A STUDY ON A NOVEL QUICK RETURN MECHANISM Wen-Hsiang Hsieh and Chia-Heng Tsai

Department of Automation Engineering, National Formosa University, E-mail: allen@nfu.edu.tw

Received April 2008, Accepted September 2009 No. 08-CSME-13, E.I.C. Accession 3051

ABSTRACT
This work aims to propose a novel design for quick return mechanisms, and the new mechanism is composed by a generalized Oldham coupling and a slider-crank mechanism. First, the kinematic dimensions that affect the time ratio are found by investigating the geometry of the proposed design. By transforming into its kinematically equivalent mechanism, and then the design equations of time ratio are derived. Furthermore, a design example is given for illustration. Moreover, the design is validated by kinematic simulation using ADAMS software. Finally, a prototype and an experimental setup are established, and the experiment is conducted. The results show that proposed new mechanism is feasible and with reasonable accuracy. In addition, it is more compact and easier to be balanced dynamically than a conventional quick return linkage.

TUDE DUN ME CANISME A ` RETOUR RAPIDE INNOVATEUR E

SUME RE

Nous proposons une conception innovatrice dun me canisme a ` retour rapide compose dun accouplement de style Oldham et dun syste ` me bielle-manivelle. Pour commencer, en e tudiant la ge ome trie du concept propose , on e tablit les dimensions cine matiques qui affectent le rapport temps. En les transformant en un me canisme cine matique e quivalent, nous trouvons la de rive e des e quations de rapport temps, et pour illustrer le concept on donne un exemple. De plus, le concept est valide par une simulation cine matique a ` laide du logiciel ADAMS. Finalement, un prototype est cre e, et un cadre expe rimental est e tabli pour mener lexpe rience. Les re sultats re ve ` lent que le me canisme propose est re alisable et sa pre cision est acceptable. En outre, il est plus compact et il est plus facile deffectuer le quilibrage dynamique que pour un me canisme a ` retour rapide conventionnel.

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1. INTRODUCTION
A quick return mechanism is a mechanism that converts rotary motion into reciprocating motion at different rate for its two strokes. When the time required for the working stroke is greater than that of the return stroke, it is a quick return mechanism. It yields a significant improvement in machining productivity. Currently, it is widely used in machine tools, for instance, shaping machines, power-driven saws, and other applications requiring a working stroke with intensive loading, and a return stroke with non-intensive loading. Several quick return mechanisms can be found in the literatures [12], including the offset crank-slider mechanism, the crank-shaper mechanisms, the double crank mechanisms, and the Whitworth mechanism. All of them are linkages. A linkage has its strengths and weaknesses. It is inexpensive to make and easy to lubricate; however, it is bulky and difficult to balance. In situations, if compact space is essential to the design, then a linkage may not be a good choice. Therefore, how to find a new alternative of quick return mechanisms is an open topic that deserves to be examined. There are many scholars devoted to the studies of quick return mechanisms, and many valuable contributions have been made. Dwivedi [3] used the Whitworth mechanism to constructing a high velocity impacting press. Suareo & Gupta [4] performing the design of the spatial RSSR quick return mechanism. Beale [5] employed Galerkins method to investigate the dynamic and stability of a flexible link used in a quick return mechanism. Fung [69] and Lin [1011] utilized different control approaches to investigate the response of a quick return mechanism with or without a flexible link. Hat et al. [12] proposed a finite difference method with fixed and variable grids to approximate the numerical solutions of a flexible quick-return mechanism. Chang [13] investigated the coupling effect of the geared rotor on the quick-return mechanism undergoing three-dimensional vibration. This work aims to present a new design for the quick return mechanisms, and verify its feasibility by conducting simulation and experimental studies. In this work, Section 2 introduces the composition of the proposed system. The equations for calculating time ratio are investigated in Section 3. Section 4 performs kinematic analysis. A design example is given for illustration in Section 5. Section 6 presents the prototype experiment. Conclusions are summarized in Section 7.

2. NEW QUICK RETURN MECHANISM

An Oldham coupling is used to transmit the motion or the power between two parallel shafts. It can be classified, by its shape of its slots or ribs, as classical Oldham couplings (straight slot), generalized Oldham couplings with circular slots, and generalized Oldham couplings with curvilinear slots [14]. Fig. 1 shows the generalized Oldham coupling which consists of a frame (link 1), an input disk (link 2), a floating disk (link 3), and an output disk (link 4). The radii, r1 and r2, of the centerline of the slots need not be equal, and the two centerlines are usually, but not necessary, designed to intersect at the axis of the floating disk. The classical Oldham coupling will transmit uniform motion between the input and output shafts. However, the generalized Oldham coupling with circular slots and curvilinear slots will transmit non-uniform motion and produce quick return motion. And it may lead to many potential applications to devices requiring non-uniform transmission. Hsieh [1518] applied the generalized Oldham coupling to various mechanical devices, including mechanical presses [15], cam mechanisms [16], ball screw mechanisms [17], and vibrating conveyors. In addition, with proper
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Fig. 1. Generalized Oldham coupling.

arrangement, Oldham couplings can be used as a balancer to eliminate shaking forces and shaking moment [19]. Figs. 2(a) and 2(b) depicts the schematic sketch and the kinematic sketch of the proposed new mechanism, respectively. It consists of a generalized Oldham coupling and a crank-slider mechanism. A motor is connected to the input disc of the generalized Oldham coupling at pivot a0, and then the coupling drives the crank-slider mechanism to produce quick return motion. The advantages of the new design are easier to be balanced dynamically and more compact in volume (as discussed in Sec. 3) than a conventional quick return linkage. In addition, the building cost is inexpensive if a generalized coupling with circular slots is adopted.

3. MOTION GEOMETRY
Due to the complexity of the geometry for a generalized Oldham coupling with curve slots, the investigation on the geometry is limited to that with circular slots in this work. In Fig. 2, points a0 and b0 denote the axes of rotation of the input and the output disks, respectively, and let r1 5 a0b0 be the distance of centers of two fixed pivots. Furthermore, points a and b denote the arc centers of the slots on the input and the output disks, respectively, and the distance of two centers is set as r3 5 ab, and point o is the point of intersection of the two arcs. Moreover, let r2 5 oa and r4 5 ob be the radii of the circular slots of input disk and output disk, respectively. Also, angle a 5%aob denotes the intersection angle between two circular arcs, and angle b 5%cb0b is that of b0b makes with b0c, measured in counterclockwise. In addition, let r4 5 b0c and r5 5 cd be the link lengths of the crank and the connecting rod, respectively. Also, let r6 be the offset, the perpendicular distance between the line produced by the rectilinear

Fig. 2. New quick return mechanism.

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Fig. 3. Equivalent linkages.

motion of joint d and the line passing through two fixed pivots a0 and b0. Also, by applying Cosine law to triangle Daob, it leads to
2 2 r2 3 ~r2 zr4 {2r2 r4 cos a

(1)

Additionally, it is noted that angle b represents the relative position of assembly between the coupling and the slider-crank mechanism. Since the output disk of the coupling will be attached to the crank in the proposed design, b is a constant. Apparently, the output motion will vary with different choices of b. Finally, the kinematic dimensions of the system will be fully defined if ri (i5126), r4, a, and b are specified. The mechanism can be converted into its equivalent mechanism, called the drag link quick return mechanism, as shown in Fig. 3. By comparing Fig. 2(b) and 3, the proposed new design is more compact than its equivalent linkage. In addition, if a proper design is made as that proposed by Tsai [19]. To perform the time ratio design, the associated design equations have to be derived firstly. The two limit positions of the slider are depicted in Fig. 3, and the subscripts 1 and 2 denote the right limit position and the left limit position of the slider, respectively. Let e be the intersection of perpendicular line of b0 with the extended line of d1d2, from Triangles Db0d2e and Db0d1e, the stroke S of the slider can be found as q q S~ (r4 0 zr5 )2 {r6 2 { (r4 0 {r5 )2 {r6 2 (2) Also, let c1 5%b0d1d and c2 5%b0d2e, we obtain c1 ~ sin{1 r6 =(r5 zr4 0 ) c2 ~ sin{1 r6 =(r5 {r4 0 ) (3) (4)

and both angles are measured in counterclockwise. Furthermore, let w12 be the angular displacement of the link 2 when the slider moves from position 1 to 2 (link 2 rotating in clockwise), and w21 for position 2 to 1. Then, it can be seen from Fig. 3 that w21 ~p{d1 zd2 w12 ~2p{w21
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(5) (6)
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where d1 5%b0a0a1 and d2 5%b0a0a2, both measured in counterclockwise. Moreover, let ww and wr denote the angular displacement of the link 2 for the working and the return strokes, respectively. For a quick return mechanism, ww is greater than wr. If d2 . d1, then w21 . w12. Therefore, ww ~w21 Otherwise, ww ~w12 In addition, ww zwr ~2p (9) (8) (7)

By definition, the time ratio TR is the time of the working stroke tw to that of the return stroke tr. If the input is running at constant speed, then the time ratio tw to tr equals to that of ww to wr. Then, TR~tw =tr ~ww =wr (10)

Therefore, the time ratio of the design can be determined if d1 and d2 are obtained. Let l15 a0b1, from Da0b0b1 in Fig. 4(a), then we have
2 2 l1 ~r2 1 zr4 {2r1 r4 cosp{(b{c1 )

(11)

Moreover, let g1 5%b1a0a1 and j1 5%b0a0b1, then it yields g1 ~ cos{1

2 2 l1 zr2 2 {r3 2l1 r2

(12)

from Da1a0b1. And j1 ~ tan{1 r4 sin (b{c1 ) r4 cos (b{c1 )zr1 (13)

from Db1a0b0. Moreover, d1 is the sum of g1 and j1, that is d1 ~g1 zj1 (14)

Fig. 4. Limit positions.

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Substituting Eqs. (12)(13) into Eq. (14), we have d1 ~ cos{1

2 2 l1 zr2 r4 sin (b{c1 ) 2 { r3 z tan{1 r4 cos (b{c1 )zr1 2l1 r2

(15)

Similarly, let l2 5 a0b2, then from Da0b0b2 in Fig. 4(b), it yields

2 2 ~r2 l2 1 zr4 {2r1 r4 cos(b{c2 )

(16)

Let g2 5%b2a0a2 and j2 5%b0a0b2, where b0 is a point that b0 mirrors with respect to the vertical line passing through a0. Then, we obtain g2 ~ cos{1
2 2 l2 zr2 2 { r3 2l2 r2

(17)

from Da2a0b2. Furthermore, j2 ~ tan{1 r4 sin (b{c2 ) r4 cos (b{c2 ){r1 (18)

from Db2a0b0. And d2 is the sum of g2 and j2, that is d2 ~g2 zj2 Substituting Eqs. (17)(18) into Eq. (19), it yields d2 ~ cos{1
2 2 l2 zr2 r4 sin (b{c2 ) 2 { r3 z tan{1 r4 cos (b{c2 ){r1 2l2 r2

(19)

(20)

Hence, d1 and d2 can be solved from Eqs. (15) and (20). Then, substituting them into Eqs. (5) and (6), w12 and w21 can be obtained. Moreover, ww and wr can then be determined through Eqs. (7)(9). Finally, time ratio can be work out by Eq. (10). In addition, the time ratio design for the proposed mechanism can then be conducted through the design equations derived above.

4. KINEMATIC ANALYSIS
The main approaches for kinematic analysis of closed loop mechanisms are relative velocity/ acceleration, vector loop, and matrix loop approaches. The vector loop approach can be easily computerized and is suitable for the analysis of planar mechanisms, therefore it is adopted for the kinematic analysis in this study.

4.1. Position Analysis Fig. 5 shows the vector representation of the proposed design. It has two independent vector loops, and their equations can be formulated as:
I I I I r2 z r3 { r4 { r1 ~ 0 I I I I I r1 z r4 z r5 { r6 { r7 ~0

(21) (22)
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Fig. 5. Vector representation.

Eq. (21) can be resolved into its x and y components, respectively, as: r2 cos h2 zr3 cos h3 {r4 cos h4 {r1 cos h1 ~0 r2 sin h2 zr3 sin h3 {r4 sin h4 {r1 sin h1 ~0 where h1 5 0. Rearranging Eqs. (23) and (24), we have r3 cos h3 ~r4 cos h4 {r2 cos h2 zr1 r3 sin h3 ~r4 sin h4 {r2 sin h2 The square sum of Eqs. (25) and (26) can be found to be A cos h4 zB sin h4 ~C where A~2r4 (r1 {r2 cos h2 ) B~{2r2 r4 sin h2 C ~(r3 2 {r4 2 {r1 2 {r2 2 )z2r1 r2 cos h1 cos h2 p Dividing Eq. (30) by A2 zB2 and simplifying it, we obtain C cos w cos h4 z sin w sin h4 ~ p A2 zB2 where (28) (29) (30) (27) (25) (26) (23) (24)

(31)

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A cos w~ p A2 zB2 and B sin w~ p 2 A zB2

(32)

(33)

Applying the adding formula of trigonometric functions to Eq. (31), then the closed form of h4 can be solved by   C {1 p h4 ~w+ cos (34) A2 zB2 Dividing Eq. (26) by Eq. (25), and then followed by rearrangement, it yields   r4 sin h4 {r2 sin h2 {1 h3 ~ tan r1 zr4 cos h4 {r2 cos h2

(35)

Furthermore, let h4 5 h42b, h6 5 270u, and h7 5 0u, and substituting into Eq. (22), its x and y components can be solved by r1 zr4 0 cos h4 0 zr5 cos h5 {r7 ~0 r4 0 sin h4 0 zr5 sin h5 zr6 ~0 Solving Eq. (37), it yields   0 0 {1 {(r4 sin h4 zr6 ) h5 ~ sin r5 Substituting Eq. (38) into Eq. (36), then the displacement of the slider is r7 ~r1 zr4 0 cos h4 0 zr5 cos h5 (39) (36) (37)

(38)

4.2. Velocity Analysis Velocity analysis can be worked out by differentiating the equations deduced in position analysis with respect to time. Due to the limit on the number of pages, the results for velocity and acceleration analysis are presented directly without proofs. For velocity analysis, their deduced equations are:
_2 _ 3 ~ r2 sin (h4 {h2 ) h h r3 sin (h3 {h4 ) _2 _ 4 ~ r2 sin (h3 {h2 ) h h r4 sin (h3 {h4 ) (40)

(41)

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_ 40 {r4 0 cos h4 0 h _ h5 ~ r5 cos h5 The velocity of the slider can thus be calculated by _ 4 {r5 sin h5 h _5 _ 7 ~{r4 0 sin h4 0 h r
0

(42)

(43)

4.3. Acceleration Analysis Acceleration analysis can be performed by differentiating the equations derived in velocity analysis with respect to time. The derived equations are:
IK {HL h3 ~ GK {HJ GL{IJ h4 ~ GK {HJ where G~{r3 sin h3 H ~r4 sin h4 _ 2 2 cos h2 zr3 h _ 3 2 cos h3 {r4 h _ 4 2 cos h4 I ~r2 h2 sin h2 zr2 h J ~r3 cos h3 K ~{r4 cos h4 _ 2 2 sin h2 zr3 h _ 3 2 sin h3 {r4 h _ 4 2 sin h4 L~{r2 h2 cos h2 zr2 h Furthermore,
0 _ 4 02 sin h0 zr5 h _ 5 2 sin h5 h4 cos h4 zr4 0 h { r4 0 4 h5 ~ r5 cos h5

(44)

(45)

(46) (47) (48) (49) (50) (51)

(52)

Finally, the acceleration of the slider can be obtained by

0 _ 4 02 cos h4 0 {r5 _ 5 2 cos h5 r7 ~{r4 0 h4 sin h4 0 {r4 0 h h5 sin h5 {r5 h

(53)

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5. DESIGN EXAMPLE
An example is given here for illustrating the design process of the proposed mechanism. It is assumed that the time ratio TR of the design is 1.65, the stroke S is 102.61 mm, and the working stroke is the one moving from the limit position 1 to position 2. By specifying r4 5 50 mm, r5 5 175 mm, then substituting them as well as S into Eq. (2), we have r6 5 37.5 mm. Furthermore, r4, r5, and r6 are substituted into Eq. (3) and Eq. (4), then we obtain c1 5 9.59u and c2 5 17.46u, respectively. Moreover, substituting TR into Eq. (10) and followed by solving simultaneously with Eq. (9), it yields ww 5 224.15u and wr 5 135.85u. Since the design is at working when moves from the limit position 1 to 2, i.e., ww 5 w12 and wr 5 w21, w21 5 224.15u and w12 5 135.85u. Also, d2 has to be greater than d1, based on Eq. (5). Then, assume d1 5 115.99u, then d2 5 159.3u can be solved from Eq. (5). Moreover, substituting the above known data to Eqs. (1), (11), (15), (16), and (20), we have five equations and eight unknowns (r12r4, l1, l2, a, b). Therefore, three unknowns can be freely specified, and three parameters r1 5 13.29 mm, r4 5 60 mm, and b 5 120u are assigned here, and then l1 5 69.86 mm and l2 5 53.30 mm can be solved by substituting the parameters as well as c1 and c2 into Eqs. (11) and (16). Finally, substituting r1, r4, l1, l2, and b to Eqs. (1), (15), and (20), we have r2 5 60 mm, r3 5 84.85 mm, and a 5 90u. In addition, the kinematic dimensions of the design are drawn in Fig. 6. To validate the design, its solid model is established by CATIA software, as shown in Fig. 7. Then, the model is introduced into ADAMS software for kinematic simulation, and the output displacement is shown in Fig. 7.

6. EXPERIMENT
To verify the feasibility of the proposed design, a prototype shown in Fig. 8 is designed and fabricated. In order to have higher precision, an AMT linear guideway with a carriage (MSB 15 TS-BH FC H) and a rail (MSB 15 R 460 - 20 /20 H) is used to replace the slider and the guideway, respectively, in the prototype. The slots and ribs are made of S45C Steel, and their profiles are machined and then grinded with a CNC machine. Two 6903ZZ ball bearings are

Fig. 6. Kinematic sketch.

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Fig. 7. Kinematic simulation.

used for the bearings of the input and the output shafts of the generalized Oldham coupling. Moreover, an experimental system shown in Fig. 9 and Fig. 10 is set up for measuring and testing. The system comprises an AC servo motor (Mitsubishi, HC-KFS73, 750W, 3000 rpm) with a servo driver (MR-J2S-70A), a flexible coupling (TSD, MHC-1218L48), an linear encoder (Easson, GS100200, 10 mm/m), and a servo amplifier (Elmo, CEL 5/60) for data acquisition. To adjust the input at constant speed more easily, a servo motor is adopted in the system as the power source. In practical application, a motor runs at constant speed can be used instead. By connecting the motor shaft and the input shaft with the flexible coupling, then the servo motor drives the input shaft of the prototype at constant speed with open loop control. The displacement of the slider (carriage) is measured by the linear encoder. The pulses generated by the linear encoder are counted by the servo amplifier, and then transmitted to the Elmo composer software, installed in a PC, for converting it into the output displacement. The comparisons of output motions between the simulation and the experiment at the input speed of 60 rpm are shown in Fig. 11. It can be observed from the figure that both the outputs agree fairly with each other, the experimental output has only a slight lag occurred. Also, the time ratio of the simulation and the experiment can be found by calculating the time for each stroke. For example, the maximum displacement occurred in the simulation is at the time of 0.624 sec in Fig. 11(a), then the time for the working stroke is tw 5 0.624 sec, and the time for the return stroke is tr 5 0.376 sec. Therefore, by definition, its time ratio is TR 5 1.659.
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(a) Assembly drawing

(b) Photo

Fig. 8. Prototype.

Fig. 9. Schematic diagram of the experimental system.

Fig. 10. Experimental set up.

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(a) Displacement

(b) Velocity

(c) Acceleration

Fig. 11. Comparisons.

Similarly, in the experiment, tw 5 0.621 sec, and tr 5 0.379 sec, therefore TR 5 1.638. It can be easily found that the error is 0.021 which is 1.27 % to the simulation. Therefore, the proposed design is not only feasible, but also has reasonable accuracy.

7. CONCLUSIONS
In this work, a novel design for the quick return mechanism, i.e., a crank-slider driven by a generalized Oldham coupling, has been proposed. The design equations for time ratio have been derived from its geometry. Kinematic analysis has been performed. Then, a design example has been given for illustrating the design process. Moreover, a computer simulation using ADAMS software has been carried out. Finally, to verify the feasibility and accuracy, a prototype has been made, and then an experiment has been conducted. The experimental result shows that the proposed mechanism can produce the designed time ratio with reasonable accuracy. In addition, the new design will consume less space and can be balanced more easily, compared to a conventional quick return linkage. Hence it provides a good alternative for the quick return mechanism that requires more compact volume and better dynamical balance.

ACKNOWLEDGEMENT
The support of the National Science Council, Republic of China (Taiwan), under Grants NSC 96-2221-E-150-049 and NSC 97-2221-E-150-019, is gratefully acknowledged.

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