3.

Graphical Linkage Synthesis

3.1 Types of Motion

Function Generation: correlation of output motion with input motion

Example: Scotch Yoke.

Input: Rotation
Output: Sinusoidal Function

Path Generation: control of a point on a mechanism such that it follows a prescribed path.

TDC
Example: piston engine

Control Points: TDC, BDC

BDC

Motion Generation: Control of a line on a mechanism such that in assumes a set of sequential
positions

Example: Windshield Wiper (Mercedes)

- Vertical in middle of windshield

- Angled at edges of windshield
- Does not move in a circular arc!

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3.2 Graphical Dimensional Synthesis

Given: a set of prescribed positions & link angles, find the dimensions (link lengths & pivot
positions) to produce this motion.

Example 3-1: 2 Position synthesis with rotational displacement (windshield wiper)

Find a linkage which produces 60 of rocker rotation with equal time forward and back using a
constant-speed motor. (windshield wiper mechanism)

Given: 2 desired output angles

Find: Link lengths, fixed and moving pivot locations

1. Draw link O4B in extreme positions B1, B2 so that 60 is swept out.

Note: link 4 is already defined at this point, as is the position of one fixed pivot. Now we must find
a way to drive the rocker through 60. The simplest way is to push point B back and forth
horizontally.

2. Draw chord B1B2.

3. Draw a circle having as its center the midpoint of B1B2 and radius extending out to B2.
4. Extend B1B2 out to a convenient point.
5. Select a point O2 on B1B2 for the other fixed pivot.
6. Copy the circle drawn in Step 3 so that its center is at O2.
7. Label the intersections of circle and B1B2 A1 and A2.
8. Measure length of coupler from A1B1 or A2B2.
9. Measure rocker length O4B1, crank length O2A1.
10. Find Grashof condition. If non-Grashof redo steps 3-8 with O2 further from O4.

Note: Two free choices

1. length of O4B
2. length of O2B

This implies an infinite number of possible solutions.

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Example 3-1

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Example 3-2: 2 position synthesis with complex displacement (bottle capper)

For this example we wish to move a line on the rocker through two specified locations.

1. Draw link CD in its desired positions C1D1 and C2D2

2. Draw lines from point C1 to C2 and D1 to D2
3. Bisect lines C1C2 and D1D2 and extend perpendicular bisectors in convenient directions.
Their intersection is the “rotopole”

Note: it takes three points to define a circular arc. The three points may be on the arc, or two points
may be on the arc with the remaining point at the center. In this case we require two circular arcs
with a common center: the arcs swept out as C1 moves to C2 and D1 to D2. The two perpendicular
bisectors we just drew are possible center locations for arcs which pass through C 1 C2 and D1 D2,
respectively. Their intersection is thus a common center.

4. Select a convenient radius and draw an arc about O4 to intersect O4C1 and O4C2
5. Label the intersection points B1 and B2.
6. Do steps 2 through 8 of Example 3-1

Note: Free choices

1. position of joint B
2. length of O2B

this problem reduced to Example 3-1 once the correct rocker link geometry was found.

What happens if C1D1 and C2D2 are parallel to each other?

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Example 3-2

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Example 3-3: 2 positions with complex coupler output

Here we wish to move a line on the coupler through two positions. This is useful in situations where
rocker output is not up to the job (e.g. parallel movement.)

1. Draw link CD in two desired positions (coupler link)

2. Bisect lines C1D1 and C2D2 and draw perpendicular bisectors.
3. Select convenient points on bisectors for O2, O4.
4. Connect O2 with C1: link 2
5. Connect O4 with D1: link 4

Note: this time our arc centerpoints are separated since we are defining two links instead of just one.
Since this fourbar has two rocker links, we must construct a driver dyad to drive it.

6. Select a point on link 2, call it B1.

7. Draw arc around O2 to intersect B1 and O2C2. Call the intersection B2.
8. Rest is same as example 3-1.

Free choices:

1. length of link 2
2. length of link 4
3. position of joint B
4. length of O6B

Note: there is a problem with this linkage, in that it probably cannot move smoothly between
positions 1 and 2. Linkage design is an iterative process!

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Example 3-3

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Example 3-4: 3 positions with complex coupler output

Here we wish to synthesize a linkage which will move the coupler through 3 positions.

1. Draw link CD in its three desired positions.

2. Draw construction lines between C1C2, C2C3, etc.
3. Bisect lines C1C2 and C2C3 and extend perpendicular bisectors until they intersect. Label the
intersection O2.

Note that in this case we have three points which define an arc about O2. The intersections of the
bisectors is the center of the arc.

4. Bisect lines D1D2 and D2D3 and extend perpendicular bisectors until they intersect. Label the
intersection O4.
5. Connect O2 with C1 and call it link 2. Connect O4 with D1 and call it link 4.
6. Construct a driver dyad to drive the linkage between its two extreme positions.

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Example 3-5: 3 positions with alternate moving pivots

In some cases we wish a line on the coupler which is distinct from the line between the two pivots
to move through a specified path. This might happen in the case of a windshield wiper mechanism,
where we do not want to locate pivot points in the middle of the windshield.

1. Draw line CD in the three desired positions.

2. Define new attachment points E and F on coupler link. These points have a fixed
relationship with CD. Draw E1F1 on link 1. Draw a cirele of radius E1C1 about C2. Draw a
circle of radius E1D1 about C2. The intersection of these circles is point E2. Use the same
procedure to find F2, E3 and F3.

Explanation: Essentially we are using similar triangles to transfer the relationship between C 1D1 and
E1 to C2D2 and E2. The first circle we drew makes the distance E2C2 the same as the distance E1C1.
The second circle makes the distance E2D2 the same as E1D1. Since the distance E1C1=E2C2, the
three sides of the triangles E1C1D1 and E2C2D2 are the same, thus, similar triangles.

3. Draw construction lines E1E2 and E2E3. Repeat for F.

4. Draw perpendicular bisectors of E1E2, E2E3, F1F2 and F2F3.
5. Label intersections O2 and O4.
6. Connect E with O2 and F with O4 to make links 2 and 4, respectively.
7. Construct a driver dyad to drive the linkage.

Note: free choices

1. Locations of E and F on coupler link

There is a problem with this construction! The pin at O4 appears to interfere with link 2. It would
be nice if there were a procedure to specify the locations of the fixed pins and find the locations of
the moving pins on the coupler (points E and F.)

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Example 3-5

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Example 3-6: 3 position synthesis with specified fixed pivots

This problem is called an “inversion” problem, that is, we will pretend a moving link is fixed, and
perform the analysis from there.

1. Draw line CD in its three desired positions. Draw ground link O2O4 in its position. For the
remainder of the analysis we will rename O2O4 G1H1.
2. Take the relationship between line C2D2 and O2O4 and transfer it to C1D1. Call the new line
G2H2.
3. Take the relationship between line C3D3 and O2O4 and transfer it to C1D1. Call the new line
G3H3.

Note: what we are doing here is pretending that C1D1 is a fixed link and that the ground link moves
around it. This is the so-called “inversion” part of the analysis. The three positions that the
“moving” ground link takes bear the same relationship with “fixed” C1D1 as those between the
“fixed” ground link and moving CD.

4. Draw construction lines G1G2 and G2G3. Repeat for H.

5. Draw perpendicular bisectors of G1G2, G2G3, H1H2 and H2H3.
6. Label intersections E1 and F1. E1F1 is the coupler link in position 1.
7. Connect E with O2 and F with O4 to make links 2 and 4, respectively.
8. Construct a driver dyad to drive the linkage.

To find the layout of the rockers and coupler in positions 2 and 3, we must repeat steps 2 and 3,
transferring the relationships to lines C2D2 and C3D3, respectively.

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Example 3-6

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 Egg

Quick-Return Mechanisms
In the preceding examples, we didn’t worry about how long it took for the linkage to travel its path.
In the case of the windshield wiper mechanism, for example, it is probably best for the linkage to
spend an equal time pushing the wipers to the left as to the right. But for some mechanisms, timing
is critical. Consider the “egg lifter” mechanism shown above. The purpose of this mechanism is to
lift an egg (or other delicate object) from one conveyor belt to another. We wish to lift the egg
slowly and gently, so as not to damage it, but the return stroke (when the egg is not on the platform)
should be quick, so as not to waste time.

o
180 back

o
180 forward

To see how we might accomplish this, consider the “cartoon” above. As you can see, the rocker
spends and equal time moving forwards as backwards, because the crank sweeps out 180° for each
motion. To change the timing, we need to tailor the angle of sweep to our needs.

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 o
200 forward

o
160 back

By simply lowering the fixed crank pivot, we change the parts of the crank’s rotation that are spent
moving forward or backward. In the figure above, the crank spends 200° of rotation moving the
rocker “forward” and 160° of rotation moving the rocker “backward”. Let us call the forward angle
β and the return angle α. Now define the time ratio as

𝛼
𝑇𝑅 =
𝛽

In most cases, the time ratio will be specified, and we must construct the linkage to accomplish this
motion. Finally, we’ll use the construction angle δ to help design our linkage.

𝛿 = 𝛽 − 180

𝛼 + 𝛿 = 180

𝛼 + 𝛽 = 360

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Example 3-7

2-position quick-return mechanism

Problem Statement: design a driver dyad which sweeps out 40 of rocker rotation and has a time
ratio of 1.25:1

1
𝑇𝑅 = = 0.8
1.25
0.8
𝛼 = 360° · = 160°
1 + 0.8

𝛽 = 360° − 160° = 200°

𝛿 = |180° − 𝛼| = 20°

1. Draw output link O4B in desired position

2. Draw a construction line through B1 at a convenient angle
3. Draw a line through B2 at an angle  with the first line
4. Label the intersection O2
5. Measure lengths O2B1 and O2B2

Note:
𝐿2 + 𝐿3 = 𝑂2 𝐵2
𝐿3 − 𝐿2 = 𝑂2 𝐵1

Solve for L2 and L3:

1
𝐿3 = (𝑂 𝐵 + 𝑂2 𝐵1 )
2 2 2
1
𝐿2 = (𝑂 𝐵 − 𝑂2 𝐵1 )
2 2 2

6. Measure angle 

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Example 3-7

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