GFBM Transmission angle optimization Conclusion Page No. i ii iii 1 2 3 3 3 3 3 4 4 5 5 6 7 8 10 11 13

ABBREVIATIONS
GFBM i/p o/p GEARED FOUR BAR MECHANISM INPUT OUTPUT

LIST OF FIGURES
FIG. NO. 1.1 4.1 4.2 4.3 4.4 5.1 6.1 TITLE OF FIGURE TOPOLOGY TYPE A, AND TOPOLOGY TYPE B. SHOWING TRANSMISSION ANGLE. DOUBLE-ROCKER MECHANISM. THE CRANK-ROCKER MECHANISM. DOUBLE-ROCKER MECHANISM. ENUMERATION OF THE GFBM. THE GFBM AND THE CORRESPONDING FOUR-BAR MECHANISM WHEN THE GEARS ARE REMOVED. 7.1 THE FBD OF THE LINKS WHEN LINK 2 IS ROTATING COUNTERCLOCKWISE. 7.2 8.1 THE FBD OF LINK 4 WHEN LINK 2 IS ROTATING CLOCKWISE. THE DEAD-CENTER POSITIONS OF THE GFBM.

ii

LIST OF GRAPHS
GRAPH NO 8.1 9.1 9.2 9.3 9.4 Z1 AND Z2 CIRCLES FOR THE VALUES OF =50 AND =10. THE DESIGN CHART FOR CW INPUT ROTATION AND R=1. THE DESIGN CHART FOR CCW INPUT ROTATION AND R=1. THE DESIGN CHART FOR CW INPUT ROTATION AND R=2. THE DESIGN CHART FOR CW INPUT ROTATION AND R=4. TITLE OF GRAPH

iii

1 INTRODUCTION
Geared linkages are useful mechanisms, which can be formed by combining planar linkages with one or more pairs of gears. A geared five link mechanism in general is a one degree of freedom planar mechanism with five revolute joints, one gear pair, and five links. Two different topologies are possible as shown in (Fig.1.1). In type A, there is a ternary joint between links 1, 2 and 3 whereas in type B all revolute joints are binary. Type A contains a four-bar loop whereas type B has a five-bar loop when the gear pairs are removed. The mechanism studied in this work has type A topology, which is named as GFBM in the literature. Geared four-bar mechanisms are generally investigated to obtain large swing angle, dwell motions and motion with approximately constant transmission ratio ranges. Mechanisms for non-uniform transmission of motion such as linkages are characterized by continuously changing transmission ratios. Ideally a smooth motion throughout the whole range of operation is expected. For designing such mechanisms it is important to utilize fully all possibilities known from theory and practical experiences. The criteria for the design of mechanism are low fluctuation of input torque, compact in size and links proportion, good in force transmission, low periodic bearing loads, less vibrations, less wear, optimum transmission angle and higher harmonics. The transmission angle is an important criterion for the design of mechanism.

Fig. 1.1. Topology Type A, And Topology Type B.

2 LITERATURE REVIEW
Tuan-Jie Li , Wei-Qing Cao , in their paper , Kinematic analysis of geared linkage mechanism, present a general approach to the kinematic analysis of planar geared linkage mechanisms (GLMs) is presented based on their structural topological characteristics. Firstly, a systematic method for decomposing a GLM into a series of sequential independent kinematic units, such as the simple links and the dyad link groups is proposed. The criteria and process for the structural decomposition and for choosing circuits using the theory of type transformation are established. Then the kinematic equations and the analytic solutions for the kinematic units are derived, and the method for the kinematic analysis of position, velocity and acceleration of GLMs is obtained in an algorithmic fashion [2]. Shrinivas S Balli , Satish Chand , in their paper, Transmission angle in mechanisms (Triangle in mech), present that the transmission angle is an important criterion for the design of mechanisms by means of which the quality of motion transmission in a mechanism, at its design stage can be judged. It helps to decide the Best among a family of possible mechanisms for most effective force transmission [3]. M. Khorshidi , M. Soheilypour, M. Peyro, A. Atai, M. Shariat Panahi, in their paper, Optimal design of four-bar mechanisms using a hybrid multi-objective GA with adaptive local search, present that a novel approach to the multi-objective optimal design of four-bar linkages for path-generation purposes. Three, often conflicting criteria including the mechanism's tracking error, deviation of its transmission angle from 90 and its maximum angular velocity ratio are considered as objectives of the optimization problem [4].

3 SYNTHESIS OF MECHANISM
The synthesis of mechanism is the design or creation of a mechanism to produce a desired output motion for a given input motion. In other words, the synthesis of mechanism deals with the determination of proportions of a mechanism for the given input and output motion. In the application of synthesis, to the design of a mechanism, the problem divides itself into the following three parts. 1) Type synthesis 2) Number synthesis 3) Dimensional synthesis 3.1. TYPE SYNTHESIS: Type synthesis refers to the kind of mechanism selected; it might be a linkage, a geared system, belts and pulleys, or even a cam system. 3.2. NUMBER SYNTHESIS: Number synthesis deals with the number of links and the number of joints or pairs that are required to obtain certain mobility. Number synthesis is the second step in design following type synthesis. 3.3. DIMENSIONAL SYNTHESIS: The third step in design, determining the dimensions of the individual links, is called dimensional synthesis. Following are various problems occurring in dimensional synthesis. 3.3.1. Function generation A frequent requirement in design is that of causing an output member to rotate, oscillate, or reciprocate according to a specified function of time or function of the input motion. This is called function generation. That is correlation of an input motion with an output motion in a linkage. A simple example is that of synthesizing a four-bar linkage to generate the function the function y=f(x). In this case, x would represent the motion (crank angle) of the input crank, and the linkage would be designed so that the motion (angle) of the output rocker would approximate the function y.

Other examples of function generation are as follows: In a conveyor line the output member of a mechanism must move at the constant velocity of the conveyor while performing some operation for example, bottle capping, return, pick up the cap, and repeat the operation. The output member must pause or stop during its motion cycle to provide time for another event. The second event might be a sealing, stapling, or fastening operation of some kind. The output member must rotate at a specified no uniform velocity function because it is geared to another mechanism that requires such a rotating motion. 3.3.2. Path generation A second type of synthesis problem is called path generation. This refers to a problem in which a coupler point is to generate a path having a prescribed shape that is controlling a point in a plane such that it follows some prescribed path. Common requirements are that a portion of the path be a circular arc, elliptical, or a straight line. Sometimes it is required that the path cross over itself. For this minimum 4-bar linkage are needed. It is commonly to arrive a point at a particular location along the path without/with prescribed times. 3.3.3. Motion generation The third general class of synthesis problem is called body guidance. Here we are interested in moving an object from one position to another. The problem may call for a simple translation or a combination of translation and rotation. In the construction industry, for example, heavy parts such as a scoops and bulldozer blades must be moved through a series of prescribed positions.

4 TRANSMISSION ANGLE
The transmission angle is an important criterion for the design of mechanisms by means of which the quality of motion transmission in a mechanism, at its design stage can be judged. It helps to decide the Best among a family of possible mechanisms for most effective force transmission. Transmission angle is a smaller angle between the direction of velocity difference vector VBA of driving link and the direction of absolute velocity vector VB of output link both taken at the point of connection (Fig 4.1). It is the angle between the follower link and coupler of a 4-bar linkage. The definitions are related to a joint variable and depend on the choice of driver and driven links. It appears to be an acute angle and an obtuse angle (180). It varies throughout the range of operation and is most favorable when it is 90. The recommended transmission angle is 9050. In mechanism having a reversal of motion, i.e. if roles of i/p and o/p links are reversed during the cycle, transmission angle must be investigated for both directions of motion transmission. Transmission of motion is impossible when transmission angle is 0 or 180. If transmission angle is zero, no torque can be realized on output link, i.e. mechanism is at its dead center position. A large transmission angle does not necessarily guarantee the low fluctuation of torque. Very small or very large transmission angle results in large error of motion, high sensitivity to manufacturing error, noisy and unacceptable mechanism. It is not the absolute value of transmission angle but its deviation from 90 that is significant. Different limits for transmission angle suggested are 35145; 40140; 45135. 4.1. MAXIMUM AND MINIMUM TRANSMISSION ANGLES The transmission angles at the extreme positions of a double rocker linkage will also be the minimum and maximum values of transmission angle for the entire motion of mechanism (Fig. 4.2). In case of crank-rocker and drag mechanisms, the transmission angle will be minimum when input crank angle is zero and maximum when input crank angle is 180 (Fig.4.3 and Fig.4.4).These occur twice in each revolution of the driving crank. They do not occur at the extreme positions of the linkage

Fig. 4.1. Showing Transmission Angle.

Fig. 4.2. Double-Rocker Mechanism

Fig. 4.3 The Crank-Rocker Mechanism.

Fig. 4.4 Double-Crank Mechanism.

4.2. OPTIMUM TRANSMISSION ANGLE The deviation of transmission angle from 90 is the measure of reduction in effectiveness of force transmission. So the aim in linkage design is to proportion the links so that these deviations are as small as possible, especially in the presence of appreciable joint friction. If the range of operation is sufficiently small, it seems as if we could obtain a linkage with optimum variation of transmission angle if it is set equal to 90 in the designed position . Among the family of possible 4-bar linkages, there is one linkage that has a minimum transmission angle, which is greater than the minimum transmission angles of all the others. This is called optimum transmission angle and this particular linkage has the best dimensions for most effective force transmission. If the designer tries to optimize the linkage with respect to its force transmission characteristics simultaneously with optimum transmission angle synthesis, it increases the difficulty of problem extensively. Therefore combined force transmission and synthesis studies have been restricted to relatively simple linkages. On the other hand, the problem simplifies significantly if the transmission angle is restricted such that =maximum deviation of transmission angle from optimum one and bound on where specific

5 ENUMERATION OF THE GFBM

The mechanism studied in this work has a topology type A, which is simply a gear pair combined with a four-bar mechanism. Different mechanisms can be obtained by fixing links 1 to 5 respectively. These mechanisms can be summarized as in (Fig.5.1). Moreover, by changing the input and output links, different inputoutput functions can be achieved. Note that, instead of external gears internal gears can also be used in some of these mechanisms. Type A3 is nothing but a four-bar driven by another gear, and type A5 is a four-bar with a floating gear pair. The mechanism studied in this work is of topology type A1. One of the gears is rigidly connected to the coupler and the other gear has a fixed axis of rotation. This forms a planetary gear train with link 3 as the arm. The input torque is applied to link 2, and the output is obtained at the arm (link 3). Thus, the input and the output displacements are about the same rotation axis.

Fig. 5.1 Enumeration Of The GFBM.

6 MOTION ANALYSIS OF THE GFBM

In order to obtain the relationship between the input (12) and output (13), an equation can be obtained from the loop closure equation of the four-bar mechanism (Fig.6.1). a3 + a4 a1 = a5 (1)

There is another equation which is the velocity ratio of the planetary gear arrangement formed by links 2, 3 and 4: = = R (2)

Integrating this equation: 14 = 13 +k (3)

Where, R = r4/r2 and k is a constant determined by the initial relative positions of links 2 and 4 with respect to link 3 (integration constant). Eq. (3) can be used in Eq. (1) to eliminate 14 and a new equation can be obtained. Then, this obtained equation can be multiplied by its complex conjugate (eliminating 15) to obtain a relationship between 12 and 13. However, obtaining an explicit relationship between the input and the output is very hard if not impossible by this method. Therefore, a novel approach is used to determine the inputoutput relationship in two steps. It is assumed that the input link of the mechanism is not link 2 but link 4. Hence, according to this assumption, an explicit relationship between 14 and 13 can be determined from the loop closure equation of the four-bar mechanism. Since, 13 is determined as a function of 14, then by using Eq. (3) a relationship between 12 and 14 can be obtained. Hence, for a given 14 corresponding 13 and 12 can be determined explicitly. Therefore, a chart which gives the relationship between the input 12 and output 13 can be determined. With this approach, an iterative numerical solution is eliminated. For link 2 to have a complete rotation, the coupler link (link 4) must also have a complete rotation, while links 3 and 5 will have oscillations only. The full cycle rotation of link 3 imparts a full cycle rotation of the coupler link of the four-bar formed by links 1, 3, 4 and 5 (Fig. 3). This four-bar mechanism must then be of Grasshof type double-rocker mechanism (the sum of the longest and shortest link lengths is less than the sum of the two intermediate link lengths and the link opposite the shortest link is the frame). 8

With this consideration, the rotation of link 3 can be determined in terms of the rotation of the coupler (link 4). Multiplying the loop closure Eq. (1) by its complex conjugate, the output 13 can be determined as a function of 14. 13 = 2arc tan ( Where, A = K1K2 cos 14 + K3K4 cos 14 B = 2K2 sin 14 C = K1 + K2 cos 14K3K4cos14 K1 = a21 + a23 + a24 a25 K2 = 2a3a4 K3 = 2a1a3 K4 = 2a1a4. Since 13 is determined for a given 14, corresponding 12 can be determined from Eq. (3). 12 = (R + 1) 13 - R 14 + K (4) and (5) respectively. k is a constant determined by the initial relative positions of links 2 and 4 with respect to link 3 (integration constant). It can be choosen arbitrarily. While obtaining inputoutput curves, in order to start 12 values from 0 (when 14=0, 13initial is calculated, so in order to obtain 12=0), k is chosen as: k = (R + 1) 13initial. (5) Therefore, the inputoutput relationship can be determined at two steps by solving Eqs.

(4)

Fig. 6.1. The GFBM And The Corresponding Four-Bar Mechanism When The Gears Are Removed.

7 TRANSMISSION ANGLE OF THE GFBM

The transmission angle of a mechanism is defined as : tan() = Neglecting the mass of the links, the free-body diagrams of the links of the GFBM will be as shown in Fig.7.1. Where, Ti is the input torque applied to link 2, To is the output torque at link 3, and is the pressure angle of the gears. The transmission angle of the mechanism can be obtained as: tan() = F43t / F43n the transmission angle can be determined as: tan() =

(6)

From the free-body diagrams of the links, F43t and F43n can be obtained, and from Eq. (6),

If the direction of rotation of the input link is changed, then the transmission angle of the GFBM alters since the line of action of the force between links 2 and 4 changes (Fig.7.2). In this case, the transmission angle will be given by: tan() =

Note that there is a minus sign in front of the term including . Unlike all other mechanisms known up to now, for this mechanism the force transmission characteristics are also a function of rotation direction. A mechanism which has proper transmission angle values in one rotation direction can even lock if the direction of rotation of the input is reversed.

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Fig. 7.1. The FBD Of The Links When Link 2 Is Rotating Counterclockwise.

Fig. 7.2 The FBD Of Link 4 When Link 2 Is Rotating Clockwise.

8 SYNTHESIS OF THE GFBM

The problem is considered in two parts. The first part is the synthesis problem in which one must determine a four-bar mechanism of Grashof type with double-rocker proportions that have given swing angles and for links 3 and 5 respectively. There is an infinite set of solutions for this part of the problem. The second part of the problem is concerned with the optimization. Out of the infinite possible set of solutions obtained in the first part, one must determine a particular mechanism whose maximum transmission angle deviation from 90 is a minimum. The extended and folded positions of the mechanism are shown in Fig. 8.1. At the extended position link 3 is at the forward position and at the folded position link 3 is at the fully withdrawn position. is the angle of link 3 and is the angle of link 5 at the folded position. The loop closure equations for the folded and extended positions of the mechanism can be written as: a3ei = a1 + (a5a4) ei a3ei( + ) = a1 + ( a5 + a4) ei( + ) One can define Z1, Z2 and as: Z1 = a3ei Z2 = a5ei = Without a loss of generality the fixed link can be chosen as unity; a1=1. Then, Eqs. (7) and (8) can be written in normalized form as: Z1Z2 (1) = 1 Z1eiZ2ei (1 + ) = 1 can be solved in terms of , , and as: Z1 = Z2 =

(7) (8)

(9) (10) (11)

(12) (13)

These complex equations are linear in terms of the unknowns Z1 and Z2. Then, Z1 and Z2

(14) (15)

As changes from to +, Z1 and Z2 describe a curve which is the loci of the tip of the vectors AoAf and BoBf. These loci are two circles for any given value of and . In (Graph 8.1), these two circles are shown for the values of =50 and =10. 11

A line can be drawn from (0, 0), which is Ao, at an angle with respect to AoBo. Af is the intersection point of this line and the Z1 circle. Another line can be drawn from Bo at angle with respect to AoBo which intersects the circles at Af and Bf, respectively. This corresponds to the folded position of the mechanism, where the link lengths are, AoA = a3, AfBf = a4, BoBf=a5 and AoBo=a1 Analytically, link lengths can be determined as:

The link lengths are functions of the free parameter , and swing angles , and . For a given and , there is a set of solutions with respect to the free parameter . A necessary but not sufficient condition for double-rocker proportions is: 900 .

In order to obtain double-rocker proportions there are limits on swing angles as: . 900

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Fig. 8.1. The Dead-Center Positions Of The GFBM.

Graph 8.1. Z1 And Z2 Circles For The Values Of =50 And =10.

9 TRANSMISSION ANGLE OPTIMIZATION

Among the set of solutions for a given and , the one for which the maximum deviation of the transmission angle from 90 is a minimum must be selected (opt will be determined). The design charts are obtained for a given output swing angle and the corresponding input link rotation . Therefore, the optimum mechanism in terms of the transmission angle can be determined, for a given output swing angle and a time ratio, from the design charts. Using Eq. (5) at the folded and extended positions, can be obtained for a gear ratio R, and according to the input direction of rotation ( sign for cw input) as: = (R + 1) R R

A parametric optimization routine is developed and design charts for optimum GFBM are prepared by using MATLAB. According to the direction of rotation of the input, the transmission angle of the GFBM changes. That condition leads to two different optimum mechanisms which have the same output swing angle and corresponding input rotation . Therefore, transmission angle optimization is performed for both of the input directions of rotation and two sets of design charts are prepared. The affect of gear ratio (R) is very clear, it affects the transmission angle; if R is increased, then the transmission angle improves. Therefore, transmission angle optimization is performed for several gear ratios and the corresponding design charts are also prepared. Some of those design charts are displayed in (Graph 9.1-9.4). The Y-axis represents the output swing angle , and the X-axis represents the corresponding input link rotation . The full lines represent the optimum parameter, and the dotted lines represent the maximum deviation of the transmission angle from 90 (max) for the corresponding mechanism. Since, and are the given parameters, a value for and another value for is chosen from Y and X axes respectively. Then, these values are intersected and the value of optimum parameter, and for that mechanism, the value of maximum deviation of the transmission angle from 90 can be obtained. If the obtained max is not preferred, then or is changed, and another optimum solution can be obtained. Therefore, by the aid of these design charts, by specifying and , the corresponding optimum mechanism and max for that mechanism can be determined easily.

13

It can be observed that transmission characteristics of the mechanisms deteriorate as the input rotation approaches to R180 (R=1,2,3,4). Therefore, for an acceptable transmission angle, centric mechanisms can be obtained for small output swing angles only. Hence, it can be concluded that this type of GFBM is useful for quick-return motions. This condition is explained as below. If a mechanism is to be designed from graph 8.1, which has an output swing angle =50 and a large time ratio of 2 (=120), from the intersection point of these values it is seen that the value of 0.7, and for that mechanism the maximum deviation of the transmission angle from 90 is 42. If a smaller time ratio is desired, for example 210/150 (still =50) is chosen as 150. Then, from the intersection point of these values it is determined that 0.67 and max 62 which lead to a mechanism with poor transmission characteristics. So, it can be observed that as the time ratio approaches to 1 ( approaches to 180) for a fixed value of , the maximum deviation of the transmission angle from 90 (max) of the corresponding mechanism increases (also note that in graph 9.3, since R=2, as time ratio approaches to 1, approaches to 360). The gear ratio R significantly affects the transmission angle of the GFBM. As R increases, the transmission angle improves and mechanisms with larger output swing angles can be obtained (Graph 9.3 and 9.4). Conversely, if R is decreased, transmission characteristics deteriorate. Therefore, transmission angle optimization is performed for several gear ratios and the corresponding design charts are also prepared.

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Graph 9.1.The Design Chart For CW Input Rotation And R=1.

Graph 9.2. The Design Chart For CCW Input Rotation And R=1.

Graph 9.3. The Design Chart For CW Input Rotation And R=2.

Graph 9.4.The Design Chart For CW Input Rotation And R=4.

CONCLUSION
In this work a new type of geared four-bar mechanism for which the input and output shafts are collinear has been investigated. A novel analysis method is devised, expressions for the transmission angle are derived and charts are prepared for the optimum design of such mechanisms. By the aid of these design charts, by specifying the output swing angle and the time ratio, the corresponding mechanism which has the best transmission characteristics can be determined easily. It is observed that, the gear ratio significantly affects the transmission angle; as the gear ratio (R) increases, the transmission angle improves. According to the direction of rotation of the input, there are two different optimum mechanisms which have the same output swing angle and corresponding input rotation. During the working stroke, approximately constant angular velocity at the output link is observed. This type of GFBM is suitable as a quick-return mechanism. Large time ratios can be obtained with acceptable force transmission characteristics.

ACKNOWLEDGEMENT
First of all I thank the almighty for providing me with the strength and courage to present the seminar. I would to like to express my sincere thanks to Prof. A. V. Patil Head of Department of Mechanical engineering for all his assistance. I wish to express my deep sense of gratitude to Prof. R. B. Barjibhe, Department of Mechanical Engineering who guided me throughout the seminar. His overall direction and guidance has been responsible for the successful completion of the seminar. I am also indebted to all the teaching and non-teaching staff of the Department of Mechanical Engineering for their cooperation and suggestions, which is the spirit behind this report. Last but not the least, I express my sincere gratitude from the depth of my heart to my parents, friends and all well wishers for their kind support and encouragement in the successful completion of my report work.

Y. B. Patil

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