987

Kinematic analysis and synthesis of the knotting

mechanisms can be used in the production of
handmade carpet: a case study
M Topalbekiroğlu
Department of Textile Engineering, University of Gaziantep, 27310 Gaziantep, Turkey

The manuscript was received on 20 April 2005 and was accepted after revision for publication on 11 May 2005.

DOI: 10.1243/095440605X31733

Abstract: The weaving process in a handmade carpet contains independent knots, which have a
complex structure. A new production method, mechanism, or machine for producing knots in
handmade carpets has not been developed since thousands of years. They are still woven by
human hand. Two different types of knots are used to form handmade carpets, which are
called as the Turkish (Gördes knot) and the Persian (Sehna knot) knots. In this article, the con-
ceptual design and dimensional synthesis for mechanisms used to produce these knots are
studied. To generate all-acceptable one-degree of freedom (DOF) and two-DOF planar knotting
mechanism, a systematic methodology is presented. First, the functional requirements of the
knotting mechanism are established according to the problem statement. Some of the functional
requirements of the knotting mechanism are then translated into the structural characteristics
of mechanism. On the basis of the requirements and the structural considerations, the unwanted
mechanism is screened out. Finally, two different mechanisms are developed for the knotting
mechanism and their dimensions are determined by dimensional synthesis method.

Keywords: kinematic analysis and synthesis, mechanisms, conceptual design, dimensional

synthesis, handmade carpets

1 INTRODUCTION which will be employed in solving a given design

Mechanism synthesis utilizing computational
resources and tools has been an active research
area during the last 100 years [1, 2]. The motion is
specified and the mechanism for this job is obtained
by applying various techniques. This is simply the
essence of kinematic synthesis. Kinematic synthesis
is the problem of determining a three-dimensional
structure of rigid parts which implement a given
task. Kinematics considers motions only and not
the forces that cause the motions. The solution to
kinematic synthesis problem is grouped into two
different categories [3– 7]. The first category includes
the determination of the topological arrangement of
links and the nature of the kinematic connections
between links, and it is called type and number
syntheses (conceptual design). This is an early
stage of design. The designer chooses the concepts
problem and decides how to interconnect them
into an appropriate system architecture [8]. The
second category which is concerned with the deter-
mination of the suitable dimensions of the mechan-
ism and necessary to satisfy the desired motions is
called as ‘dimensional synthesis’ (size or geometric
synthesis). The requirement is to determine all
necessary design variables by defining the geometry
of a mechanism while satisfying certain motion
requirements. Sophisticated numerical packages
are available for dimensional synthesis [2] and the
research is now active [9 –17] in the area of concep-
tual design.
The conceptual synthesis problem is very difficult,
as designs are specified in incomplete terms. There is
no general theory that relates function and structure
in mechanical devices. Artobolevsky’s catalogue [18]
provides a library of known mechanisms indexed by

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988
type and function. They are a useful starting point for
a designer who can use systematic adaptation of
these designs to create devices that meet the
specified functionality.
Many dimensional synthesis problems are
included in one of the three following categories
depending on the task in which the linkage performs
the function generation synthesis, the path gener-
ation synthesis, and the motion generation synthesis
(rigid body guidance) [3– 6]. The methodologies used
for solving these problems can be classified as ‘the
precision point’ and ‘the approximate synthesis’
[19]. Both graphical and analytical techniques with
and without prescribed timing are well studied [20].
Numerical techniques are commonly combined
with various optimization schemes such as the gen-
etic algorithms [21 –23], the evolutionary techniques
[24], the interior-point method [25], and the gauss
constrained method [26]. Recently Hoeltzel and
Chieng [27] have developed methods for dimen-
sional synthesis of four-bar linkages from specifica-
tions of planar trajectories by using the neural nets
to perform pattern matching over these trajectories.
The precision point method synthesizes a mecha-
nism such that a point on the coupler link will pass
through a number of prespecified positions or
points. Generally, the maximum number of precision
points depends on the number of design variables
associated with the mechanism of interest in this
method. If the number of equations generated by
the precision points is less than that of the design
variables, the designer is free to choose the value of
certain design variables. Freudenstein and Sandor
[28], Roth and Freudenstein [29], Suh and Radcliffe
[30], Mclarnan [31], Erdman [32], and Tsai and Lu
[33] have performed studies related to precision
point synthesis in the literature.
In the approximate synthesis technique, a designer
chooses more precision points than the precision
point synthesis technique suggests. An error function
based on the difference between the generated and
the desired precision points is constructed. As the
error function is minimized with respect to the
design variables, an optimum linkage is obtained.
Therefore, this method returns a better distribution
of the error between the synthesized and the desired
paths over the entire range. The most widely used
approximate synthesis technique is the least-squares
methods. Han [34], Nolle and Hunt [35], Akhras and
Angeles [36], Sancibrian et al. [37], Shiakolas et al.
[2], and Maura Da Lio et al. [38] have studied this
method.
The concept design method for a knotting mech-
anism to form both the Turkish knot and the Persian
knot on two warps is presented here. A systematic
methodology [9, 39] is used to identify all admissible
one- and two-degree-of-freedom (DOF) planar
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M Topalbekiroğlu
mechanisms for a knotting mechanism design. The
functional requirements of a knotting mechanism
are established. Some of the functional requirements
are then translated into mechanism structural
characteristics. Four-bar with one DOF and five-bar
with two DOF are found applicable according to the
functional requirements and the structural consider-
ations. The dimension of four-bar mechanism is
determined by using the precision point dimensional
synthesis method. The other mechanism is obtained
by using an atlas of coupler curves of geared five-bar
mechanism (GFBM) drawn by Zhand et al. [40] and
by Norton [3]. The GFBM is obtained by a modifi-
cation on the five-bar mechanism. Two DOF device
requires two simultaneous inputs for constraint. By
coupling two links together with a gearset, a single
input to any link results in a coupled input to a
second link through the gearset, thus reducing DOF
to one. Although the four-bar mechanism has great
versatility in terms of kinds of paths and function
generations obtainable, the GFBM introduces several
additional design parameters, namely, gear ratio,
phase angle, and link ratio.
2 PROBLEM STATEMENT
The problem statement is important to give a clear
and obvious definition while designing a mechan-
ism. The schematic diagram given in Fig. 1 illustrates
the knotting mechanism as a box, where the input
is a pile of yarn and the output is the knot. The box
will be driven by a servomotor, a stepper motor, a
pneumatic, or a hydraulic actuator system.
There are many ways of knotting the pile yarn
around the warp. The two most common knots are
the Turkish knot and the Persian knot, which are
shown in Figs 2(a) and (b).
In the Turkish knot the pile yarn wraps around two
warps and locks. It has a symmetrical structure and a
very secure pile. Two tufts come between the same
warp space. In the Persian knot, the pile yarn
encloses only one warp and goes under another
warp resulting in an asymmetrical structure. Two
Fig. 1 Flow diagram of knotting mechanism
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Fig. 2 Types of knots

tufts are separated between the same warp space.
Here, the problem is to design and create knotting
mechanisms to produce both the Turkish and the
Persian knots.
3 FUNCTIONAL REQUIREMENTS
A knotting mechanism must have the flexibility for
forming both the Turkish knot and the Persian knot
on two warps, while running at high speeds to pro-
duce these knots economically with easy control.
The knotting mechanism should also be compact
in size with respect to the frame.
The knotting mechanism for producing the Turkish
knots may contain two-symmetrical mechanisms to
their symmetrical properties shown in Fig. 3(a). In
producing the Turkish knots, a pair of warp yarns is
distinguished from the others, separated from each
other at a certain distance, and gets into the same
line by following the trajectory as seen in Fig. 3(a).
However, the same knotting mechanism for the
Persian knots involves one mechanism due to their
asymmetrical properties represented in Fig. 3(b).
In this type knots, a pair of warp yarns knotted the
pile yarn is not at the same line and one of warp
yarn can be driven forward as shown in Fig. 3(b).
The pile yarn is passed through the pair of warp
yarns.
The mechanism in the left side is called
Mechanism-I and the other is called Mechanism-II.
Mechanism-I and Mechanism-II are essentially the
same mechanisms. The design studies are carried
out on Mechanism-I. The Mechanism-I is capable
of producing forward and backward motions. In the
forward motion, the mechanism traces a trajectory
(represented by dashed line), passing through three
precision points (P1, P2, and P3). It holds the end
of the pile yarn at the point P1, passes through
the point P2, and finally releases the end of the pile
yarn at the point P3. Similarly, it traces the same
trajectory in the backward motion.

Fig. 3 Representative figures of the knotting mechanism

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990
Fig. 4 Precision points for producing Turkish knots on two warps
The desired DOF for the knotting mechanism can
be selected as one or two. In general, when designing
a mechanism having one DOF, the point synthesis is
suitable. In this method, a specific point on the
mechanism follows a trajectory which passes
through a set of predefined positions. However, if
the control of the full trajectory is important for the
design of the mechanism, a two-DOF mechanism
or a cam mechanism is recommended. Two alterna-
tive trajectories for producing the Turkish and
Persian knots on two warps are given in Figs 4
and 5, respectively.
For the first alternatives (as seen in Figs 4(a) and
5(a)), the knotting mechanism requires at least one
DOF to carry out the trajectory which passes through
three precision points. Point synthesis can be used
for the first alternatives. The last alternative in Figs
4(b) and 5(b) has only full trajectory. Two-DOF
mechanism or cam mechanism is required to
follow the full trajectory.
If the knotting mechanism has more than two
DOF, then the speed of the mechanism will be slow
and the control algorithm becomes complex owing
to their structural configurations. In contrast, if a
knotting mechanism is designed with only one
DOF, then the speed of a knotting mechanism will
Fig. 5 Precision points for producing Persian knots on two warps
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M Topalbekiroğlu
be fast and the control algorithm becomes simple.
Besides, each number of DOF may be considered
as a driver in the form of a servomotor, stepper
motor, solenoid, or air cylinder to provide the input
motion. If the number of drivers is increased, the
cost of the system will be high. When the DOF of
the knotting mechanism is two, four drivers will be
needed. The size of the mechanism will be increased,
which is an expensive choice. The functional require-
ments of a planar knotting mechanism can be
summarized as follows.
1. If the control of a specific point on the knotting
mechanism draws a trajectory that passes through
three precision points, the point synthesis will be
used and one-DOF mechanism will be selected.
2. If the control of specific points on the knotting
mechanism following a full trajectory is required,
a two-DOF mechanism or a cam mechanism will
be used.
3. The knotting mechanism should be able to move
forward and backward and the driver system
must have a feature of bi-directional control.
4. The knotting mechanism should be able to run
at high speeds to produce the Turkish knots econ-
omically and have a simple control algorithm. The
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knotting mechanism must be compact in size
with respect to frame and have a low cost.
4 KINEMATIC SYNTHESIS
4.1 Conceptual design
Structure specifications of the knotting mechanism
of interest are determined by using type synthesis.
Conceptual synthesis, which can be subdivided into
number synthesis, topological synthesis, and topolo-
gical analysis, tries to predict combination of linkage
topology and type of joints which are the best suited
for a given task [3, 6]. In structural synthesis, link and
in joint numbers can be determined in terms of DOF
and total link numbers in a mechanism. This can be
achieved by using modified form of Gruebler
equation in equation (1)
DOF ¼ 3(L
1)
2J1
J2
where L represents the number of total links, J1 is the
number joints with two constraints, and J2 is the
number joints with one constraint. Considering that
the mechanisms have only J1 type of joints, the
Grubler’s equation can be written as
DOF ¼ 3(L
1)
2J1
and Euler equation [1]
LN ¼ J1
L
1
where LN represents the number of loops in a mech-
anism. The total number of links in any mechanism
will be
L¼BþT þQþPþH
where B, T, Q, P, and H represent the number of
binary, ternary, querternary, pentagonal, and hexa-
gonal links, respectively. As two link nodes are
needed to make one joint
Nodes
J1 ¼
2 Table 1 All possible link combinations for one-DOF
Nodes ¼ order of link  no. of links of that order
(2B þ 3T þ 4Q þ 5P þ 6H þ    )
J1 ¼
2 6
To determine link combinations, equations (2) and
(6) are used.
L
DOF
3 ¼ T þ 2Q þ 3P þ 4H þ   
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Solution of equation (7) determines all sets of
higher-order links which satisfy the desired DOF.
Each set of the total number of links is called as
kinematic link set solution.
In topological synthesis, kinematic chains
produced for each combination of links are used.
The mechanisms are then generated by applying the
method of mechanism inversion. All potential candi-
date mechanisms are then examined one by one.
In topological analysis, an answer is given by
how the drivers and different types of joints can be
chosen and distributed throughout the mechanisms.
According to the functional requirements given in (1)
and (2), a planar knotting mechanism should have
one DOF and two DOF, respectively. The search
begins with link combinations for one DOF, up to
eight links and for two DOF, up to seven links, to
hexagonal order and using only full revolute joints.
Thus, the unnecessary complication associated
with large number of links is avoided.
(1)
4.2 Search of one-DOF mechanism
Structure specifications for one-DOF knotting
mechanism are that the input link must be a base-
connected crank or rocker and the output link must
be a floating link. Any mechanism with a ternary
grounding link is to be excluded. A ternary grounding
(2) link does not satisfy the size requirement of the
mechanism. Using equations (4) and (7), all compa-
tible link combinations are determined systemati-
cally as given in Table 1. The first column of the
(3) table shows the total number of links and the other
columns represent binary, ternary, quaternary, pen-
tagonal, and hexagonal links in each combination.
All kinematic chains and mechanisms for each
kinematic link set solution are given in Appendix 1.
(4)
4.3 Search of two-DOF mechanism
The following structure specifications for two-DOF
knotting mechanism can be considered. The input
links must be a base-connected crank or rocker and
the output link must be a floating link. Using
(5)
mechanisms up to eight links
Total number of links B T Q P H
(6) 4 4 – – – –
4 2 – – –
6 5 – 1 – –
8 4 4 – – –
8 5 2 1 – –
8 6 – 2 – –
8 6 1 – 1 –
8 7 – – – 1
(7)
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Table 2 All possible link combinations for two-DOF
mechanisms up to seven links
Total number of links B T Q P
5 5 – –
7 5 2 –
7 6 – 1
equations (4) and (7), all compatible link combi-
nations are determined systematically as shown in
Table 2.
All kinematic chains and mechanisms for each
kinematic link set solution are given in Appendix 2.
5 EVALUATION OF STRUCTURAL SYNTHESIS
A single DOF mechanism may be used to pass
through precision points to trace the path of the
knot. Three precision points motion generation
method may be used for the synthesis of such
mechanisms. Four-bar and the other mechanisms
are compared in terms of their structures and
kinematic analysis. It is obvious that a four-bar
mechanism has a simple structure and compact in
size than the other mechanism, as it contains only
four links. The kinematic synthesis and analysis of
the other mechanisms are more difficult than for
the four-bar mechanism. Here, the four-bar mechan-
ism may be an admissible mechanism for the knot-
ting mechanism (Mechanism-I), according to the
requirements (1) and (4). If the control of a specific
point on the mechanism is to follow a full trajectory,
a two-DOF mechanism or a cam mechanism will be
the solution. For this situation, a five-bar mechanism
can be selected according to of requirement (2).
6 DIMENSIONAL SYNTHESIS
Three precision points are enough to synthesize
four-bar mechanism for the Mechanism-I. Synthesis
for two and three precision points is relatively
straightforward, and each one of the cases can be
reduced to a system of linear simultaneous
equations. In general, two basic methods can be
used for solving the problems of three precision
point synthesis for four-bar mechanism [31, 32, 39].
Graphical or geometrical synthesis methods (the
simplest, quickest, and straightforward method of
design) were largely used by the early scholars. In
practice, the graphical synthesis method is preferred
for the solution of mechanism-design problems, as it
is useful in the initial stages of kinematic space avail-
able. Designers like to see directly how the linkage
mechanism ‘moves’ and how it fits the space.
Graphical techniques have limitations of accuracy
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M Topalbekiroğlu
owing to drawing error. However, the analytical syn-
thesis method is performed by using a computer.
The advantages of accuracy and repeatability are
H
available. Once a mechanism is modelled mathemat-
– – ically and coded for the computer, the mechanism
– – parameters can easily be calculated afterwards.
– –
Second model for Mechanism-I is supplied by
using an atlas of coupler curves of geared five-bar lin-
kages drawn by Zhang et al. [8, 31]. Five-bar linkage
mechanisms with two DOF are admitted according
to the functional requirement (2). However, two dri-
vers are needed for two-DOF mechanisms. Increas-
ing the number of driver, increases the cost and
the size of the system. This choice will be expensive
and it will not satisfy requirement (4). Therefore,
some modifications will be needed on five-bar
mechanism to reduce its DOF to one [8]. Two links
of five-bar mechanism which are connected to the
ground link are coupled together with a gearset. A
single input to any link results in a coupled input to
a second link through the gearset, thus reducing its
DOF to one.
6.1 Four-bar mechanism synthesis for
Mechanism-I
Here, the graphical solution of Mechanism-I will be
presented and then correlated with the results
found from the analytical solution. Graphical sol-
ution is useful in the initial stages of synthesis of
Mechanism-I. It has to meet some criteria, such as
the size of the mechanism, location of the ground
pivots and the interference of the rotating links,
and the warp threads and the pile yarn. Four-bar
mechanism for Mechanism-I must be compact and
the ground pivots must be located in reasonable
locations. In addition, the rotating links must not
interfere with warps threads and the pile yarn as
the mechanism performs the task. The dimensions
of Mechanism-I are obtained according to the
following procedure.
The position, the angular orientation, and the geo-
metry of the coupler link are given in three positions
as in Fig. 6. The problem statement is given as: design
a four-bar mechanism to move the link AB shown in
Fig. 6 from position A1 B1 to A2 B2 and then to position
A3 B3 . Moving pivots are at A and B. The acceptable
locations of ground pivots A0 and B0 are found at
the given instants. The solution of this problem is
shown in Fig. 7 and the location of the ground
pivots A0 and B0 is found by the intersection of the
perpendicular bisectors. The coupler link shown in
Fig. 7 interferes with warp threads. To avoid this
condition, geometrical modification is done on the
tracing path point (P) of coupler link.
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Fig. 6 Three prescribed positions for the first model

The results of parameters for Mechanism-I are
given in Table 3. In addition, Mechanism-I is
checked for Grashof condition, transmission angles,
and toggle position, for example.
In Grashof condition, length of the longest link
g(A0 B0 ) is 48.26 mm, length of the shortest link
w(A0 A1 ) ¼ 22 mm, and length of two intermediate
links v(A1 B1 ) ¼ 40 mm and u(B0 B1 ) ¼ 37 mm.
Equation g þ w , v þ u is satisfied and a crank –
rocker mechanism is obtained; the shortest link
(link 2) fully rotates and the other link pivoted to
ground oscillates. For toggle condition, a cardboard
model is constructed, and it is moved by getting it
from initial to final position without encountering
any limit positions. In transmission angle, when the
link AB and the ground link AB are collinear like in
Fig. 8, the transmission angles are measured as
mmax ¼ 1328; mmin 1 ¼ 488, and mmin 2 ¼ 408. The maxi-
mum deviation of the transmission angle is given
by Dmmax ¼ max½(mmax
908) or (908
mmin ) (mmin ¼
min½mmin 1 ,mmin 2 ). It is found that Dmmax ¼ 508, there-
fore Mechanism-I will not lock.
An analytical model of the mechanism must be
developed to understand the design variables and
the free choices. Several mathematical methods,
such as algebraic, matrix, and complex numbers,
have been used for planar synthesis objectives. The
complex number method is the simplest and the
most versatile method. Modelling linkages as combi-
nation of vector pairs dyads can also be used to solve
the mechanism synthesis problems. The four-bar
linkage shown in Fig. 9(a) can be perceived as two
dyads: the left side of the linkage is illustrated as a
vector pair (W and Z) and the right side as U and S.
In Fig. 9(a), the dyad W1 and Z1 in the left side and
the dyad U1 and S1 in the right side are represented

Table 3 Graphical results for the first model

Magnitude Angles (degree) for
Link (mm) three positions

Ground 1 g ¼ 48:26 1 ¼ 848 fixed angle

(Link A0 B0 )
Crank 2 w ¼ 22 u1 ¼
618,u2 ¼ 49:58,u3 ¼ 718
(Link A0 A)
Coupler 3 v ¼ 40 f1 ¼ 678,f2 ¼ 46:58,f3 ¼ 31:58
(Link AB)
Rocker 4 u ¼ 37 s1 ¼
578,s2 ¼
4:58,s3 ¼
118
(Link B0 B)
Fig. 7 Geometrically synthesized four-bar mechanism

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994
Fig. 8 Transmission angle
at first precision position. In addition, dyad Wi and Zi
in the left side and the dyad Ui and Si in the right side
are denoted at ith precision position (i represents
the precision position). Vectors V1 and G1 represent
the coupler link and the ground link vectors, respect-
ively. Vectors V1 and G1 are determined when dyad
pairs are known. The tracing point (P) on the coupler
link of the four-bar mechanism moves from position
1 to position i. The co-ordinates of P1 and Pi are rep-
resented as precision point 1 and precision point i,
respectively. They are defined in a fixed (arbitrarily
located) complex co-ordinate system by R1 and Ri ,
respectively. The vector Pi1 denotes the vector from
Fig. 9 Four-bar mechanism
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M Topalbekiroğlu
P1 to Pi (Pi1 ¼ Ri
R1 ). The angle di represents the
angular position difference vectors Pi1 which is
drawn from P1 to Pi .
The angle ai represents the angular rotation of the
vector Zi from the first position to the ith position.
The angle bi denotes the angular rotation of the
vector Wi from the first position to the ith position.
The angles u1 and s1 represent the angular displace-
ment of the position vectors W1 and U1 . The angles
f1 and c1 denote the angular displacement of the
position vectors Z1 and S1 .
Vector W originates at the fixed ground pivot and
terminates at the moving pivot, whereas the vector
Z starts at the moving pivot and ends at the path
tracer point. The positions of W dyad in three
precision points method are shown in Fig. 9(b).
The vector W has two components, Wx and Wy .
The angles u1 , u2 , and u3 represented in Fig. 9(b)
define absolute orientations of the input link in its
first (W1 ), second (W2 ), and third (W3 ) positions,
respectively. The rotations from the first position to
the second and to the third are denoted by b2
and b3 . All vector rotations are measured positive
counterclockwise. The quantity w denotes the mag-
nitude of the vectors W1 , W2 , and W3 , which is the
same in all three positions because it represents the
same line of a rigid link. The same can be written
about vectors Z1 , Z2 , and Z3 whose common
magnitude z remains constant.
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 Knotting mechanisms in production of handmade carpet
The first position of W vector can be expressed as a
complex number in Cartesian form as
W1 ¼ W1x þ jW1y
This can also be expressed in polar form as
W1 ¼ we ju1
where w and u1 denote the magnitude and the angle
of the vector W1 in the first position, respectively
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi  

1 Wy
w ¼ W1x þ W1y u1 ¼ tan
2 2
Wx
Combining equation (9) with Euler identity
(eju ¼ cos (u) þ j sin (u)) for the first position as
W1 ¼ w( cos u1 þ j sin u1 )
In Fig. 9(b), the vectors in the second position W2
and in the third position W3 can be written in
terms of its first position. Thus
u2 ¼ u1 þ b 2 and u 3 ¼ u 1 þ b3 ;
j(u1 þb2 )
W2 ¼ we and W3 ¼ we j(u1 þb3 )
The complex number notation can be easily applied
for other vectors in Fig. 9(a). Consider the first and ith
positions of the left-hand dyad of the four-bar mech-
anism shown in Fig. 9(a). Summing the vectors clock-
wise around the loop containing a dyad loop closure
equation form Wi , Zi , Pi1 , Z1 , and W1
Wi þ Zi
Pi1
Z1
W1 ¼ 0 i ¼ 2, . . . , n
where n represents the total number of positions to be
solved for. Substituting the complex number equiva-
lents for the vectors given in equation (13)
we j(u1 þbi ) þze j(f1 þai )
pi1 e jdi
ze jf1
we ju1 ¼ 0
This can be put in a more compact form by substi-
tuting vector notation for those terms to which they
apply, W1 ¼ we ju1 , Z1 ¼ ze jf1 , and Pi1 ¼ pi1 e jdi then
W (e jbi
1) þ Z(e jai
1) ¼ pi1 e jdi i ¼ 2,... , n
Equation (15) is simply the vector sum around the
loop describing the first and ith positions of the left
side of the four-bar linkage. Equation (15) is the so-
called standard form [35, 36], if Pi1 is prescribed or
known and either ai or bi is prescribed or known. A
similar equation can be derived for the dyad on the
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right side (U and S) of the four-bar linkage with
changes to variable names as required
(8) U1 (e jbi
1) þ S1 (e jai
1) ¼ pi1 e jdi i ¼ 2,..., n (16)
The four-bar linkages may be easily modelled by
using standard form equations for function gener-
(9) ation, path generation, and motion generation tasks.
A four-bar mechanism for Mechanism-I can be syn-
thesized in the motion generation task, using
equations (15) and (16) for its three position. In
analytical solution, Mechanism-I is mathematically
modelled. A computer program (in Pascal) is written
(10) to determine easily the unknown parameters. The
flow chart of this program is given in Fig. 10.
The input variables and free choices shown in
Fig. 10 are taken from graphical solution, and the
dimension of Mechanism-I is then determined. The
coordinates of the tracer path point shown in Fig. 6
(11)
are P1x ¼ 0:0 mm, P1y ¼ 0:0 mm, P2x ¼ 33 mm,
P2y ¼ 16:5 mm, P3x ¼ 42:5 mm, and P3y ¼ 0:0 mm.
The angle changes of the coupler between precision
points are a2 ¼
20:58 and a3 ¼
35:58. The free
choices for the link angles are b2 ¼ 110:58 and b3 ¼
1328 for left dyad and g2 ¼ 52:58 and g3 ¼ 468 for
right dyad.
The computer program is used for solving
(12) equations (15) and (16). The unknowns W1 , Z1 , U1 ,
and S1 vector component are found and given in
Table 4. Thus, the link lengths of four-bar mechanism
can be computed. The results in analytical solution
are approximately the same as in graphical solution.
Isometric view of the knotting mechanism (four-bar
mechanism) to form the Turkish knot and the Persian
knot are shown in Figs 11(a) and (b), respectively.
(13)
6.2 Five-bar mechanism synthesis for
Mechanism I
The coupler curves of geared five-bar mechanism are
more complex than the four-bar mechanism. The
geared five-bar introduces three additional design
(14) parameters; gear ratio (l ¼ NGear2 =NGear5 ), additional
link ratio (a ¼ Link3=Link2, b ¼ Link1=Link2), and
phase angle (f ¼ u þ s), the coupler curves have
higher degree than those of the four-bar mechanism.
Zhang, Norton, and Hammond atlas of geared five-
bar mechanism containing 732 coupler curves traced
(15) for these linkages limited to symmetrical geometry
(Link2 ¼ Link5 and Link3 ¼ Link4). The tracer
point is the joint between the coupler links and the
gear ratios are þ1, 21, þ2, 22. The data [8, 31] are
given for either six or 12 curves on a page. This atlas
is used to serve as a resource to machine designers
and to aid in the design and selection of potential
geared five-bar mechanisms for specific applications
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996 M Topalbekiroğlu

Fig. 10 Flow chart of three precision point four-bar synthesis programme

Table 4 Analytical results can be considered as the main steps for the design
of the knotting system. Then, the finest subsystems,
Link Magnitude (mm) Angles (degree)
assemblies, and components are developed to
Ground 1 (link A0 B0 ) g ¼ 48:39 1 ¼ 84:6 provide these functions. The flow diagram of the
Crank 2 (link A0 A) w ¼ 22:007 u1 ¼
61 knotting system consists of the following mecha-
Coupler 3 (link AB) v ¼ 40:467 f1 ¼ 67
Rocker 4 (link B0 B) u ¼ 36:428 s1 ¼
57 nisms; the knotting mechanism involving the
Coupler 3 (link AP) z ¼ 101:069 f1 ¼ 67 vacuum unit, the warp control mechanism, the pile
Coupler 3 (link BP) s ¼ 60:018 c1 ¼ 67 yarn manipulating mechanism, including the pattern
study and the auxiliary mechanisms (the holding
mechanism and the cutting mechanism), and the
knot positioning mechanism are shown in Fig. 14.
[8, 31]. Using the atlas of geared five-bar linkage cou-
The pile yarn manipulating mechanism performs
pler curves, a model for knotting mechanism, shown
the function of supplying a coloured yarn related to
in Fig. 12, satisfies the task. The properties of geared
the pattern to the knotting mechanism, meanwhile
five-bar mechanism are the additional link ratio a ¼
one end of the pile yarn can be kept by the pile
5:0 and b ¼ 3:0, the gear ratio l ¼ 2:0, and the phase
yarn holding mechanism. The warp control mecha-
angle f ¼
1208. The tracer point (P) of the mechan-
nism serves to prepare a pair of warp yarns by
ism follows the desired trajectory, while the input
distinguishing them from the other pairs and sepa-
link fully rotates.
rates them from each other by a certain distance,
The solution details of the mechanism are shown
according to the knot type. The knotting mechanism
in Fig. 13.
then holds the pile yarn by the vacuum system and at
the same time, the cutting mechanism cuts off the
pile yarn at the end. Finally, the knotting mechanism
forms the knot. The knot positioning mechanism
7 FUTURE WORK then places the knot by pulling down the tips of the
pile yarn.
The constraint modelling of the knotting mecha- Here, the knotting mechanism can be considered
nisms shown in Figs 11 to 13 is impossible to use in as the basic mechanism. However, the other mech-
production of handmade carpet alone. A complex anisms serving the functions of preparing the pile
mechanism or system is required forming the knots yarn and controlling the pair of warps may be
practically and referred to as the knotting system accepted as the auxiliary mechanisms. As a future
herein. The design problem for such a system can work, the auxiliary mechanisms may be developed
be solved by separating it into partial subproblems. and designed referring to the knotting mechanism
The function of the system and its decomposition as shown in Figs 11 and 13.

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 Knotting mechanisms in production of handmade carpet 997

Fig. 11 Isometric view of the knotting mechanisms (four-bar type mechanism)

8 DISCUSSION AND CONCLUSION using kinematic synthesis methods. First model is a

This study mainly focuses on developing the knotting
mechanism by using kinematic linkage mechanisms.
Two different mechanisms forming the Turkish knot
and the Persian knot on two warps are developed by
four-bar mechanism shown in Fig. 11. As the kin-
ematic synthesis and analysis of four-bar linkage
are already studied, both the graphical and the
analytical synthesis methods are used for the first
model. The graphical solution is presented and

Fig. 12 Geared five-bar mechanism for Mechanism I

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998 M Topalbekiroğlu

Fig. 13 Isometric view of the knotting mechanism (five-bar geared type mechanism)

compared with the analytical solution. The results
found in analytical solution are the same as that in
graphical solution. Second model is a geared five-
bar mechanism with one DOF shown in Fig. 13. It
can be obtained by using the atlas of geared five-
bar linkage coupler curves serving as a resource to
machine designers.
However, these mechanisms are not sufficient to
produce the knots. Some auxiliary mechanisms
serving the function of preparing, holding, and
cutting the pile yarn and controlling the pair of
warps are needed for the knotting mechanism.
These mechanisms should be developed and
designed by considering these knotting mechanisms.

Fig. 14 The flow diagram of the knotting system

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 Knotting mechanisms in production of handmade carpet
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Proc. IMechE Vol. 219 Part C: J. Mechanical Engineering Science
1000 M Topalbekiroğlu

APPENDIX 1 one of the loops has zero or negative DOF, these

In kinematic link set solution for DOF ¼ 1 and L ¼ 4,
only one linkage is available as seen in Fig. 15, this is
four-bar linkage. The kinematic synthesis and analy-
sis of this type linkage are already studied and under-
stood. Four-bar linkage type mechanisms are
acceptable mechanisms in this study, as functional
requirements are satisfied.
Kinematic link set solution for DOF 5 1, L 5 4
When the number of links is six, there are two kin-
ematic links set solution as shown in Fig. 16. These
two kinematic link set solutions yield eight kinematic
chains. For the first six, chains are obtained by using
seven joints, four binary and two ternary links. The
other two chains are obtained with five binary links
and one quaternary link. Using equation (3), the
number of loops in this kinematic chain is two. If
kinematic chain will be neglected, because these
mechanisms can be practically converted into sub-
mechanism groups and failed freedom distribution
criterion.
In these kinematic chains, the first two chains in
Figs 16(a) (Stephenson’s Chain) and (b) (Watt’s
Chain) satisfy the freedom distribution criterion.
The other six chains in Figs 16(c) to (f) fail the free-
dom distribution criterion. The mechanisms in Figs
16(a.1) to (a.3) are derived from topologic inversions
of Stephenson’s chains and the mechanisms in Figs
16(b.1) and (b.2) are obtained from topologic inver-
sions of Watt’s chains. The motion of each mechan-
ism axis does not completely depend on the motion
of any other axis, but on the combination of other
two axes. For this reason, the mechanisms given in
Fig. 16(a.3) are neglected. According to the require-
ment given in (4), the mechanism shown in Figs
16(a.1) and (b.1) can be eliminated.

Fig. 15 Type synthesis for four-link and one DOF chains

Fig. 16 Type synthesis for six-link and one DOF chains

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 Knotting mechanisms in production of handmade carpet 1001

Fig. 16 (Continued)

Kinematic link set solution for
DOF 5 1, L 5 6
Similar to the six-bar linkage, in eight-bar linkage,
there are five kinematic links set solutions. These
two kinematic link set solutions yield 19 kinematic
chains. The number of loops in these kinematic
chains is three. Except for kinematic chains in
Figs 17(a) and 18(a) the other kinematic chains
have one or two loops, having zero or negative
DOF, and these kinematic chains are neglected.
The mechanisms in Figs 17(a.1) and (a.2) are derived
from topologic inversions of kinematic chain in
Fig. 17(a) and the mechanisms in Figs 18(a.1) to
(a.8) are obtained from topologic inversions of
kinematic chain in Fig. 18(a).

Kinematic link set solution for DOF 5 1 and L 5 8

Fig. 17 Type synthesis for eight-link and one DOF chains for first solution

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1002 M Topalbekiroğlu

Fig. 17 (Continued)

Fig. 18 Type synthesis for six-link and one DOF chains for second solution

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 Knotting mechanisms in production of handmade carpet 1003

Fig. 18 (Continued)

Fig. 19 Type synthesis for six-link and one DOF chains for third solution

Fig. 20 Type synthesis for six-link, and one DOF chains for fourth solution

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1004 M Topalbekiroğlu

Fig. 21 Type synthesis for six-link and one DOF chains for fifth solution

APPENDIX 2 Kinematic chains in Fig. 24 fail the freedom distri-

In kinematic link set solution for DOF ¼ 2 and L ¼ 5,
one linkage with five-bar linkage mechanism can be
as seen in Fig. 22.
Kinematic link set solution for DOF 5 2, L 5 5
(B 5 5)
When the link number is seven, there are two kin-
ematic links set solutions. They are shown in
Fig. 23. Five kinematic chains are yielded for this
scheme link combination. Kinematic chains in first
solution satisfy the freedom distribution criterion.
bution criterion in the second solution. Using kin-
ematic chain in Fig. 23(a), the mechanisms are
created by mechanism inversion method in Figs
23(a.1) to (a.3). Figures 23(b.1) to (b.4) show the
mechanisms that are derived from kinematic chains
in Fig. 23(b). The mechanisms in Figs 23(c.1) to
(c.4) are created using topologic inversions of kin-
ematic chain in Fig. 23(c). The motion of each mech-
anism axis does not completely depend on the
motion of the other axis, but on the combination of
other two axes. In addition, it is not easy to control
these mechanisms due to complex structure of
properties.

Fig. 22 Type synthesis for five-link and two DOF chains

Kinematic link set solution for DOF 5 2 and L 5 7

Fig. 23 Type synthesis for seven-link and two DOF chains

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 Knotting mechanisms in production of handmade carpet 1005

Fig. 23 (Continued)

Fig. 24 Type synthesis for seven-link and two DOF chains

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