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Mechanism (Design
with COSMOSMotion 2007
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ISBN: 978-1-58503-482-6
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Copyright © 2008 by Kuang-Hua Chang.
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Mechanism Design with COSMOSMotion
Preface
This b o o k is written to help y o u b e c o m e familiar w i t h COSMOSMotion, an add-on m o d u l e of the
SolidWorks software family, w h i c h supports m o d e l i n g a n d analysis (or simulation) of m e c h a n i s m s in a
virtual (computer) environment. Capabilities in COSMOSMotion support y o u to use solid m o d e l s created
in SolidWorks to simulate and visualize m e c h a n i s m m o t i o n and performance. Using COSMOSMotion
early in the product development stage could prevent costly (and sometimes painful) redesign due to
design defects found in the physical testing phase. Therefore, using COSMOSMotion for support of
design decision m a k i n g contributes to a m o r e cost effective, reliable, and efficient product design process.
This b o o k covers the basic concepts and frequently used c o m m a n d s required to advance readers
from a novice to an intermediate level in using COSMOSMotion. Basic concepts discussed in this b o o k
include m o d e l generation, such as assigning m o v i n g parts and creating j o i n t s and constraints; carrying out
simulation and animation; and visualizing simulation results, such as graphs and spreadsheet data. These
concepts are introduced using simple, yet realistic examples.
Verifying the results obtained from the computer simulation is extremely important. O n e of the
u n i q u e features of this b o o k is the incorporation of theoretical discussions for kinematic a n d dynamic
analyses in conjunction with the simulation results obtained using COSMOSMotion. T h e p u r p o s e of the
theoretical discussions lies in solely supporting the verification of simulation results, rather than
providing an in-depth discussion on the subject of m e c h a n i s m design. COSMOSMotion is not foolproof.
It requires a certain level of experience and expertise to master the software. Before arriving at that level,
it is critical for y o u to verify the simulation results w h e n e v e r possible. Verifying the simulation results
will increase y o u r confidence in using the software and prevent y o u from being fooled (hopefully, only
occasionally) by any erroneous simulations produced by the software.
http://www.solidworks.com/
This b o o k should serve self-learners well. If such describes y o u , y o u are expected to h a v e basic
Physics and Mathematics background, preferably a B a c h e l o r ' s degree in science or engineering. In
addition, this b o o k assumes that y o u are familiar with the basic concept and operation of SolidWorks part
and assembly m o d e s . A self-learner should be able to complete all lessons in this b o o k in about fifty
hours. An investment of fifty hours should advance y o u from a novice to an intermediate level user.
This b o o k also serves class instructions well. The b o o k will m o s t likely be used as a supplemental
textbook for courses like Mechanism Design, Rigid Body Dynamics, Computer-Aided Design, or
ii Mechanism Design with COSMOSMotion
Computer-Aided Engineering. This b o o k should cover four to six w e e k s of class instruction, depending
on h o w the courses are taught and the technical b a c k g r o u n d of the students. S o m e of the exercise
problems given at the end of the lessons m a y require significant effort for students to complete. The
author strongly encourages instructors and/or teaching assistants to go through those exercises before
assigning t h e m to students.
KHC
Norman, Oklahoma
May 15,2008
Acknowledgements
I w o u l d like to thank my family for the patience and support they h a v e given to me in completing
this book, especially, my wife Sheng-Mei for her unconditional giving and encouragement. T h a n k s are
due to my children, Charles and Annie, for their understanding, caring, a n d appreciation. Especially, I
appreciate their patience in reviewing the w h o l e b o o k and correcting a few sentences for m e .
T h a n k s are also due to undergraduate students at the University of O k l a h o m a ( O U ) for their help in
testing e x a m p l e s included in this book. T h e y m a d e n u m e r o u s suggestions that i m p r o v e d clarity of
presentation and found n u m e r o u s errors that w o u l d h a v e otherwise crept into the book. Their
contributions to this b o o k are greatly appreciated.
I am grateful to my current and former students, T h o m a s Cates, Petr Sramek, and Tyler Bunting, for
their excellent contribution in creating examples for the application lesson; i.e., Lesson 8. T h e assistive
device project e m p l o y e d as the example in Lesson 8 was successful and well recognized.
Finally, I w o u l d like to thank our Creator, w h o has given me the strength and intelligence to
complete this book.
Mechanism Design with COSMOSMotion iii
Dr. C h a n g w o n awards in b o t h teaching and research in the past few years. He is a recipient of the
S A E R a l p h R . Teetor A w a r d (2006), Outstanding Asian A m e r i c a n A w a r d sponsored b y O k l a h o m a Asian
A m e r i c a n Association (2003), a n d Public E m p l o y e e A w a r d o f O K C M a y o r ' s C o m m i t t e e A w a r d o n
Disability Concerns (2002). In addition, he received several awards from O U , including the OU A l u m n i
Teaching A w a r d (Spring 2007 and Fall 2007), R e g e n t s ' A w a r d on Superior Research a n d Creative
Activities (2004), B P A M O C O G o o d Teaching A w a r d (2002), and Junior Faculty A w a r d (1999). Dr.
C h a n g w a s n a m e d Williams Companies Foundation Presidential Professor in 2005 by OU President
D a v i d L. B o r e n for meeting the highest standards of excellence in scholarship and teaching.
In addition to the soccer ball kicking device, students at OU h a v e been involved in developing m a n y
other assistive devices. Currently, an Undergraduate student t e a m is developing a transporting device that
will help a local resident with only functional right h a n d m o v e from her wheelchair to her b e d and vise
versa independently. Students w e r e also involved in developing special b a b y crib, pediatric assistive
w a l k i n g device, and modification of a child walker, etc., in the past. All these projects require customized
features to meet special needs. These projects h a v e b e e n supported by H o n o r s College of O U ,
Schlumberger, and private donations. All supports are sincerely appreciated.
iv Mechanism Design with COSMOSMotion
Table of Contents
Preface i
11
Acknowledgments
A b o u t the A u t h o r iii
i v
Table o f Contents
Lesson 2: A Ball T h r o w i n g E x a m p l e
Lesson 4: A Simple P e n d u l u m
L e s s o n 5: A S l i d e r - C r a n k M e c h a n i s m
Lesson 6: A C o m p o u n d S p u r G e a r Train
Lesson 7: C a m a n d Follower
In this lesson, we will start with a brief introduction to COSMOSMotion and the various types of
physical problems that COSMOSMotion is capable of solving. We will then discuss capabilities offered
by COSMOSMotion for creating m o t i o n m o d e l s , conducting m o t i o n analyses, a n d v i e w i n g m o t i o n
analysis results. In the final section, we will m e n t i o n examples e m p l o y e d in this b o o k and topics to learn
from these examples.
N o t e that materials presented in this lesson will be kept brief. M o r e details on various aspects of
m e c h a n i s m design and analysis using COSMOSMotion will be given in later lessons.
1.2 W h a t is COSMOSMotion?
COSMOSMotion is a computer software tool that supports engineers to analyze and design
m e c h a n i s m s . COSMOSMotion is a m o d u l e of the SolidWorks product family developed by SolidWorks
Corporation. This software supports users to create virtual m e c h a n i s m s that answer general questions in
product design as described next. An internal combustion engine s h o w n in Figures 1-1 a n d 1-2 will be
u s e d to illustrate s o m e typical questions.
1. Will the c o m p o n e n t s of the m e c h a n i s m collide in operation? For example, will the connecting rod
collide with the inner surface of the piston or the inner surface of the engine case during operation?
5. W h a t is the reaction force or torque generated at a connection (also called joint or constraint)
b e t w e e n c o m p o n e n t s (or bodies) during m o t i o n ? For example, w h a t is the reaction force at the j o i n t
between the connecting r o d and the piston pin? This reaction force is critical since the structural
integrity of the piston pin and the connecting r o d m u s t be ensured; i.e., they m u s t be strong and
durable e n o u g h to sustain the load in operation.
The capabilities available in COSMOSMotion also help y o u search for better design alternatives. A
better design alternative is very m u c h p r o b l e m dependent. It is critical that a design p r o b l e m be clearly
defined by the designer up front before searching for better design alternatives. For the engine example, a
better design alternative can be a design that reveals:
In order to vary c o m p o n e n t sizes for exploring better design alternatives, the parts and assembly
m u s t be adequately parameterized to capture design intents. At the parts level, design parameterization
implies creating solid features and relating dimensions properly. At the assembly level, design
parameterization involves defining assembly mates and relating dimensions across parts. W h e n a solid
m o d e l is fully parameterized, a change in dimension value can be propagated to all parts affected
automatically. Parts affected m u s t be rebuilt successfully, and at the same time, they will h a v e to maintain
proper position a n d orientation w i t h respect to one another without violating any assembly mates or
revealing part penetration or excessive gaps. F o r example, in this engine example, a change in the bore
diameter of the engine case will alter not only the geometry of the case itself, but all other parts affected,
such as the piston, piston sleeve, a n d even the crankshaft, as illustrated in Figure 1-3. M o r e o v e r , they all
have to be rebuilt properly and the entire assembly must stay intact through assembly mates.
K i n e m a t i c s is the study of m o t i o n w i t h o u t regard for the forces that cause the motion. A kinematic
m e c h a n i s m m u s t be driven by a servomotor (or m o t i o n driver) so that the position, velocity, and
acceleration of each link of the m e c h a n i s m can be analyzed at any given time. Typically, a kinematic
analysis m u s t be conducted before dynamic b e h a v i o r of the m e c h a n i s m can be simulated properly.
(1.1)
w h e r e (•) appearing on top of the physical quantities represents t i m e derivative of the quantities, m is the
total m a s s of the block, k is the spring constant, and c is the d a m p i n g coefficient.
F o r a rigid b o d y , m a s s properties
(such as the total m a s s , center of m a s s ,
m o m e n t of inertia, etc.) are taken into
account for d y n a m i c analysis. For
example, m o t i o n of a p e n d u l u m
s h o w n in Figure 1-7 is g o v e r n e d by
the following equation of motion,
Y M = -mgl s i n 0 = 10 = m£ 0
d
2
(1.2)
D y n a m i c analysis of a rigid b o d y system, such as the single piston engine s h o w n in Figure 1-3, is a
lot m o r e complicated than the single b o d y problems. Usually, a system of differential and algebraic
equations governs the m o t i o n a n d the d y n a m i c behavior of the system. N e w t o n ' s law m u s t be o b e y e d by
every single b o d y in the system at all time. T h e m o t i o n of the system will be determined by the loads
acting on the bodies or j o i n t axes (e.g., a torque driving the system). Reaction loads at the j o i n t
connections h o l d the bodies together.
Operation Mode
User Interfaces
W h e n y o u click the Motion button, the b r o w s e r will provide y o u with a graphical, hierarchical v i e w
of m o t i o n m o d e l and allow y o u to access all COSMOSMotion functionalities t h r o u g h a combination of
drag-and-drop and right-click activated m e n u s .
F o r example, y o u m a y drag
and drop connectingrod_asm-l
under the Assembly Components,
as s h o w n in Figure 1-11 to
Moving Parts u n d e r the Parts
branch to define it as a m o v i n g
part. Y o u m a y also right click an
entity a n d choose to define or edit
its property. F o r example, y o u
m a y right click the Springs n o d e
u n d e r Forces b r a n c h in Figure 1-
12, and choose Add Translational
Spring to add a spring.
Table 1-2 gives a brief explanation of each tab available in the IntelliMotion Builder.
Constraints
A constraint (or connection) in COSMOSMotion can be a joint, contact, or coupler that connects t w o
parts and constrains the relative m o t i o n b e t w e e n them. Typical joints include a revolute, cylindrical,
spherical, etc. Each independent m o v e m e n t permitted by a constraint is a free degree of freedom (dof).
The degrees of freedom that a constraint allows can be translational or rotational along the three
perpendicular axes. T h e free dof is revealed by the symbol of the constraint. F o r example, the symbol of
cylindrical joints, such as those defined in the engine e x a m p l e s h o w n in Figure 1-15, show t w o concentric
cylinders implying t w o free d o f s, a translational and a rotational, both are along the c o m m o n axis, as
illustrated in Figure l - 1 6 b . Also, a revolute joint, for e x a m p l e the one b e t w e e n the propeller and the case
shown in Figure 1-15, allows only one rotational dof, as depicted in a hinge symbol s h o w n in Figure 1-
16c. Understanding the j o i n t symbols will enable y o u to read existing m o t i o n m o d e l s . Also, a j o i n t
produces equal and opposite reactions (forces and/or torques) on the bodies connected due to N e w t o n ' s
r d
3 L a w . M o r e about j o i n t s will be discussed in later lessons and for a list of c o m m o n l y e m p l o y e d joints,
please refer to A p p e n d i x A.
Degrees of Freedom
D = 6M-N-0 (1.3)
w h e r e D is the G r u e b l e r ' s count representing the total degrees of freedom of the m e c h a n i s m , M i s the
n u m b e r of bodies excluding the g r o u n d b o d y , TV is the n u m b e r of d o f s restricted by all joints, and O is the
n u m b e r of m o t i o n drivers defined in the system.
D = 6x1 -2x5 = -4
For kinematic analysis, the G r u e b l e r ' s count m u s t be equal to or less than 0. T h e ADAMS/Solver
recognizes a n d deactivates redundant constraints during analysis. For a k i n e m a t i c analysis, if y o u create a
m o d e l and try to animate it with a G r u e b l e r ' s count greater than 0, the animation will n o t r u n and an error
m e s s a g e will appear.
T h e single-piston engine s h o w n in Figure 1-15 consists of three bodies (excluding the ground body),
one revolute j o i n t and three cylindrical joints. A revolute j o i n t r e m o v e s five degrees of freedom, and a
cylindrical j o i n t r e m o v e s four d o f s. In addition, a m o t i o n driver is a d d e d to the rotational d o f of the
revolute joint. Therefore, according to Eq. 1.3, the G r u e b l e r ' s count for the engine e x a m p l e is
If the G r u e b l e r ' s count is less than zero, the solver will automatically r e m o v e redundancies. In this
engine example, if the t w o of the cylindrical j o i n t s ; b e t w e e n piston and the piston pin, and b e t w e e n the
connecting r o d and the crank shaft, are replaced by revolute joints, the G r u e b l e r ' s count b e c o m e s
D = 6x(4-l)-(3x5-1x4) - lxl = -2
To get the G r u e b l e r ' s count to zero, it is often possible to replace j o i n t s that r e m o v e a large n u m b e r
of constraints with j o i n t s that r e m o v e a smaller n u m b e r of constraints a n d still restrict the m e c h a n i s m
m o t i o n in the s a m e w a y . COSMOSMotion detects the redundancies a n d ignores r e d u n d a n t d o f s in all
analyses, except for d y n a m i c analysis. In d y n a m i c analysis, the redundancies lead to an o u t c o m e with a
possibility of incorrect reaction results, yet the m o t i o n is correct. F o r complete a n d accurate reaction
forces, it is critical that y o u eliminate redundancies from y o u r m e c h a n i s m . T h e challenge is to find the
joints that will i m p o s e n o n - r e d u n d a n t constraints and still allow for the intended motion. E x a m p l e s
included in this b o o k should give y o u s o m e ideas in choosing proper j o i n t s .
Forces
A p p l i e d forces are forces that cause the m e c h a n i s m to m o v e in certain w a y s . A p p l i e d forces are very
general, b u t y o u m u s t supply y o u r o w n description of the force by specifying a constant force value or
expression function, such as a h a r m o n i c function. The applied forces in COSMOSMotion include action-
only force or m o m e n t (where force or m o m e n t is applied at a point on a single rigid body, and no reaction
forces are calculated), action a n d reaction force and m o m e n t , and impact force. T h e force and m o m e n t
symbols in COSMOSMotion are s h o w n in Figure 1-17 and 1-18, respectively.
Flexible connectors resist m o t i o n a n d are simpler and easier to use than applied forces because y o u
only supply constant coefficients for the forces, for instance a spring constant. T h e flexible connectors
include translational springs, torsional springs, translational dampers, torsional d a m p e r s , a n d bushings,
which symbols are s h o w n in Figure 1-19.
A m a g n i t u d e and a direction m u s t be included for a force definition. Y o u m a y select a predefined
function, such as a h a r m o n i c function, to define the m a g n i t u d e of the force or m o m e n t . F o r spring and
damper, COSMOSMotion automatically m a k e s the force m a g n i t u d e proportional to the distance or
velocity b e t w e e n t w o points, b a s e d on the spring constant a n d d a m p i n g coefficient entered, respectively.
The direction of a force (or m o m e n t ) can be defined by either along an axis defined by an edge or along
the line b e t w e e n t w o points, w h e r e a spring or a d a m p e r is defined.
Initial Conditions
Motion Drivers
Motion Simulation
As discussed earlier, kinematics is the study of m o t i o n without regard for the forces that cause the
motion. A m e c h a n i s m can be driven by a motion driver (e.g., a servomotor) for a kinematic analysis,
w h e r e the position, velocity, a n d acceleration of each link of the m e c h a n i s m can be analyzed at any given
time. Figure 1-21 shows a servomotor drives a m e c h a n i s m at a constant angular velocity.
In COSMOSMotion, results of the m o t i o n analysis can be realized using animations, graphs, reports,
and queries. A n i m a t i o n s show the configuration of the m e c h a n i s m in consecutive time frames.
Animations will give y o u a global v i e w on h o w the m e c h a n i s m b e h a v e s , for example, the single-piston
engine s h o w n in Figure 1-23. Y o u m a y also export the animation to A V I or V R M L for various purposes.
In addition, y o u m a y choose a j o i n t or a part to generate result graphs, for example, the position vs.
time of the piston in the engine e x a m p l e shown in Figure 1-24. T h e s e graphs give y o u a quantitative
understanding on the characteristics of the m e c h a n i s m .
Y o u m a y also query the results by m o v i n g the cursor closer to the curve and leave the cursor for a
short period. T h e result data will appear next to the cursor. In addition, y o u m a y ask COSMOSMotion for
a report that includes a complete set of results output in the form of textual data or a Microsoft® Excel
spreadsheet.
We will start w i t h a simple ball-throwing example in Lesson 2. This e x a m p l e will give y o u a quick
run-through on using COSMOSMotion. Lessons 3 through 7 focus on m o d e l i n g and analysis of basic
m e c h a n i s m s and d y n a m i c systems. In these lessons, y o u will learn various j o i n t types, including revolute,
planar, cylindrical, etc.; forces and connections, including springs, gears, cam-followers; drivers and
forces; various analyses; and graphs and results. Lesson 8 is an application lesson, in w h i c h an assistive
soccer ball kicking device that can be m o u n t e d on a wheelchair will be introduced to show y o u h o w to
apply w h a t y o u learn to real-world applications. All examples a n d m a i n topics to be discussed in each
lesson are s u m m a r i z e d in the following table.
2.1 O v e r v i e w of the L e s s o n
2.2 T h e Ball T h r o w i n g E x a m p l e
Physical Model
and choose the Document Properties tab in the System Options - General dialog b o x , click the Units
n o d e , and then p i c k the units system y o u prefer, as s h o w n in Figure 2-2.
T h e assembly Lesson2.SLDASM consists of t w o parts: the ball (ball.SLDPRT) and the ground
(ground.SLDPRT). T h e ball is fully assembled with the g r o u n d by three assembly mates of three pairs of
reference planes. T h e y are Front (ball)/Front (ground), Right (ball)/'Right (ground), a n d Top (ball)/7b/?
(ground), as s h o w n in Figure 2 - 3 . T h e distance b e t w e e n the reference planes Top (ball) and Top (ground)
is 100 in., w h i c h defines the initial position of the ball, as s h o w n in Figure 2-4. T h e radius of the ball is 10
3
in., and the ground is m o d e l e d as a 30*500*0.04 in. rectangular block.
N o t e that the 7-axis of the global
coordinate system (located at the
lower left corner of the SolidWorks
graphics screen, as s h o w n in Figure 2-
4) is pointing u p w a r d , w h i c h is
consistent with the default direction of
the gravity, but in the opposite
direction.
Motion Model
2
A gravitational acceleration -386 i n / s e c is defined in the 7-direction of the global coordinate
system. T h e ball will reveal a parabolic trajectory due to gravity. A 3D contact constraint will be added to
characterize the impact b e t w e e n the ball and the ground. As discussed earlier, a coefficient of restitution
C = 0.75 will be specified to determine the force that acts on the ball w h e n the impact occurs. In this
R
2.3 U s i n g COSMOSMotion
In this lesson, we will use the IntelliMotion Builder for m o s t of the steps. The IntelliMotion Builder
is the primary interface in COSMOSMotion. It is a t a b b e d dialog b o x and a w i z a r d that leads y o u through
Before we start, we will suppress t w o assembly mates
to allow the ball to m o v e on the X-Y plane. C h o o s e the
Assembly button on top of the browser, a n d e x p a n d the
Mates branch by clicking the small button in front of it.
To use the IntelliMotion Builder, right click the Motion Model n o d e from the browser, a n d then
select IntelliMotion Builder (see Figure 2-5). The first tab of the IntelliMotion Builder is Units, w h i c h
brings up the Units p a g e . As shown in Figure 2-9, the IPS units system h a s b e e n chosen. No action is
needed.
At the lower-left corner of each p a g e in
the IntelliMotion Builder are the Back a n d
Next buttons, which help you move
sequentially through the motion model
creation, simulation, and animation process.
C h o o s e Next or click the Gravity tab.
Defining Bodies
Click ball-1 and drag it by holding d o w n the left-mouse button, m o v i n g the m o u s e until the cursor is
over the Moving Parts n o d e , a n d then releasing the m o u s e button. Part ball-1 is n o w added to the m o t i o n
m o d e l as m o v i n g parts (can m o v e ) . R e p e a t the same steps to m o v e ground-1 to the Ground Parts n o d e .
N o w , the part Ground-1 is a d d e d to the m o t i o n m o d e l as a g r o u n d part (cannot m o v e ) .
Defining Joints
Running Simulation
Click the Next button three times or click the Simulation tab directly (no spring or driver is n e e d e d
for this example; therefore, we are skipping the Spring and Motion tabs). As s h o w n in Figure 2 - 1 5 , the
simulation duration is 1 second a n d the n u m b e r of frames is 50 as defaults. We will stay with these
default values for the time being. Click Simulate to run a simulation.
After a few seconds, the ball will start m o v i n g . As s h o w n in Figure 2-16 the ball will fall through the
ground, w h i c h is n o t realistic. N o t e that the trace path that indicates the trace of the center of the ball is
turned on in Figure 2-16. We will learn h o w to do that later. For the time being we will h a v e to add a 3D
Contact constraint b e t w e e n the ball and the ground in order to m a k e the ball b o u n c e b a c k w h e n it hits the
ground. T h e 3D Contact constraint will create a force to prevent the ball from penetrating the ground.
This constraint will be only activated if the ball comes into contact with the ground.
F r o m the p u l l - d o w n m e n u , choose
or from the browser, right click the Contact branch, and then select
Add 3D Contact, as s h o w n in Figure 2-17. The Insert 3D Contact
dialog b o x will appear (Figure 2-18).
COSMOSMotion calculates w h e t h e r the parts' b o u n d i n g boxes (usually the rectangular box, similar to thai
of Figure 2-8, b u t for individual parts) interfere. If they interfere, COSMOSMotion performs a finer
interference calculation b e t w e e n the t w o bodies. At the same time, ADAMS/Solver c o m p u t e s and applies
an impact force on both bodies.
F r o m the browser, select Ground-7, the g r o u n d part will be listed in the first container (upper field),
as s h o w n in Figure 2-18. Click the Add Container for contact pairs button (in the m i d d l e ) , and pick ball-1
The part ball-1 will be listed in Container 2 (lower field).
Click the Contact tab to define contact parameters. N o t e that we will define a coefficient of
restitution for the impact. In the three sets of parameters appearing in the dialog b o x (Figure 2-19). turn
off the Use Materials (deselect the entity) and Friction (click None). C h o o s e Coefficient of Restitution I in
the middle), and enter 0.75 for Coefficient Restitution, as shown in Figure 2-19. Click Apply to accept the
3D Contact. T h e 3D Contact constraint should appear in the browser, as s h o w n in Figure 2-20. Y o u w i l l
h a v e to e x p a n d the Constraints branch and then the Contact branch to see the contact constraint.
Before we rerun the simulation, we will h a v e to adjust some of the simulation parameters. Especially
we will ask COSMOSMotion to u s e precise geometry to check contact in each frame of simulation.
R i g h t click the Motion Model n o d e from the browser and choose Simulation Parameters. In the
COSMOS Education Edition Options dialog b o x appearing (Figure 2-21), choose Use Precise Geo/?;,
for 3D Contact, and enter 3 seconds for Duration and 500 for Number of Frames. N o t e that we increase
the n u m b e r of frame so that we will see smooth graphs in various result displays. Increasing the number
of frame will certainly increase the simulation time. H o w e v e r , the increment is insignificant for this
simple example. Click OK io accept the definition a n d close the dialog b o x .
R i g h t click the Motion Model n o d e from the b r o w s e r and choose Run Simulation. After a few
seconds, the ball starts m o v i n g . As s h o w n in Figure 2-22 the ball will hit the ground and b o u n c e back a
few times before the simulation ends. T h e ball did n o t fall t h r o u g h the g r o u n d this t i m e due to the
addition of the 3D Contact constraint.
COSMOSMotion allows y o u to graphically display the path that any point on any m o v i n g part
follows. This is called a trace path. N o t e that the trace path of the ball w a s displayed in both Figures 2-16
and 2-22. We will first learn h o w to create a part trace path.
F r o m the browser, right click the Results n o d e , a n d choose Create Trace Path (see Figure 2-23) to
bring up the Edit Trace Path dialog box, as s h o w n in Figure 2-24. N o t e that Assem2 should be listed in
the Select Reference Component text b o x , w h i c h serves as the default reference frame for the trace path.
T h e default reference frame is the global reference frame included as part of the g r o u n d body. No change
is needed.
To select the part u s e d to generate the trace curve, select the Select Trace Point Component text field
(should be highlighted in red already), and then select one m o v i n g part; i.e., the ball, from the graphics
screen. The part ball-1 will be listed in the Select Trace Point Component text field, and ball-
l/DDMFace2 is listed in the Select Trace Point on the Trace Point Component text b o x .
Click Apply button, y o u should see the trace path appears in the graphics screen, similar to that of
Figure 2-22.
Next, we will create a graph for the 7-position of the ball using the XY Plots. F r o m the browser, right
click ball-1 (under Parts, Moving Parts) a n d choose Plot > CM Position > Y.
T h e XY Plot for the CM (Center of M a s s ) position of the ball in the 7-direction will appear, similar
to that of Figure 2 - 2 5 . N o t e that y o u m a y adjust properties of the graph, for instance the axis scales,
following steps similar to those of Microsoft® Excel spreadsheet graphs.
The graph shows that the ball w a s t h r o w n from Y= 100 in. and hits the ground at Y= 10 in. ( C M of
the ball) a n d time about t— 0.6 seconds. T h e ball b o u n c e s b a c k and m o v e s up to an elevation determined
by the coefficient of restitution. T h e m o t i o n continues until reaching the end of the simulation.
N o t e that y o u m a y click any location in the graph to bring up a fine r e d vertical line that correlates
the graph with the position of the ball in animation. As s h o w n in the graph of Figure 2.25, at t = 1.4
seconds, the ball is r o u g h l y at Y= 44 in. T h e snapshot of the ball at that specific time a n d 7-location is
shown in the graphics screen.
turned off all friction for the 3D Contact constraint earlier, therefore, no energy loss due to contact.
Figure 2-27 shows 7-velocity of the ball. T h e ball m o v e s at a linear velocity due to gravity. The 7-
velocity is about -263 in/sec at t = 0.67 seconds. Y o u m a y see this data by m o v i n g the cursor close to the
corner point of the curve and leave the cursor for a short period. The data will appear.
Equation of Motion
respectively; P and P y are the initial positions in the X- and 7-directions, respectively; V a n d Vg are
0x 0 0x y
the initial velocities in the X- and 7-directions, respectively; and g is the gravitational acceleration.
T h e s e equations can be i m p l e m e n t e d using, for e x a m p l e , Microsoft® Excel spreadsheet shown in
Figure 2-30, for numerical solutions. In Figure 2-30, C o l u m n s B and C s h o w the results of Eqs. 2.1a a n d
2.1b, Nrespectively;
o t e that w h ewith
n the a ball
timehits the ground,
interval from 0 we to 3will
seconds and increment of 0.01 seconds. C o l u m n s D
have to reset the velocity to 7 5 % of that at the prior
and E show the results of E q s . 2.2a a n d 2.2b, respectively.
time step a n d in the opposite direction.
(ii) Derive and solve the equations that describe the position and velocity of the ball. C o m p a r e your
solutions with those obtained from COSMOSMotion.
(iii) Calculate the time for the ball to reach the g r o u n d and the distance it travels. C o m p a r e your
calculation with the simulation results obtained from COSMOSMotion.
2. A 1 "xl "xl" block slides from top of a slope (due to gravity) w i t h o u t friction, as s h o w n in Figure
E 2 - 2 . The material of the b l o c k and the slope is AL2014.
(ii) Create a LimitDistance m a t e to stop the b l o c k w h e n its front lower edge reaches the e n d of the
slope. Y o u m a y w a n t to review COSMOSMotion h e l p m e n u or p r e v i e w Lesson 3 to learn m o r e
about the LimitDistance m a t e .
(iii) Derive and solve the equation of m o t i o n for the system. C o m p a r e y o u r solutions with those
obtained from COSMOSMotion.
3.1 O v e r v i e w of the L e s s o n
In this lesson, we will create a simple spring-mass system and simulate its d y n a m i c responses u n d e r
various scenarios. A schematics of the system is s h o w n in Figure 3 - 1 , in w h i c h a steel b l o c k of V'xV'xl"
is sliding along a 30° slope with a spring connecting it to the top e n d of the slope. T h e b l o c k will slide
b a c k and forth along the slope u n d e r three different scenarios. First, the b l o c k will slide due to a small
initial displacement, essentially, a free vibration. F o r the second scenario, we will add a friction b e t w e e n
the b l o c k and the slope face. Finally, we will r e m o v e the friction and add a sinusoidal force p(t) 9
therefore, a forced vibration. Gravity will be turned on for all three scenarios. In this lesson, y o u will
learn h o w to create the spring-mass m o d e l , r u n a m o t i o n analysis, and visualize the analysis results. In
addition, y o u will learn h o w to add a friction to a joint, in this case, a planar (or coincident) joint. T h e
analysis results of the spring-mass e x a m p l e can be verified using particle dynamics theory. Similar to
Lesson 2, we will formulate the equation of motion, solve the differential equations, graph positions of the
block, a n d c o m p a r e our calculations w i t h results obtained from COSMOSMotion. Specifically, we will
focus on the first a n d the last scenarios; i.e., free and forced vibrations, respectively.
Physical Model
F o r this lesson, the parts and assembly h a v e b e e n created for y o u in SolidWorks. There are six files
created, block. SLDPRT, ground. SLDPRT, Lesson3. SLDASM, Lesson3Awithresults. SLDASM,
Lesson3Bwithresults.SLDASM, and Lesson3Cwithresults.SLDASM. Y o u can find these files at the
p u b l i s h e r ' s w e b site (http://www.schroffl.com/). We will start with Lesson3.SLDASM, in w h i c h the b l o c k
is a s s e m b l e d to the g r o u n d and no m o t i o n entities h a v e b e e n added. In addition, the assembly files
Lesson3Awithresults. SLDASM, Lesson3Bwithresults. SLDASM, and Lesson3Cwithresults. SLDASM
contain the complete simulation m o d e l s with simulation results for the three respective scenarios.
top of the graphics screen, and drag the b l o c k in m the graphics screen, y o u should be able to m o v e the
b l o c k on the slope face, but not b e y o n d the slope face. This is because the third m a t e is defined to restrict
the b l o c k to m o v e b e t w e e n the lower a n d upper limits. We will take a look at the assembly m a t e
LimitDistancel.
LimitDistance 1.
Motion Model
This m o d e l is adequate to support a free vibration simulation u n d e r the first scenario. N o t e that we
will m o v e the b l o c k 1 in. d o w n w a r d along the slope face for the simulation. This can be a c c o m p l i s h e d by
changing the distance from 3 to 4 in. in the LimitDistancel assembly m a t e .
3.3 U s i n g COSMOSMotion
Before entering COSMOSMotion, we will suppress two assembly mates, Coincident3 and
LimitDistancel. F r o m the Assembly browser, e x p a n d the Mates branch, right click Coincident3, and
choose Suppress. The mate Coincident3 will become inactive. Repeat the same to suppress
LimitDistancel. Save your model.
In this lesson, instead of using IntelliMotion Builder (as in Lesson 2), we will use the browser, and
basic drag-and-drop and right click activated m e n u s to create and simulate the b l o c k motion.
Before creating any entities, always check the units system. Similar to Lesson 2, choose from the
null-down m e n u
Defining Bodies
F r o m the browser, e x p a n d the Assembly Components b r a n c h (right underneath the Motion Model
node) by clicking the small + button in front of it. Y o u should see t w o parts listed, block-1 a n d ground-7,
as s h o w n in Figure 3-5. A l s o expand the Parts branch; y o u should see Moving Parts and Ground Parts
listed. We will m o v e block-1 to Moving Parts and ground-1 to Ground Parts by using the drag-and-drop
method.
Defining Spring
F r o m the browser, right click the Spring n o d e a n d choose Add Translational Spring (see Figure 3-7).
In the Insert Spring dialog b o x (Figure 3-8), the Select 1st Component field is highlighted in red and
r e a d y for y o u to pick. Pick the face at top right of the g r o u n d (see Figure 3-9), the Select 2nd Component
field should n o w highlight in red, a n d ground l/DDMFace4 should appear in the Select Point on 1st
Component field, w h i c h indicates that the spring will be connected to the center point of the face.
Rotate the view, and then pick the face in the block, as s h o w n in Figure 3-9. N o w , block-1 and
block-l/DDMFace3 should appear in the Select 2nd Component field and Select Point on 2nd Component
field, respectively. Also, a spring symbol should appear in the graphics screen, connecting the center
points of the t w o selected faces.
Defining Initial Position
We w o u l d like to stretch the spring 1 in. d o w n w a r d along the slope face as the initial position for the
block. T h e b l o c k will be released from this position to simulate a free vibration; i.e., the first scenario. We
will go b a c k to the Assembly m o d e , unsuppress LimitDistancel, change the distance d i m e n s i o n from 3 to
4 in., and then sunnress the m a t e before returning to COSMOSMotion.
Go b a c k to COSMOSMotion by clicking the Motion button (y . Click the Motion Model n o d e , press
the right m o u s e button a n d select Simulation Parameters. Enter 0.25 for simulation duration and 500 for
the n u m b e r of frames.
Click the Motion Model n o d e again, press the right m o u s e button and select Run Simulation. Y o u
may also click the Run Simulation button | J | ] right b e l o w the browser to run a simulation. Y o u should see
the b l o c k start m o v i n g b a c k and forth along the slope face. We will graph the position of the b l o c k in
terms of the m a g n i t u d e (instead o f X - or 7-component) next.
Displaying Simulation Results
Since there is no position graph defined for the block, we will h a v e to create one. We will create a
graph for the distance b e t w e e n the t w o faces that w e r e selected to define the spring.
E x p a n d the Constraints branch and then the Joints branch. Right click the Coincident! n o d e and
choose Properties. In the Edit Mate-Defined Joint dialog b o x , choose the Friction tab, click the Use
Friction, enter 0.25 for Coefficient (mu), and enter Joint dimensions, Length: 1, Width: 1, a n d Radius:
1.414, as shown in Figure 3-17. Click Apply button to accept the definition.
R u n a simulation (with the same simulation parameters as those of Scenario T). Graph the
displacement of the block; y o u should see a graph similar to that of Figure 3-18. T h e amplitude of the
graph (that is, the distance the b l o c k travels) is decreasing over time due to friction. Save y o u r m o d e l . We
will m o v e into Scenario 3. Y o u m a y save the m o d e l again under different n a m e and use it for the next
scenario.
In this scenario we will add an external force p(t) = 10 cos 360t at the center of the end face of the
block in the d o w n w a r d direction along the slope. At the same time, we will r e m o v e the friction in order to
simplify the problem.
Before creating a force, we will delete the simulation results and r e m o v e the friction. Delete the
Right click the Coincidentl n o d e and choose Properties. In the Edit Mate-Defined Joint dialog b o x ,
choose the Friction tab, a n d deselect the Use Friction by clicking the small b o x in front of it. All
parameters a n d selections on the dialog b o x should b e c o m e inactive. Click Apply button to accept the
change.
The force can be a d d e d by expanding the Forces branch, right clicking the Action Only n o d e , a n d
choosing Add Action-Only Force, as s h o w n in Figure 3-19. In the Insert Action-Only Force dialog b o x
(see Figure 3-20), the Select Component to which Force is Applied field will be active (highlighted in red)
and ready for y o u pick the component.
Pick the end face of the block, as s h o w n in Figure 3 - 2 1 . T h e part block-1 is n o w listed in the Select
Component to which Force is Applied field, and block-l/DDMFace8 is listed in both the Select Location
and the Select Direction fields. That is, the force will be applied to the center of the selected end face a n d
in the direction that is normal to the selected face.
N o w in the Insert Action-Only Force dialog box, the Select Reference Component to orient Force
field is active (highlighted in red) a n d is ready for selection. We will p i c k the g r o u n d part for reference.
P i c k any place in the g r o u n d part, ground-1 will n o w appear in the Select Reference Component to orient
Force field.
Click the Function tab (see Figure 3-22), choose
Harmonic, and enter the followings:
Amplitude: 10
Frequency: 360
Phase Shift: -90
N o t e that in s o m e occasions, the b l o c k m a y slide out of the slope face during the simulation, as
s h o w n in Figure 3-24. W h e n this h a p p e n s , simply unsuppress the assembly m a t e ; for example,
Coincident3, to restricts the b l o c k to stay on the slope face.
After unsuppressing Coincident3, the planar j o i n t
will b e c o m e a translational j o i n t (converted by
COSMOSMotion) c o m p o s e d of t w o assembly mates,
Coincident 1 and Coincident^. Please refer to the
assembly file Lesson3Cwithresults.SLDASM for the
translational j o i n t e m p l o y e d for this example.
T h e double dots on top of x represent the second derivative of x with respect to time. R e a r r a n g e Eq.
3.2, w e h a v e
mx + kx = mgsin 0 + Uk (3.3)
2
corresponding force unit o f l b i s l b i n / s e c according t o N e w t o n ' s S e c o n d L a w .
m m
Equation 3.7 can be i m p l e m e n t e d into Microsoft® Excel
spreadsheet, as s h o w n in Figure 3-28. C o l u m n B in the
spreadsheet shows the results of Eq. 3.7, w h i c h is graphed in
Figure 3-29. C o m p a r i n g Figure 3-29 with Figure 3-14, the
results obtained from theory and COSMOSMotion agree very
well, w h i c h m e a n s the m o t i o n m o d e l has b e e n properly
defined, and COSMOSMotion gives us g o o d results.
C o m p a r i n g Figure 3-31 with Figure 3-25, the results obtained from theory and COSMOSMotion are
very close. N o t e that the spreadsheet s h o w n in Figure 3-28 can be found at the p u b l i s h e r ' s website
(filename: lesson3.xls).
Exercises:
1. S h o w that Eq. 3.12 is the correct solution of Scenario 3 g o v e r n e d by Eq. 3.8 by simply plugging Eq.
3.12 into Eq. 3.8.
2. R e p e a t the Scenario 3 of this lesson, except changing the external force to p(t) = 10 cos 9798. Ot l b .f
Will this external force c h a n g e the vibration amplitude of the system? Can y o u simulate this
resonance scenario in COSMOSMotion!
using COSMOSMotion.
(i) Calculate the natural frequency of the system and compare y o u r calculation with that of
COSMOSMotion.
(ii) Derive a n d solve the equations that describe the position and velocity of the m a s s . C o m p a r e
your solutions with those obtained from COSMOSMotion.
4.1 O v e r v i e w of the Lesson
4.2 T h e Simple P e n d u l u m E x a m p l e
Physical Model
T h e physical m o d e l of the p e n d u l u m is c o m p o s e d
of a sphere and a r o d rigidly connected, as shown in
Figure 4 - 1 . T h e radius of the sphere is 10 m m . T h e
length and radius of the thin r o d are 90 mm and 0.5
m m , respectively. T h e top of the rod will be connected
to the wall with a revolute joint. This revolute j o i n t
allows the p e n d u l u m to rotate. B o t h r o d and sphere are
m a d e of A l u n i m u m . N o t e that from the SolidWorks
material library the Aluminum Alloy 2014 has b e e n
selected for b o t h sphere and rod. The MMGS units
system is selected for this e x a m p l e (millimeter for
length, N e w t o n for force, and second for time). N o t e
that in the MMGS units system, the gravitational
2
acceleration is 9,806 m m / s e c .
We w o u l d like to m a k e sue the gravity is set up properly. F r o m the browser, right-click the Motion
Model n o d e and select System Defaults. In the Options dialog b o x (Figure 4-6), enter 9806 for
Acceleration (mm/sec**2) w h i c h should appear as default already, and m a k e sure the Direction is set to
-7 for Y. Click OK to accept the gravity setting.
Click the Motion Model node, press the right m o u s e button and select Simulation Parameters. Enter
1.5 for simulation duration and then 300 for the n u m b e r of frames.
Click the Motion Model n o d e again, press the right m o u s e button and select Run Simulation. Y o u
should see the p e n d u l u m start m o v i n g b a c k and forth about the axis of the revolute joint. We will graph
the position, velocity, and acceleration of the p e n d u l u m next.
The results of angular position, velocity, and acceleration of the p e n d u l u m can be directly obtained
by right clicking the m o v i n g part, pendulum-7, from the browser.
The results of angular position, velocity, and acceleration of the p e n d u l u m can be directly obtained
by right clicking the m o v i n g part, pendulum-7, from the browser.
F r o m the browser, e x p a n d the Parts n o d e and the then Moving Parts n o d e . Right-click pendulum-7,
and choose Plot > Bryant Angles > Angle 3.
N o t e that the Bryant angles are also k n o w n as X-Y-ZEuler angles or Cardan angles. T h e y are simply
the rotation angles of a spatial object along the 7-, and Z-axes of the reference coordinate system.
Angle 3 is m e a s u r e d about the Z-axis.
A graph like that of Figure 4-7 should appear. F r o m the graph, the p e n d u l u m swings about the Z-axis
b e t w e e n -10 and 10 degrees, as expected (since no friction is involved). Also, it takes about 0.6 seconds
to complete a cycle. N o t e that y o u can export the graph data, for e x a m p l e , by right clicking the graph and
choosing Export CSV. O p e n the spreadsheet and e x a m the data. F r o m the spreadsheet, the t i m e for the
p e n d u l u m to swing b a c k to its original position; i.e., -10 degrees., is 0.64 second, as s h o w n in the
spreadsheet of Figure 4 - 8 . We will carry out calculations to verify these results later. Before we do that,
we will graph the angular velocity and acceleration of the p e n d u l u m .
and c h o o s e Angular Acceleration > Z Component. Y o u should see graphs like those of Figures 4-9 and 4-
10. Figure 4-9 s h o w s that the angular velocity starts at 0, w h i c h is expected. T h e angular velocity varies
b e t w e e n r o u g h l y -100 a n d 100 degrees/sec. Also, the angular acceleration varies b e t w e e n roughly -1,000
2
and 1,000 degrees/sec . A r e these results correct? We will carry out calculations to verify if these graphs
are accurate.
In this section, we will verify the analysis results obtained from COSMOSMotion using particle
dynamics theory.
There are four assumptions that we h a v e to m a k e in order to apply the particle dynamics theory to
this simple p e n d u l u m p r o b l e m :
Energy Conservation
Referring to Figure 4 - 1 1 , the kinetic energy and potential energy of the p e n d u l u m can be written,
respectively, as
T=- J 0 (4.1)
2
w h e r e J is the polar m o m e n t of inertia, i.e., J = m£ \
and
U=mg/(l-<:os 6)
Physical Model
T h e slider-crank m e c h a n i s m is
essentially a four-bar linkage, as s h o w n
in Figure 5 - 1 . T h e y are c o m m o n l y
found in m e c h a n i c a l systems; e.g.,
internal combustion engine and oil-well
drilling equipment. F o r the internal
c o m b u s t i o n engine, the m e c h a n i s m is
driven by a firing load that pushes the
piston, converting the reciprocal
m o t i o n into rotational m o t i o n at the
crank.
In the oil-well drilling equipment, a torque is applied at the crank. The rotational m o t i o n is converted
to a reciprocal m o t i o n at the piston that digs into the ground. N o t e that in any case the length of the crank
m u s t be smaller than that of the r o d in order to allow the m e c h a n i s m to operate. This is c o m m o n l y
referred to as the G r a s h o f s law. In this example, the lengths of the crank and r o d are 3" and 8",
respectively.
N o t e that the units system chosen for this e x a m p l e is IPS (in-lbj-sec). All parts are m a d e of
A l u m i n u m , 2014 Alloy. No friction is assumed between any pair of the components (parts or
subassemblies).
SolidWorks Parts and Assembly
T h e slider-crank system consists of five parts and one subassembly. T h e y are bearing, crank, rod,
pin, piston, and rodandpin (subassembly, consisting of r o d and pin). An exploded v i e w of the m e c h a n i s m
is s h o w n in Figure 5-2. SolidWorks parts and assembly h a v e b e e n created for you. T h e y are
bearing.SLDPRT, crank. SLDPRT, rod.SLDPRT, pin.SLDPRTpiston.SLDPRT, and rodandpin.SLDASM.
In addition, there are three assembly files, Lesson5.SLDASM, Lesson5Awithresults.SLDASM, and
LessonSBwithresults.SLDASM. Y o u can find these files at the p u b l i s h e r ' s w e b site.
We will start with LessonS. SLDASM, in w h i c h all c o m p o n e n t s are properly assembled. In this
a s s e m b l y the bearing is anchored (ground) and all other parts are fully constrained. We will suppress one
a s s e m b l y m a t e in order to allow for m o v e m e n t .
There are eight assembly mates, including five coincident and three concentric, defined in the
assembly. Y o u m a y w a n t to expand the MateGroupl branch in the b r o w s e r to see the list of mates. M o v e
y o u r cursor on any of the m a t e s ; y o u should see the entities selected for the assembly m a t e highlighted in
the graphics screen.
T h e first three m a t e s (Concentric 1, Coincident 1, and Coincident!) assemble the crank to the fixed
bearing, as s h o w n in Figure 5-3a. As a result, the crank is completely fixed. N o t e that the m a t e
Coincident! orients the crank to the upright position. This m a t e will be suppressed before entering
COSMOSMotion. Suppressing this m a t e will allow the crank to rotate with respect the bearing.
COSMOSMotion will convert these t w o m a t e s , Concentricl and Coincident 1, to a revolute joint.
T h e next t w o mates (Concentric2 and Coincident^) assemble the r o d to the crank, as shown in
Figure 5-3b. U n l i k e the crank, the r o d is allowed to rotate with respect to the crank, leading to another
revolute j o i n t in COSMOSMotion. The next t w o m a t e s (Concentric3 and Coincident4) assemble the
piston to the pin, allowing the piston to rotate about the pin. As a result, a revolute j o i n t (or a concentric
j o i n t in some cases) will be added b e t w e e n the piston and the pin. The final m a t e (CoincidentS) eliminates
the rotation by m a t i n g t w o planes, Right Plane of the piston and the Top Plane of the assembly, as s h o w n
in Figure 5-3c. COSMOSMotion will add a translational j o i n t b e t w e e n the piston and the ground. Since
the translational j o i n t is c o m p o s e d of Coincident5 and Coincident4, Concentric3 will be carried over to
COSMOSMotion as it is. Therefore, instead of a revolute joint, a cylindrical j o i n t appears in the m o t i o n
model.
Simulation Model
Since the m e c h a n i s m has one free degree of freedom, either rotating the crank or the r o d (about the
axis of the revolute joints), or m o v i n g the piston horizontally (along the translational joint) will be
sufficient to uniquely determine the position, velocity, and acceleration of any parts in the m e c h a n i s m .
T h e m e c h a n i s m will b e f i r s t driven b y
rotating the crank at a constant angular
velocity of 360 degrees/sec. Gravity will be
turned off. This will be essentially a
kinematic simulation. This m o d e l will also
serve for interference check. It is very
important to m a k e sure no interference
exists b e t w e e n parts while the m e c h a n i s m is
in motion. The simulation results are
included in LessonSAwithresults.SLDASM.
5.3 U s i n g COSMOSMotion
Before entering COSMOSMotion, we will suppress the third assembly m a t e , Coincident2. In this
lesson, we will use drag-and-drop as well as right-click activated m e n u s , instead of the IntelliMotion
Builder.
F r o m the Assembly browser, e x p a n d the Mates branch, right click Coincident2, and choose Suppress.
T h e m a t e Coincident2 will b e c o m e inactive. Save y o u r m o d e l .
Before creating any entities, always check the units system. M a k e sure IPS units system is chosen
for this example.
Defining Bodies
Driving Joint
F r o m the browser, e x p a n d the Constraints n o d e and then the Joints n o d e . Right click the Revolute
n o d e a n d choose Properties (see Figure 5-7). In the Edit Mate-Defined Joint dialog b o x (Figure 5-8),
u n d e r the Motion tab, choose Velocity for Motion Type, choose Constant for Function, and enter 360
degrees/sec for Angular Velocity (should appear as defaults), as s h o w n in Figure 5-8. Click Apply to
accept the definition. We are ready to run a simulation.
F r o m the browser, e x p a n d the Parts branch and then the Moving Parts branch. Right click the
piston-1 n o d e , and choose Plot > CM Position > X ( s e e Figure 5-11). T h e graph should be similar to that
of Figure 5-12. N o t e that from the graph, the piston m o v e s b e t w e e n about 5 a n d 11 in. horizontally, in
reference to the global coordinate system, in w h i c h the origin of the coordinate system coincides with the
center point of the hole in the bearing.
At the starting point, the crank is at the upright position, and the piston is located at 7.42 in. (that is,
2
V8 -3 ) to the right of the origin of the global coordinate system. N o t e that the lengths of the crank and
2
r o d are 3 and 8 in., respectively. W h e n the crank rotates to 90 degrees counterclockwise, the position
b e c o m e s 5 (which is 8-3). W h e n the crank rotates 270 degrees, the piston position is 11 (which is 8+3).
R e p e a t the same steps to create graphs for the velocity and acceleration of the piston in the in-
direction. The graphs should be similar to those of Figures 5-13 and 5-14, respectively. If y o u e x p a n d the
piston-1 n o d e in the browser, y o u should see there are three entities listed, CM Accel - X-piston-1, CM
Position -X-piston-1, and CM Velocity-X-piston-1, as s h o w n in Figure 5-15.
T h e graph of the angular velocity of the j o i n t Revolute2 can be created by expanding the Constraints
b r a n c h a n d then the Joints branch, right clicking Revolute2 and selecting Plot > Angular Velocity > Z-
Component. The graph should be similar to that of Figure 5-16. An entity, Angular Vel - Z-Revolute2, is
a d d e d u n d e r the j o i n t Revolute2 in the browser.
Interference Check
(1) All the interference that occur b e t w e e n the selected c o m p o n e n t s as the m e c h a n i s m m o v e s through a
specified range of motion, or
To select the parts to include in the interference check, select the Select Parts to test text field and
then p i c k all four c o m p o n e n t s from the graphics screen (or from the browser). T h e Start Frame, End
Frame, and Increment allow y o u to specify the m o t i o n frame u s e d as the starting position, final position,
and increment in b e t w e e n for the interference check. We will u s e the default n u m b e r s ; i.e., 1, 51, a n d 2,
for the Start Frame, End Frame, and Increment, respectively. Click the Find Now button (circled in
Figure 5-17) to start the interference check.
After pressing the Find Now button, the m e c h a n i s m starts m o v i n g , in w h i c h the crank rotates a
complete cycle. At the same time, the Find Interferences Over Time dialog b o x expands. T h e list at the
lower half of the dialog b o x shows all interference conditions detected. T h e frame, simulation time, parts
that caused the interference, and the v o l u m e of the interference detected are listed.
Close the dialog b o x and save y o u r m o d e l . After saving the m o d e l , y o u m a y w a n t to save it again
u n d e r a different n a m e and u s e it for the next simulation.
Creating and Running a Dynamic Analysis
A force simulating the engine firing load (acting along the negative X-direction) will be a d d e d to the
piston for a d y n a m i c simulation. It will be m o r e realistic if the force can be applied w h e n the piston starts
m o v i n g to the left (negative X-direction) a n d can be applied only for a selected short period. In order to
do so, we will h a v e to define m e a s u r e s that monitor the position of the piston for the firing load to be
activated. Unfortunately, such a capability is n o t available in COSMOSMotion. Therefore, the force is
simplified as a step function of 3 l b along the negative X-direction applied for 0.1 seconds. T h e force will
f
be defined as a point force at the center point of the end face of the piston, as s h o w n in Figure 5 - 2 1 .
Before we add the force, we will turn off the angular velocity driver defined at the j o i n t Revolute2 in
the previous simulation. We will h a v e to delete the simulation before we can m a k e any changes to the
F r o m the browser, e x p a n d the Constraints branch, and then the Joints branch. Right click Revolute
to bring up the Edit Mate-Defined Joint dialog b o x (Figure 5-22). P u l l - d o w n the Motion Type a n d choose
Free. Click Apply to accept the change.
y o u should see As semi appear in the Select Reference Component to orient Force field.
Click the Function tab (see Figure 5-25), choose Step for function, a n d enter the followings:
Initial Value: -3
Final Value: 0
Start Step Time: 0
End Step Time: 0.1
G r a p h s created in previous simulation, such as the piston position, etc., should appear immediately at
the e n d of the simulation. As s h o w n in Figure 5-27, the piston m o v e s along the.negative X-direction for
about 0.15 seconds before reversing its direction. It is also evident in the velocity graph s h o w n in Figure
5-28 that the velocity changes signs at t w o instances (close to 0.15 a n d 0.48 seconds). Recall that the
force w a s applied for the first 0.1 seconds. H a d the force application lasted longer, the piston could be
continuously p u s h e d to the left (negative X-direction) even w h e n the piston reaches the left end and tries
to m o v e to the right (due to inertia). As a result, the crank w o u l d h a v e b e e n oscillating at the left of the
center of the bearing; i.e., b e t w e e n 0 a n d 180 degrees about the Z-axis, w i t h o u t m a k i n g a complete turn.
G r a p h the reaction force for the applied force at the piston by expanding the Forces branch, then the
Action Only branch, right clicking the ForceAO, a n d choosing Plot. T h e reaction force that represents the
actual force applied to the piston appears, as s h o w n in Figure 5-29. T h e graph shows that the force of 3 lbf
w a s applied at the beginning of the simulation. T h e force gradually decreases to 0 in the 0.7-second
period, w h i c h is w h a t we expected and is consistent with the force function, as seen in Figure 5-26.
G r a p h the reaction force at the j o i n t Revolute (between crank and the ground) along the X-direction;
y o u should see a graph like that of Figure 5-30. There are three peaks in Figure 5-30 representing w h e n
the largest reaction forces occur at the joint, w h i c h occurs at close to 0.15, 0.48, a n d 0.8 seconds; i.e.,
w h e n the piston reverses its m o v i n g direction. The results m a k e sense.
5.4 Result Verifications
In this section, we will verify the m o t i o n analysis results using kinematic analysis theory often found
in m e c h a n i s m design textbooks. N o t e that in kinematic analysis, position, velocity, a n d acceleration of
given points or axes in the m e c h a n i s m , are analyzed.
In kinematic analysis, forces a n d torques are not involved. All b o d i e s (or links) are a s s u m e d
massless. H e n c e , m a s s properties defined for bodies are not influencing the analysis results.
T h e slider-crank m e c h a n i s m is a planar kinematic analysis problem. A vector plot that represents the
positions of joints of the planar m e c h a n i s m is s h o w n in Figure 5-31. The vector plot serves as the first
step in c o m p u t i n g position, velocity, and accelerations of the m e c h a n i s m .
T h e real and imaginary parts of Eq. 5 . 1 , corresponding to the X and / c o m p o n e n t s of the vectors, can
be written as
In Eqs. 5.2a and 5.2b, Zj, Z , and 6 are given. We are solving for Z a n d 6 . Equations 5.2a and
2 A 3 B
5.2b are non-linear. Solving t h e m directly for Z and 0 is not straightforward. Instead, we will calculate
s B
1. Derive the acceleration equations for the slider-crank m e c h a n i s m , by taking derivatives of Eqs, 5.5a
a n d 5.5b with respect to time. Solve these equations for the linear acceleration of the piston and the
angular acceleration of the j o i n t Revolute2, u s i n g a spreadsheet. C o m p a r e y o u r solutions with those
obtained from COSMOSMotion.
2. U s e the same slider-crank m o d e l to conduct a static analysis using COSMOSMotion. The static
analysis in COSMOSMotion should give y o u equilibrium configuration(s) of the m e c h a n i s m due to
gravity (turn on the gravity). S h o w the equilibrium configuration(s) of the m e c h a n i s m and use the
energy m e t h o d y o u learned from S o p h o m o r e Statics to verify the equilibrium configuration(s).
3. C h a n g e the length of the crank from 3 to 5 in. in SolidWorks. R e p e a t the kinematic analysis
discussed in this lesson. In addition, change the crank length in the spreadsheet {Microsoft Excel file,
lesson5.xls). Generate position and velocity graphs from b o t h COSMOSMotion and the spreadshee:
Do they agree with each other? D o e s the m a x i m u m slider velocity increase due to a longer crank? Is
there any interference occurring in the m e c h a n i s m ?
4. D o w n l o a d five SolidWorks parts from the p u b l i s h e r ' s w e b site to your c o m p u t e r (folder name
Exercise 5-4).
(i) U s e these five parts, i.e., bearing, crankshaft, connecting rod, piston pin, and piston (see Figure
E5-1), to create an assembly like the one s h o w n in Figure E 5 - 2 . N o t e that the crankshaft m u s :
orient at 45° C C W , as s h o w n in Figure E 5 - 2 .
In this lesson we will discuss h o w to simulate m o t i o n of a spur gear train. A gear train is a set or
system of gears arranged to transfer torque or energy from one part of a m e c h a n i c a l system to another. A
gear train consists of driving gears that are m o u n t e d on the input shaft, driven gears m o u n t e d on the
output shaft, and idler gears that interpose b e t w e e n the driving and driven gears in order to maintain the
direction of the output shaft to be the same as the input shaft or to increase the distance b e t w e e n the drive
and driven gears. There are different kinds of gear trains, such as simple gear train, c o m p o u n d gear train,
epicylic gear train, etc., depending on h o w the gears are shaped and arranged as well as the fuctions they
intend to perform. T h e gear train we are simulating in this lesson is a c o m p o u n d gear train, in w h i c h t w o
or m o r e gears are u s e d to transmit torque or energy. All gears included in this lesson are spur gears;
therefore, the shafts that these gears m o u n t e d on are in parallel.
In COSMOSMotion, gear pair is defined as a special coupler constraint. Joint couplers allow the
m o t i o n of a revolute, cylindrical, or translational j o i n t to be coupled to the m o t i o n of another revolute,
cylindrical or translational joint. T h e t w o coupled j o i n t s m a y be of the same or different types. For
example, a revolute j o i n t m a y be coupled to a translational joint. The coupled motion m a y also be of the
same or different type. For example, the rotary m o t i o n of a revolute j o i n t m a y be coupled to the rotary
m o t i o n of a cylindrical joint, or the translational m o t i o n of a translational j o i n t m a y be coupled to the
rotary m o t i o n of a cylindrical joint. To create a gear pair, we will be coupling t w o revolute j o i n t s . Usually
a concentric and a coincident mates will lead to a revolute joint, as seen in previous lessons. Coupling t w o
revolute j o i n t s for a gear pair will be carried out in SolidWorks using the advance assembly m a t e option,
w h e r e t w o axes that pass through the respective revolute j o i n t s (or gears) are picked for the gear mate.
T h e gear m a t e will be m a p p e d to a gear m a t e j o i n t in COSMOSMotion.
In fact, neither SolidWorks nor COSMOSMotion cares about the detailed geometry of the gear pair;
i.e., if the gear teeth m e s h adequately. Y o u m a y simply uses cylinders or disks to represent the gears. No
detailed tooth profile is necessary for any of the computations involved. Apparently, force and m o m e n t
b e t w e e n a pair of teeth in contact will not be calculated in gear train simulations. H o w e v e r , there are other
important data being calculated by COSMOSMotion, such as reaction force exerting on the driven shaft
(for a d y n a m i c analysis), w h i c h is critical for m e c h a n i s m design. In any case, pitch circle diameters are
essential for defining gear pair and gear trains in COSMOSMotion. Gear ratio of the gear train, w h i c h is
defined by the ratio of the angular velocities of the output a n d input gears, is determined by the pitch
circle diameters of the individual gear pairs in the gear train.
6.2 T h e G e a r Train E x a m p l e
Physical Model
T h e gear train e x a m p l e we are using for this lesson is part of a gearbox designed for an experimental
lunar rover. The gear train is located in a gear b o x w h i c h is part of the transmission system of the rover,
driven by a m o t o r p o w e r e d by solar energy. The p u r p o s e of the gear train is to convert a high-speed
rotation a n d small torque generated by the m o t o r to a low speed rotation and large torque output in order
to drive the wheels of the rover. The gear train consists of four spur gears m o u n t e d on three parallel
shafts, as s h o w n in Figure 6 - 1 .
T h e four spur gears form t w o gear pairs: Pinion 1 and Gear 7, and Pinion 2 and Gear 2, as depicted
in Figure 6-1 a n d 6-2. N o t e that Pinion 1 is the driving gear that connects to the m o t i o n driver; e.g., a
motor. T h e m o t o r rotates in a clockwise direction, therefore, driving Pinion 1. Gear 1 is the driven gear of
the first gear pair, w h i c h is m o u n t e d on the same shaft as Pinion 2. B o t h rotate in a counterclockwise
direction. Gear 2 is driven by Pinion 2, and rotates in a clockwise direction. N o t e that the diameters of the
pitch circles of the four gears are: 50, 120, 60, and 125 m m , respectively; a n d the n u m b e r s of teeth are 2 5 ,
6 0 , 2 4 , and 50, respectively. Therefore, the circular pitch P the diametral pitch P , a n d m o d u l e m of the
C9 d
In this lesson, SolidWorks parts of the gear train h a v e b e e n created for you. There are six files
created, gbox housing.SLDPRT, gbox input.SLDPRT, gboxjniddle.SLDPRT, gbox_output.SLDPRT,
Lesson6.SLDASM, and Lesson6withresults.SLDASM. Y o u can find these files at the p u b l i s h e r ' s w e b site
(http://www.schroffl.com/). We will start with Lesson6.SLDASM, in w h i c h the gears are a s s e m b l e d to the
housing. In addition, the assembly file Lesson6withresults.SLDASM consists of a complete simulation
m o d e l with simulation results.
If y o u turn on the axis display (View > Axes), axes that pass through the center of the gears about the
Z-axis are defined for each gear. These axes are necessary for creating gear m a t e s .
Simulation Model
N o t e that if the axes of the t w o gears are pointing in the opposite direction, y o u will h a v e to click
Reverse (right b e l o w the Ratio text field in the Mate dialog b o x ) to correct the rotation direction. In this
example, all three axes are pointing in the same direction. Therefore, do not choose Reverse.
R e p e a t the same steps to define the second gear mate. This time, p i c k the axes of the m i d d l e and
output gears, and enter 60mm a n d 125mm for Ratio. T w o n e w m a t e s , Gear Mate 1 (gbox_input<l>,
gbox_middle<l>) and GearMate2(gbox_middle<l>,gbox_output<l>), are n o w listed u n d e r Mates.
N o w we are r e a d y to enter COSMOSMotion.
Driving Joint
Click the Motion Model n o d e , press the right m o u s e button and select Run Simulation. After a few
seconds, y o u should see the gears start turning. T h e input gear rotates 360 degrees as expected since the
default simulation duration is 7 second.
F r o m the browser, e x p a n d the Parts branch and then the Moving Parts branch. Right-click the
ghox_output-l n o d e , and choose Plot > Angular Velocity > Z Component (Figure 6-11). T h e graph
should appear and is similar to that of Figure 6-12, w h i c h shows that the output velocity is a constant of
72 degrees/sec. N o t e that this m a g n i t u d e is one fifth of the input velocity since the gear ratio is 7:5. B o t h
the input (Pinion 7) and output gears (Gear 2) rotate in the same direction. COSMOSMotion gives g o o d
results.
Save your m o d e l .
Exercises:
1. T h e same gear train will be u s e d for this exercise. Create a constant torque for the input gear
(gboxinput.SLDPRT) about the Z-axis. Turn on friction for all three axles (Steel-Dry/Steel-Dry).
Define and r u n a 2-second d y n a m i c simulation for the gear train.
(i) W h a t is the m i n i m u m torque that is required to rotate the input gear, and therefore, the entire
gear train?
(ii) If the torque applied to the input gear is 100 mm N, w h a t is the output angular velocity of the
gear train at the end of the 2-second simulation? Verify the simulation result using y o u r o w n
calculation.
(iii) Create a graph for the reaction m o m e n t b e t w e e n gears of the first gear pair {GearMatel) due to
the 100 mm N torque. W h a t is the reaction m o m e n t obtained from simulation?
7.1 O v e r v i e w of the Lesson
In this lesson, we will learn c a m and follower, or cam-follower. A cam-follower is a device for
converting rotary m o t i o n into linear motion. T h e simplest form of a c a m is a rotating disc w i t h a variable
radius, so that its profile is n o t circular b u t oval or egg-shaped. W h e n the disc rotates, its edge (or side
face) p u s h e s against a follower (or c a m follower), w h i c h m a y be a small w h e e l at the end of a lever or the
end of the lever or r o d itself. The follower will thus rise and fall at exactly the same a m o u n t as the
variation in radius. By profiling a c a m appropriately, a desired cyclic pattern of straight-line motion, in
terms of position, velocity, a n d acceleration, can be produced.
Physical Model
T h e camshaft and the rocker will rotate about the axes of their respective revolute j o i n t s connecting
t h e m to their respective bearings (defined as g r o u n d b o d y ) . The camshaft is driven by a m o t o r of constant
velocity of 600 r p m (or 10 rev/sec). T h e profile of the c a m consists of t w o circular arcs of 0.25 and 0.5 in.
radii, respectively, as s h o w n in Figure 7-2. T h e lower arc is concentric with the shaft, a n d the center of
the u p p e r arc is 0.52 in. above the center of the shaft. W h e n the camshaft rotates, the c a m m o u n t e d on the
shaft p u s h e s the p u s h r o d up by up to 0.27 in. (that is, 0.52+0.25-0.5 = 0.27). As a result, the rocker will
rotate and p u s h the valve at the other e n d d o w n w a r d at a frequency of 10 times/sec. T h e valve will m o v e
again up to 0.27 in. d o w n w a r d since the p u s h r o d and the valve are positioned at an equal distance from
the rotation axis of the rocker. W h e n the camshaft rotates w h e r e the larger circular arc (0.5 in. radius) of
the c a m is in contact with the follower (in this example, the pushrod), the p u s h r o d has r o o m to m o v e
d o w n w a r d . At this point, the rocker will rotate b a c k since the spring is being uncompressed. As a result,
the valve will m o v e u p , a n d therefore, close the inlet. T h e valve will be o p e n for about 120 degree p e r
cycle, b a s e d on the c a m design shown in Figure 7-2.
We will start with Lesson 7. SLDASM, in w h i c h the parts are adequately assembled. In this assembly
the first bushing is anchored (ground) and the second busing and the valve guide are fully constrained.
These three parts will be assigned as g r o u n d parts. The r e m a i n i n g four parts will be defined as m o v a b l e
parts in COSMOSMotion.
1
F r o m the browser, click the Motion button if to enter COSMOSMotion.
Again, always check the units system. M a k e sure that IPS units system is chosen for this example.
Defining Bodies
F r o m the browser, e x p a n d the Assembly Components branch. Y o u should see seven entities listed,
Bushing-1, Bushing-2, cam_shaft-1, pushrod-1, rocker-7, valve guide-1, and valve-1, as s h o w n in Figure
7-7. A l s o expand the Parts branch; y o u should see Moving Parts and Ground Parts listed. We will m o v e
Bushing-1, Bushing-2, a n d valve guide-1 to Ground Parts and the r e m a i n i n g four parts to Moving Parts
b y using the drag-and-drop m e t h o d .
F r o m the browser, click Bushing-1. Press the Ctrl k e y and click Bushing-2 and valve guide-1. All
three parts should be selected. D r a g a n d drop t h e m to the Ground Parts n o d e .
R e p e a t the same to select the r e m a i n i n g four parts u n d e r the Assembly Component branch. D r a g and
drop t h e m to the Moving Parts n o d e .
E x p a n d the Constraints branch, and then the Joints branch. Y o u should see that ten j o i n t s are listed
(see Figure 7-5). All joint symbols should appear in the graphics screen, similar to that of Figure 7-6.
E x p a n d all joints in the browser and identify the parts they connect. T a k e a look at the j o i n t Coincident2
(connecting camshaft to Bushing-2), w h e r e we will add a driver next.
Driving Joint
R i g h t click the Concentric2 n o d e a n d choose Properties (see Figure 7-8). In the Edit Mate-Defined
Joint dialog b o x (Figure 7-9), u n d e r the Motion tab (default), choose Rotate Z for Motion On, choose
Velocity for Motion Type, choose Constant for Function, and enter 3600 degrees/sec for Angular Velocity,
as s h o w n in Figure 7-9. Click Apply to accept the definition.
Defining Spring
F r o m the browser, e x p a n d the Forces branch, right click the Spring n o d e a n d choose Add
Translational Spring (see Figure 7-10). In the Input Spring dialog b o x (Figure 7-11), the Select 1st
Component field should be highlighted in red and ready for y o u to pick. Rotate the v i e w a n d pick the
b o t t o m face of the rocker (see Figure 7-12), the Select 2nd Component field should n o w highlight in red,
and rocker-1/DDMFace 19 should appear in the Select Point on 1st Component field, w h i c h indicates that
the spring will be connected to the center point of the face selected.
Stiffness: 10
Length: 1.25 (Note that y o u h a v e to deselect the Design b o x
to the right before entering this value)
Force: 0
Coil Diameter: 0.75
Number of coils: 8
Wire Diameter: 0.1
Click the Motion Model n o d e again, press the right m o u s e button and select Run Simulation. Y o u
should see that the camshaft starts rotating, the p u s h r o d is m o v i n g up a n d d o w n , w h i c h drives the rocker,
and then the valve. T h e camshaft rotates 5 times in the 0.5-second simulation duration. We will graph the
position, velocity, and acceleration of the valve next.
Graph the 7-velocity and 7-acceleration of the valve by choosing Plot > CM Velocity (and CM
Acceleration) > Y Component. The graphs of the velocity a n d acceleration are s h o w n in Figures 7-15 and
16, respectively. As s h o w n in Figure 7-15, there are t w o velocity spikes per cycle, representing that the
valve is p u s h e d d o w n w a r d (negative velocity) for opening and is being pulled b a c k (positive velocity) for
closing, respectively. T h e valve stays closed with zero velocity.
Figure 7-16 reveals h i g h accelerations w h e n the valve is p u s h e d and pulled. N o t e that such a high
acceleration is due to high-speed rotation at the camshaft. This high acceleration could p r o d u c e large
inertial force on the valve, yielding high contact force b e t w e e n the top of the valve and the socket surface
in the rocker. We w o u l d like to check the reaction force b e t w e e n the top of the valve and the rocker. The
graph of the reaction force can be created by expanding Constraints and Joints branches, right clicking
Concentric2 (between the valve a n d the rocker), a n d choosing Plot > Reaction Force > Y Component.
T h e reaction force graph (Figure 7-17) shows that the reaction force b e t w e e n the top of the valve a n d
the socket face of the rocker is about 0.4 l b , w h i c h is insignificant. N o t e that this small reaction force can
f
be attributed to the small m a s s of the valve. If y o u open the valve part and acquire its m a s s (from pull-
d o w n m e n u , choose Tools > Mass Properties), the m a s s of the valve is 0.03 l b . Therefore, the inertia for
m
2 2
the v a l v e at the p e a k accelerations is about 0.03 \b x5,600 i n / s e c = 168 l b i n / s e c = 168/386 l b = 0.44
m m f
lbf, w h i c h is consistent to peaks found in Figure 7-17. If y o u are n o t quite sure about w h y this 386 is
factored in for force calculation, please refer to A p p e n d i x B for m a s s and force unit conversions. Save
your m o d e l .
Exercises:
1. R e d e s i g n the c a m by reducing the small arc radius from 0.25 to 0.2 and reducing the center distance
of the small arc from 0.52 to 0.40, as s h o w n in Figure E 7 - 1 . R e p e a t the d y n a m i c analysis a n d check
reaction force b e t w e e n t h e valve and the rocker. D o e s this redesigned c a m alter the reaction force?
2. If we change the Parallel! m a t e b e t w e e n the Right plane of the valve and the Right plane of the first
b u s h i n g to a distance m a t e , will t h e m e c h a n i s m m o v e ? W h a t other changes m u s t be m a d e in order to
create a valid and m o v a b l e m e c h a n i s m similar to that w a s presented in this lesson?
8.1 O v e r v i e w of the Lesson
The focus of this lesson is slightly different from previous ones. Instead of focusing on discussing
h o w to use COSMOSMotion to create m o t i o n entities, we will focus on h o w to use COSMOSMotion to
support design. In order to n a r r o w d o w n the design options to be m o r e m a n a g e a b l e , we will assume all
major c o m p o n e n t s are designed w i t h dimensions determined. M o r e specifically, we will u s e
COSMOSMotion to help choose a spring, as well as determine if the required operating force is
acceptable. Since the users of this device are children with limited physical h a n d strength, the operating
force m u s t be m i n i m i z e d in order to m a k e the device useful.
Since m o s t of y o u will be often learning the software as y o u are tackling simulation and/or design
p r o b l e m s , it is strongly r e c o m m e n d e d that y o u e m p l o y the principle of spiral d e v e l o p m e n t to
incrementally build up y o u r simulation m o d e l . In another w o r d , y o u m a y w a n t to start from a simplified
m o d e l with simple scenarios by m a k i n g adequate assumptions to y o u r simulation m o d e l . M a k e the
simplified m o d e l w o r k s first, then relax the assumptions and add m o t i o n entities to m a k e y o u r m o d e l
closer to the real situation. R e p e a t the process until y o u reach a simulation m o d e l a n d simulation
scenarios that answer y o u questions a n d help y o u m a k e design decisions. In each step, m a k e sure that the
simulation m o d e l does w h a t y o u expect it to do before bringing it to the next level.
In this lesson, we will e m p l o y the spiral d e v e l o p m e n t principle. We will assume that all c o m p o n e n t s
and their physical dimensions are determined. The design is essentially n a r r o w e d d o w n to the selection of
a spring, including both spring constant and free length, and to ensure that the required force is small
e n o u g h for a child to easily operate the device. We will try our best to check and hopefully verify the
simulation m o d e l in each step. N o t e that COSMOSMotion is very sensitive to s o m e of the conditions and
parameters, such as the initial condition (that is, the handle bar orientation), spring constant, etc. S o m e of
the conditions simulated are physically meaningful a n d yet COSMOSMotion gives unrealistic simulation
results due to its limitations. Again, COSMOSMotion is not foolproof. O n e cannot blindly accept the
simulation results. W h e n a result is determined unrealistic after r e v i e w i n g animation, graphs, etc., the best
w a y to p r o c e e d is to c o m p o s e a simpler simulation m o d e l and/or try a different ( m o r e idealized) scenario
until the simulation result is physically meaningful b a s e d on y o u r educated j u d g m e n t . Y o u will see trials-
and-errors in this lesson and m a n y other real-world applications in the future.
Physical Model
This assistive device for soccer g a m e s consists of five major c o m p o n e n t s : the clamper, handle bar,
plate, kicking-rod, and spring, as illustrated in Figure 8-1. In reality these five c o m p o n e n t s will be
assembled first and c l a m p e d to the lower frame of the wheelchair for use.
The h a n d l e b a r is m o u n t e d to the plate at the pivot pin of the plate and linked to the m i d d l e pin of the
kicking rod. T h e kicking r o d is inserted into the t w o lower brackets m o u n t e d on the plate. W h e n the
handle (on top of the handle bar) is pulled backward, the handle bar rotates about the pivot pin; therefore,
drives the kicking r o d to m o v e forward along the longitudinal direction through the link b e t w e e n the
b o t t o m slot of the handle bar and the middle pin of the kicking rod. T h e forward m o v e m e n t of the kicking
r o d produces m o m e n t u m to " k i c k " the soccer ball. A spring is a d d e d b e t w e e n the u p p e r bracket and the
handle bar to restore the handle bar to its neutral position after pulling. The spring also helps the user to
pull the handle b a r with a lesser force.
T h e focus of this lesson is to u s e COSMOSMotion to simulate the position a n d velocity of the
kicking r o d for a given force that can be comfortably p r o v i d e d by a child with limited physical strength.
Lots of factors contribute to the operating force of the m e c h a n i s m . For example, one of the critical
parameters is the location of the pivot pin. T h e lower the pivot pin is located the lesser force is required to
operate the m e c h a n i s m . H o w e v e r , the purpose of this lesson is not necessarily to determine the final
design of the device, b u t illustrate t h e process of using COSMOSMotion to assist the design. Therefore, as
m e n t i o n e d earlier, t h e scope of t h e design has b e e n n a r r o w e d d o w n to the selection of the spring and to
determine if the force is small e n o u g h for a child to operate the device.
T h e final m a t e , Anglel, orients the vertical plane of the h a n d l e bar {Right Plane) respect to that of
the plate {Right Plane). This m a t e will help determine an initial condition for m o t i o n simulations. N o t e
that the Anglel m a t e to orient the handle, it will has to be suppressed to allow the handle bar to rotate
B a s e d on the geometry of the m e c h a n i s m and dimensions of its constituent c o m p o n e n t s , the kicking
r o d is able to travel a total of 12.2 in. along the longitudinal direction (Z-direction). T h e kicking r o d can
m o v e 6.82 in. forward (positive Z-direction with respect tot the m i d d l e pin) until its m i d d l e pin b e c o m e s
in contact with the inner face at the lower end of the slot, as s h o w n in Figure 8-4a. Similarly, the kicking
r o d m o v e s 5.34 in. b a c k w a r d until the side face of the handle bar b e c o m e s in contact w i t h the front end
face of the first lower bracket, as s h o w n in Figure 8-4b.
At the same time, the handle will travel a total of 18.6 in., 9.98 b a c k w a r d and 8.6 in. forward, as
s h o w n in Figures 8-4c and 8-4d, respectively. N o t e that these m e a s u r e m e n t s shown in Figure 8-4 can be
obtained by using the Measure option in SolidWorks. To access the Measure option, simply choose from
the p u l l - d o w n m e n u Tools > Measure.
Simulation Model
In this m o t i o n m o d e l , the only m o v i n g parts are the handle bar and the kicking rod. After
suppressing the m a t e Angle1, COSMOSMotion will add a revolute j o i n t to the m o t i o n m o d e l b e t w e e n the
h a n d l e bar and the plate at the pivot pin, as shown in Figure 8-5. The h a n d l e bar is allowed to rotate about
the X-axis of the global coordinate system at the pivot pin. In addition, a translational j o i n t is created by
COSMOSMotion b e t w e e n the kicking r o d and the first lower bracket. This j o i n t constrains the kicking rod
to translate along the longitudinal direction; i.e., the Z-direction. T h e third and final j o i n t is the
CamMateTangent b e t w e e n the outer surface of the m i d d l e pin and the inner surface of the slot at the
b o t t o m of the handle bar. This j o i n t restricts the pin to m o v e inside the slot.
Finally, an impulse force of 5-65 l b in a time span of 1.0 second will be added to the handle bar
f
along the Z-direction, as shown in Figure 8-5, to simulate the operating force. N o t e that the impulse force
m u s t first p u s h the handle b a r about 10 degrees forward before pulling it back, as illustrated in Figure 8-6.
In this example, we will turn on the gravity, w h i c h is acting in the negative 7-direction (vertically
d o w n w a r d ) ; i.e., the default setting. We will first a s s u m e no friction in any joints. This assumption will
greatly simplify the simulation m o d e l a n d help set up the m o t i o n m o d e l correctly. We will u s e this m o d e l
to choose a spring, including the selection of spring constant and free length. T h e simulation results of
this non-friction m o d e l h a v e b e e n created in the assembly files Lesson8TaskOne.SLDASM and
Lesson8TaskTwo. SLDASM.
T h e friction force will be turned on for both the revolute and translational joints to determine the
required force for operating the m e c h a n i s m . In addition, the operating force, m o d e l e d as an impulse force
will be a d d e d to the m e c h a n i s m . N o t e that the friction is not a d d e d to the CamMateTangent j o i n t b e t w e e n
the m i d d l e pin and the slot since such a capability is not currently supported by COSMOSMotion. Results
of these simulations can be found in Lesson8TaskThreeNoFriction.SLDASM,
Lesson8TaskThreeSmallFriction.SLDASM, and Lesson8TaskThreeLargeFriction.SLDASM.
8.3 U s i n g COSMOSMotion
In this example, we will start with a valid simulation m o d e l defined in the assembly
Lesson8.SLDASM. T h e unit system is IPS. W h e n y o u open this assembly file, y o u should see a properly
assembled m o d e l with fifteen m a t e s , as s h o w n in Figure 8-2, w h e r e the last constraint, Angle1, should
h a v e b e e n suppressed. N o t e that the m a t e angle is set to positive 10 degrees for the time being, and the
handle b a r is leaning forward (toward the Z-direction), as s h o w n in Figure 8-7. N o t e that this angle is
w h a t we a s s u m e for T a s k O n e simulations.
In T a s k T w o , we will add the spring. We will adjust the spring constant and its free length until we
reach an equilibrium configuration that we can w o r k with. N o t e that a desired free length should bring the
handle b a r b a c k w a r d a negative 5-10 degree angle ( a b o u t the X-axis). After the spring is determined, we
will add an operating force at the handle in Task Three. N o t e that the force will first p u s h the handle b a r
forward about 10 degrees (positive, a b o u t the X-axis) before pulling it b a c k w a r d in order to provide
e n o u g h travel distance for the kicking rod, and hopefully, sufficient m o m e n t u m to kick the ball.
In T a s k Three, we will start with a non-friction case, a n d then turn on friction in both the revolute
and translational joints. F r o m the friction cases, we will determine if the operating force is sufficient to
p u s h the handle forward about 10 degrees before pulling it backward. We will vary the friction
coefficients to simulate different scenarios and then determine the m a g n i t u d e of the operating forces
accordingly. The m a g n i t u d e of the force will answer the critical question: if the design is acceptable. We
h o p e to k e e p the m a x i m u m force m a g n i t u d e under 20 lbf.
We will carry out simulations for the m o t i o n m o d e l defined in Lesson8.SLDASM. In the assembly,
the handle is leaning forward 10 degrees (see Figure 8-7), the contact j o i n t Contact 3D is defined, and the
gravity is turned on. Y o u m a y w a n t to o p e n the Contact3D constraint by right clicking Contact3D from
the b r o w s e r and choosing Properties. In the Edit 3D Contact dialog box, y o u should see that the plate a n d
handle are included in the first and second containers, respectively, as s h o w n in Figure 8-9. If y o u choose
the Contact tab, y o u should see that the Coefficient of Restitution is 0.5, as s h o w n in Figure 8-10. N o t e
that no friction is i m p o s e d for this constraint. Close the dialog b o x by clicking the Apply button.
A l s o , we w o u l d like to m a k e sure that the gravity is set up properly. F r o m the browser, right click
the Motion Model n o d e and select System Defaults. In the Options dialog b o x (Figure 8-11), y o u should
2
see the acceleration is 386.22 i n / s e c , and the Direction is set to -1 for Y. Click OK to accept the gravity
setting.
Click the Motion Model n o d e from the browser, press the right m o u s e button a n d select Simulation
Parameters. Enter 2 for simulation duration a n d the 200 for the n u m b e r of frames, as s h o w n in Figure 8-
12. M a k e sure the Use Precise Geometry for 3D Contacts is selected in order for COSMOSMotion to
detect contact during simulation.
Click the Motion Model n o d e again, press the right m o u s e button and select Run Simulation. Y o u
should see that the h a n d l e bar start m o v i n g forward and the kicking r o d m o v i n g b a c k w a r d due to gravity.
W h e n the handle b a r and the first lower bracket is in contact, the handle b a r b o u n c e s b a c k slightly due to
the contact constraint we defined.
Next, we will graph the position and velocity of the kicking r o d a l o n g the Z-direction.
F r o m the browser, e x p a n d the Parts n o d e and then the Moving Parts n o d e . Right click kickingjrod-
7, a n d choose Plot > CM Position > Z, and Plot > CM Velocity > Z Component.
T w o graphs like those of Figures 8-13 and 8-14 should appear. N o t e that the vertical scales of the
graphs h a v e b e e n adjusted for clarity. T h e position graph shows that the m a s s center of the kicking r o d
w a s located at Z = 21.6 in. initially. T h e m a s s center m o v e s to the right to Z = 17.8 in., w h e r e the handle
bar is in contact with the first lower bracket. The handle bar, therefore the kicking rod, b o u n c e s back, and
the center m a s s of the kicking r o d reaches to Z = 18.6 in. before it slides to the right again due to gravity.
After about 1.5 seconds, the kicking r o d rests and stays in contact with the bracket.
T h e velocity graph (Figure 8-14) shows that the b o u n c i n g velocity is half of the i n c o m i n g velocity in
the opposite direction. This is certainly due to the 0.5 restitution coefficient defined at the contact
constraint.
In Task T w o , we will add a spring to the m e c h a n i s m . We will adjust the spring constant and its free
length until we reach an equilibrium configuration that we can w o r k with. N o t e that the free length we
specify will h a v e to bring the handle b a r b a c k w a r d about 5-10 degrees (that is, negative 5-10 degrees
a b o u t the X-axis).
Delete the simulation result.
F r o m the browser, right click the Spring n o d e and choose Add Translational Spring, the Insert
Spring dialog b o x will appear (Figure 8-15). Pick the center hole of the u p p e r bracket and the h o o k of the
handle bar, as shown in Figure 8-16. Enter the followings:
Stiffness: 30
Length: 5
Force: 0
Coil Diameter: 1
Number of coils: 10
Wire Diameter: 0.25
N o t e that the actual distance b e t w e e n the hole and the h o o k under the current configuration is about
4.34 in., w h i c h can be obtained by clicking the Design b o x to the right of the Length field. T h e n u m b e r
we enter, 5, is larger than the actual distance. Again, the purpose of entering a larger free spring length is
to m a k e the handle bar lean b a c k w a r d at equilibrium.
Click the Apply button to accept the spring. In the current configuration, the spring is c o m p r e s s e d
since the h a n d l e is leaning 10 degrees forward.
R u n a simulation.
Y o u should see that the handle bar start m o v i n g b a c k w a r d a n d the kicking r o d m o v i n g forward due
to the stretching of the spring.
W h e n the simulation is completed, the position a n d velocity graphs of the kicking r o d will appear,
similar to Figures 8-17 and 8-18. B o t h the position and velocity graphs reveal a sinusoidal type curve.
This is due to the fact that no friction has b e e n applied to the joints. Also, the handle bar is not colliding
with the bracket. The graphs s h o w that the period of one vibration is j u s t u n d e r 0.5 seconds.
N o w we will add a graph to s h o w the rotation angle of the handle b a r . Delete the simulation result.
F r o m the browser, right click the handle-1 a n d choose Plot > Bryant Angles > Angle7; i.e., about the X-
axis. R e r u n the simulation, the angle graph should appear, similar to Figure 8-19. T h e graph shows that
the h a n d l e b a r is oscillating b e t w e e n 10 and -9 degrees. T h e angle of the handle b a r at equilibrium
(assuming friction is added to dissipate energy) will be roughly the average of 10 and - 9 ; i.e., less than 1
degree, w h i c h is far less than the desired angle (negative 5-10 degrees).
Delete the simulation result, change the free length to 5.5 in., and rerun the simulation. The angle
graph s h o w n in Figure 8-20 indicates that the handle bar oscillates b e t w e e n 10 and -25 degrees, and the
m e a n angle is about -7 degrees, w h i c h is desired.
N o t e that a softer spring will increase the oscillation angle. If the spring constant is too small, say 2
lbf/in, the handle b a r m a y reach a dead lock position w i t h the m i d d l e pin of the kicking rod, similar to
w h a t w a s s h o w n in Figure 8-4a, w h i c h is not desirable. On the other hand, if the spring is too stiff, the
force required to p u s h the h a n d l e bar forward m a y be excessive. Currently, the spring constant is set to 30
lbf/in. This parameter will be revisited later in T a s k Three. Save y o u m o d e l before m o v i n g to T a s k Three.
N o w the Select Reference Component to orient Force field is active for selection. We will click the
ground button • to the right of the field. After that, y o u should see Assem5 (representing the ground)
appear in the text field. A force symbol will appear in the graphics screen pointing d o w n w a r d , w h i c h is
not w h a t we want. We will h a v e to change the force direction.
Select all the text in the Select Direction field (press the let m o u s e button and drag to select all text),
and press the Delete k e y to delete the current selection. Pick the end face of the foot, as s h o w n in Figure
8-24, to orient the force along the negative Z-direction. T h e arrow of the force symbol should n o w point
to the negative Z-direction, w h i c h is n o r m a l to the face we picked.
Click the graph button (right most, as circled in
Figure 8-25), the function graph will appear like the
one in Figure 8-26. Note that internally
COSMOSMotion will create a smooth spline
function using the data entered.
T h e position graph in Figure 8-28 s h o w s that the m a s s center of the kicking r o d starts at about 24 in.
It then travels to about 21.2 (backward) a n d then to about 26.8 in. forward due to the pulling force and
stretch of the spring. T h e overall distance that the kicking r o d travels is about 5.6 in., w h i c h seems to be
sufficient to produce e n o u g h m o m e n t u m to k i c k the ball.
Figure 8-29 shows that the velocity of the kicking r o d reaches about 27 in/sec w h e n the r o d is
p u s h e d near the foremost position. This velocity will p r o d u c e a m o m e n t u m of about 310 lbf-sec at 0.5
seconds, as s h o w n in Figure 8-30. To create a m o m e n t u m graph y o u m a y simply right click kicking_rod-l
from the browser and choose Plot > Translational Momentum > Z Component. N o t e that the velocity and
m o m e n t u m are proportional, with the m a s s of the kicking r o d as the scaling factor.
entered), assuming no friction at any joints. E v e n t h o u g h the force data we entered s h o w a polyline in
Figure 8-26, the actual force e m p l o y e d for simulation in COSMOSMotion is a spline curve generated
Save y o u m o d e l . We will turn on friction and continue determining the required operating force.
We will turn on friction at both the revolute and the translational joints. Friction for the
CamMateTangent j o i n t is currently unavailable in COSMOSMotion.
Delete the simulation result from the browser. E x p a n d the Constraints a n d then the Joints branch.
R i g h t click Revolute a n d choose Properties. In the Edit Mate-Defined Joint dialog b o x (Figure 8-33),
choose the Friction tab, click the Use Friction, and choose Aluminum Greasy for both Material 1 and
Material 2. The Coefficient (mu) will show 0.03. Enter Joint dimensions, Radius: 0.26 and Length: 0.31.
Click Apply button to accept the definition. N o t e that the dimensions entered are the diameter of the pivot
pin and the thickness of the handle b a r w h e r e the j o i n t is located.
Similarly, turn on the friction for the translational joint. Enter 7.25, 7, a n d 7, for Length, Width, and
Height, respectively, as s h o w n in Figure 8-34. N o t e that the length dimension entered is the sum of both
the lower brackets; i.e., 7 and 0.25 in. for the first and second lower brackets, respectively. The width and
height of the inner square of the brackets is 7 and 7 in., respectively.
E v e n t h o u g h the friction coefficient is small (ju = 0.03) for both joints, the handle bar hardly m o v e s .
Therefore, the force m a g n i t u d e m u s t be increased. We will follow in general the overall force pattern, and
increase the force m a g n i t u d e to p u s h the handle bar forward.
Delete the simulation result. E x p a n d the Forces a n d then the Action Only n o d e s from the browser.
Right click the ForceAO n o d e a n d choose Properties. In the Edit Action-Only Force dialog box, choose
the Function tab (see Figure 8-25), and enter the followings:
Click the graph button, the function will appear like the one in Figure 8-35. The m a x i m u m force is
n o w 12 lbf. N o t e that the first half of the force (negative part) is increased m o r e than twice, and the
positive portion remains the same. T h e positive part of the force is k e p t the same since the spring will
contribute partially to the pulling force. T h e overall force pattern is similar to that of Figure 8-26. The
force data entered are results of a few trials-and-errors.
T h e m o m e n t u m graph (Figure 8-37) shows that w h e n the rod is p u s h e d near the foremost position
the m o m e n t u m of the kicking rod is about 230 l b s e c , w h i c h is less than the previous non-friction case.
r
After reviewing the graphs, the 7 2 - l b force seems to be acceptable. H o w e v e r , this small operating force,
f
12 lbf, is due to a very small friction force; i.e., friction coefficient jU = 0.03. This result also indicates that
the spring constant 30 lbf/in seems to be adequate. Next, we will increase the friction coefficient by
changing the material from Aluminum Greasy to Aluminum Dry.
Delete the simulation result. E x p a n d the Constraints a n d then the Joints branch. R i g h t click Revolute
and choose Properties. In the Edit Mate-Defined Joint dialog box, choose the Friction tab, a n d choose
Aluminum Dry for both Material 1 and Material 2. The Coefficient (mu) will show 0.20. R e p e a t the s a m e
for the translational joint. R u n a simulation. The handle b a r is hardly m o v e d . That is, the force will h a v e
to be increased again.
Delete the simulation results. R i g h t click the ForceAO n o d e to enter the force data. N o t e that after
several attempts, a force that is large e n o u g h to m o v e the handle bar, therefore the kicking rod, is about
65 lbf. M o r e specifically, the force data entered are:
Click the graph button, the function will appear like the one in Figure 8-38. Even though the
m a x i m u m p u s h i n g force is n o w 65 lb . the pulling force (positive portion) remains the same, A r e :
f
running a simulation, the angle and m o m e n t u m graphs appear as in Figures 8-39 and 8-40, respectively
B o t h seem to be reasonable. H o w e v e r , the large operating force, 65 lb , raises a flag. The m e c h a n i s m
f
N o t e that the simulation engine, ADAMS/Solver, is very sensitive to the force data entered. Y o u may
encounter p r o b l e m s while carrying out some of the simulations in T a s k Three. W h e n this happens, simply
c h a n g e the m a x i m u m force data, e.g., 65, to a slightly different value, e.g., 63, until a simulation can be
completed.
Save y o u r m o d e l .
8.4 Result Discussion
Apparently, the biggest concern raised in the simulations is the large operating force. The friction
coefficient ju = 0.20, provided by COSMOSMotion for Aluminum-Aluminum contact without lubrication,
seems to be physically reasonable. A l t h o u g h this friction coefficient represents an extreme case since in
reality some lubricant w o u l d be added to the joints to reduce friction resistance. Nevertheless, the force is
still too large. As revealed in simulations; i.e., Task Three, the m a x i m u m operating force increases from 5
lbf for non-friction, 12 lbf for small friction (ju = 0.03) to 65 lbf for large friction (ju = 0.20). R e d u c i n g the
friction force at joints, especially the translational j o i n t b e t w e e n the kicking r o d and the t w o lower
brackets on the plate, is critical for a successful device. Y o u can easily confirm that the translational j o i n t
contributes significantly to the friction encountered in the m e c h a n i s m by conducting separate simulations
w h e r e friction is only present in one of the t w o joints.
T h e flag raised by the simulation has b e e n observed in the physical device, as s h o w n in Figure 8 - 4 1 ,
built by students following the design created in SolidWorks and COSMOSMotion. The physical device
confirms that the contact b e t w e e n the kicking r o d and the t w o brackets produces a large friction force,
resulting in a large operating force to operate the device. F o r children with limited physical strength, such
a device is unattractive.
In order to reduce the friction, four bearings are a d d e d to the device, as s h o w n in Figure 8-42. T w o
are a d d e d to the top surface of the kicking rod, and t w o are underneath the kicking rod. W i t h the bearings,
the friction is significantly reduced. Therefore, a smaller force is required to operate the device. T h e
actual operating force is less than 20 lbf.
U s i n g COSMOSMotion does answer critical questions a n d help the design process, as demonstrated
in this example. H o w e v e r , from this e x a m p l e , a n u m b e r of limitations in COSMOSMotion h a v e also b e e n
encountered. K n o w i n g these limitations will help y o u u s e COSMOSMotion m o r e effectively.
First, the simulation engine, ADAMS/Solver, w h i c h solves the equations of m o t i o n for the
m e c h a n i s m , is n o t stable. Sometimes w h e n y o u rerun the same simulation, y o u could see slightly different
results. This p r o b l e m is m o r e vivid w h e n we ran the same simulation using different computers.
Moreover, the simulation engine p r o d u c e d results, such as the velocity or m o m e n t u m (see Figures 8-37
and 8-40), with spikes, w h i c h is not quite realistic. S o m e of the spikes disappear or b e c o m e smaller w h e n
we rerun the same simulation.
Overall COSMOSMotion is an excellent tool with lots of nice features and capabilities for support of
m e c h a n i s m design and analysis. H o w e v e r , as m e n t i o n e d in this b o o k n u m e r o u s times, no software is
foolproof. Before creating a simulation m o d e l , y o u always w a n t to formulate y o u r design questions and
set up y o u r simulation m o d e l a n d scenarios gearing t o w a r d answering these specific questions. Y o u will
h a v e to e x a m the simulation results very carefully and challenge yourself about the validity of the results
since if y o u d o n ' t s o m e b o d y else will do, usually in a less friendly w a y .
APPENDIX A: DEFINING JOINTS
Degrees of F r e e d o m
Understanding degrees of freedom is critical in creating successful motion model. The free degrees
of freedom of the m e c h a n i s m represent the n u m b e r of independent parameters required to specify the
position, velocity, and acceleration of each rigid b o d y in the system for any given time. A completely
unconstrained b o d y in space has six degrees of freedom, three translational and three rotational. If y o u
add a joint; e.g., a revolute j o i n t to the b o d y , y o u restrict its m o v e m e n t to rotation about an axis, and the
free degrees of freedom of the b o d y are r e d u c e d from six to one.
(A.1)
w h e r e D is the Gruebler count representing the total free degrees of freedom of the m e c h a n i s m , M is the
n u m b e r of bodies excluding the g r o u n d b o d y , TV is the n u m b e r of d o f s restricted by all joints, and O is the
n u m b e r of the m o t i o n inputs in the system.
F o r kinematic analysis, the G r u e b l e r ' s count m u s t be equal to or less than 0. The ADAMS/Solver
recognizes and deactivates redundant constraints during m o t i o n simulation. For a kinematic analysis, if
y o u create a m o d e l w i t h a G r u e b l e r ' s count greater than 0 and try to simulate it, the simulation will not
r u n and an error m e s s a g e will appear.
If the G r u e b l e r ' s count is less than zero, the solver will automatically r e m o v e redundancies, if
possible. F o r example, y o u m a y apply this formula to a door m o d e l that is supported by t w o hinges
m o d e l e d as revolute joints. Since a revolute j o i n t r e m o v e s five d o f s , the G r u e b l e r ' s count b e c o m e s :
Redundancy
For example, if y o u m o d e l a door using t w o revolute j o i n t s for the hinges, the second revolute j o i n t
does not contribute to constraining the door's motion. COSMOSMotion detects the redundancies and
ignores one of the resolute j o i n t s in its analysis. The o u t c o m e m a y be incorrect in reaction results, yet the
m o t i o n is correct. For complete and accurate reaction forces, it is critical that y o u eliminate redundancies
from your mechanism.
Revolute Joint
A revolute joint, as depicted in Figure A - 3 , allows the rotation of one rigid b o d y w i t h respect to
another rigid b o d y about a c o m m o n axis. T h e origin of the revolute j o i n t can be located a n y w h e r e along
the axis about w h i c h the bodies can rotate with respect to each other. T h e j o i n t origin is assigned by
COSMOSMotion w h e n y o u enter COSMOSMotion from SolidWorks.
Orientation of the revolute j o i n t defines the direction of the axis about w h i c h the bodies can rotate
with respect to each other. T h e rotational axis of the revolute j o i n t is parallel to the orientation vector a n d
passes t h r o u g h the origin.
Translational Joint
A translational j o i n t allows one rigid b o d y to translate along a vector with respect to a second rigid
body, as illustrated in Figure A - 4 . T h e rigid bodies m a y only translate, not rotate, w i t h respect to each
other.
T h e location of the origin of a translational j o i n t with respect to its rigid bodies does n o t affect the
m o t i o n of the j o i n t but does affect the reaction loads on the joint. T h e location of the j o i n t origin
determines w h e r e the j o i n t symbol is located.
T h e orientation of the translational j o i n t determines the direction of the axis along w h i c h the bodies
can slide with respect to each other (axis of translation). T h e direction of the m o t i o n of the translational
j o i n t is parallel to the orientation vector and passes t h r o u g h the origin.
Cylindrical Joint
A cylindrical j o i n t allows b o t h relative rotation and relative translation of one b o d y with respect to
another b o d y , as s h o w n in Figure A - 5 . T h e origin of the cylindrical j o i n t can be located a n y w h e r e along
the axis about w h i c h the bodies rotate or slide with respect to each other.
Orientation of the cylindrical j o i n t defines the direction of the axis about w h i c h the bodies rotate or
slide along with respect to each other. T h e rotational/translational axis of the cylindrical j o i n t is parallel to
the orientation vector a n d passes t h r o u g h the origin.
Spherical Joint
A spherical j o i n t allows free rotation about a c o m m o n point of one b o d y with respect to another
body, as depicted in Figure A - 6 . The origin location of the spherical j o i n t determines the point about
w h i c h the bodies pivot freely with respect to each other.
T h e origin location of the universal j o i n t represents the connection point of the t w o bodies. T h e t w o
shaft axes identify the center lines of the t w o bodies connected by the universal joint. N o t e that
COSMOSMotion uses rotational axes parallel to the rotational axes y o u identify b u t passing t h r o u g h the
origin of the universal joint.
W h e n defining a screw joint, y o u can define the pitch. T h e pitch is the a m o u n t of translational
displacement of the t w o bodies for each full rotation of the first body. The displacement of the first b o d y
relative to the second b o d y is a function of the b o d y ' s rotation about the axis of rotation. For every full
rotation, the displacement of the first b o d y along the translation axis with respect to the s e c o n d b o d y is
equal to the value of the pitch.
Planar Joint
A planar j o i n t allows a plane on one b o d y to slide and rotate in the plane of another body, as shown
in Figure A - 9 .
Fixed Joint
A fixed j o i n t locks t w o bodies together so they cannot m o v e w i t h respect to each other. T h e fixed
j o i n t symbol is s h o w n in Figure A - 1 0 .
M a p p e d SolidWorks Mates
2
m a s s block, it will accelerate 386 i n / s e c , as s h o w n in Figure B - l b .
2
On the other hand, we h a v e the m a s s unit, 7 l b m 1/386 l b s e c / i n . It m e a n s that a 1 l b m a s s b l o c k
f m
2 2
is 386 times smaller than that of a 7 l b s e c / i n block. Therefore, a 1 l b s e c / i n b l o c k will w e i g h 386 l b
f f f
2
on earth. W h e n applying a 1 lbf force to the m a s s block, it will accelerate at a 7 i n / s e c rate, as illustrated
in Figure B - l c .
APPENDIX C: IMPORTING Pro/ENGINEER PARTS AND
ASSEMBLIES
F r o m time to time w h e n y o u use COSMOSMotion for simulations, y o u m a y encounter the n e e d for
importing solid m o d e l s from other C A D software, such as Pro/ENGINEER. SolidWorks provides an
excellent capability that support importing solid m o d e l s from a b r o a d range of software and formats,
including Parasolid, A C I S , I G E S (Initial Graphics E x c h a n g e Standards), S T E P (STandard for E x c h a n g e
of Product data), SolidEdge, Pro/ENGINEER, etc. For a complete list of supported software and formats
in SolidWorks, please refer to Figure C - 1 . Y o u m a y access this list by choosing File > Open from the
pull-down m e n u , a n d pull d o w n the Files of type in the File Open dialog box.
We will discuss the approaches of importing parts, and then importing assemblies. In each case, e
will try both options; i.e., importing solid features v s . importing geometry. We will use the gear train
e x a m p l e e m p l o y e d in Lesson 6 as the test case a n d as an example for illustrations.
sketches in the graphics screen by clicking their n a m e s listed in the browser. In addition, the b a c k plate
(Extrudel in the browser) is recognized incorrectly. Certainly, SolidWorks is capable of importing s o m e
parts correctly and completely, especially, w h e n the solid features are relatively simple (but n o t this gear
h o u s i n g part).
Importing geometry is m o r e straightforward and has a higher successful rate than that of importing
solid features.
R e p e a t the same steps to open the gear housing part, gboxjiousingprt. In the Pro/ENGINEER to
SolidWorks Converter dialog b o x (Figure C-8), choose Import geometry directly (default), a n d then
Kniting (default) in order to import solid m o d e l s instead of j u s t surface m o d e l s . N o t e that if y o u choose
BREP (Boundary Representation), only b o u n d a r y surfaces will be imported. Click OK.
T h e conversion process will start. After about a m i n u t e or two, the converted m o d e l will appear in
the graphics screen, as shown in Figure C-9. In addition, an entity Importedl will appear in the browser
(Figure C-9). As m e n t i o n e d earlier, there will be no parametric solid feature with dimensions and sketch
converted if y o u choose Option 2. However, the geometry converted seems to be accurate. All the
geometric features in Pro/ENGINEER shown in Figure C-3 were included in this imported feature. This
translation is successful. Since we do not anticipate m a k i n g any change to the gear housing, this imported
part is satisfactory. T h e gear housing part, gbox housing, sldprt, e m p l o y e d in Lesson 6 w a s created by
u s i n g Option 2.
We will import the input gear assembly (gbox_input.asm) s h o w n in Figure C-10 using b o t h options.
We will try Option 1 first; i.e.. importing solid features. As s h o w n in Figure C-10 {Pro/ENGINEER
Model Tree w i n d o w ) , there are 11 parts (and several d a t u m features) in this assembly. SolidWorks will try
to import this assembly as well as the 11 parts from Pro/ENGINEER.
Importing geometry is also m o r e straightforward for assembly and has a higher rate of success.
R e p e a t the same steps to open the input gear assembly, gbox input.asm. In the Pro/ENGINEER to
SolidWorks Converter dialog b o x (Figure C - l 3), choose Use body import for all parts (default), and then
Kniting (default) in order to import solid m o d e l s . C h o o s e Overwrite for If same name SolidWorks file is
found, and choose Import material properties and Import sketch/curve entities. Click Import. T h e
conversion process will begin.
After about a m i n u t e or t w o , the converted assembly will appear in the graphics screen, as s h o w n in
Figure C - l 4 . T h e assembly a n d all 11 parts s e e m to be correctly imported. If y o u expand any of the part
branch, for example, the gear (wheel_gbox_pinion_ls<l>), y o u will see an imported feature listed, as
depicted in Figure C-14. Again, there is no solid feature converted in any of the parts. In addition, the
Mates branch is empty.
Since we do n o t anticipate m a k i n g any change to this input gear assembly, this imported assembly is
satisfactory, except it does not have any assembly mates. Assemble all 11 parts (may be m o r e for some
cases) will take a non-trivial effort. Since we do not anticipate m a k i n g change in h o w these parts are
assembled, we will m e r g e all 11 parts into a single part.
F r o m the browser, click the first part wheel box_shaftinput<l>, press the Shift key, and then click
the last part, screw_setjip_6*6<2>. All 11 parts will be selected.
F r o m the p u l l - d o w n m e n u , choose Insert > Features > Join. T h e Join w i n d o w will appear
(overlapping with the browser) as s h o w n in Figure C-16. In the Join w i n d o w , all 11 parts are listed. All
y o u h a v e to do is to click the c h e c k m a r k on top to accept the parts. Save the assembly (and the part), and
then close the w h o l e assembly.
N o w open the part gbox Jnput. M a k e sure y o u open gbox input, sldprt instead of gboxJnput. sldasm.
T h e part gbox input will appear in the graphics screen. In addition, all entities b e l o n g to this part will be
listed in the browser, as s h o w n in Figure C-17. N o t e that there is an arrow symbol -> to the right of the
root entity, gbox Jnput. This symbol indicates that these entities enclosed in this part refer to other parts
or assembly. N o t e that the Joinl branch has the same symbol. E x p a n d the Joinl branch, y o u will see 11
parts listed, all with arrows, pointing to the actual parts currently in the same folder. W h e n the link is
broken; i.e., w h e n the referring parts are r e m o v e d from the folder, a question m a r k symbol will be added
to the arrow.
T h e three gear parts, gbox Jnput. sldprt, gboxjniddle.sldprt, and gbox output, sldprt, e m p l o y e d for
Lesson 6 w e r e created following the approach discussed. O n e axis in each part that passes t h r o u g h the
center hole of the gear w a s created simply by intersecting t w o planes, for e x a m p l e , Top a n d Right planes
for the axis in gbox Jnput. sldprt, as s h o w n in Figure C-18. T h e s e axes are necessary for creating gear
pairs, as discussed in Lesson 6.