Course of Mechanical Systems Design

This course is a synthesized extract from the book "Kinematics and Dynamics of Machinery"
by Robert L. Norton

Contents:

1 Definition: ........................................................................................................................................ 2
2 Grashof condition: ........................................................................................................................... 2
2.1 Class I: Grashof-linkage 𝑺 + 𝑳 < 𝑷 + 𝑸 ........................................................................... 2
2.2 class II: Non-Grashof linkage 𝑺 + 𝑳 > 𝑷 + 𝑸 ................................................................... 3
2.3 class III: Particular case of Grashof linkage (𝑺 + 𝑳 = 𝑷 + 𝑸) ................................................. 4
3 Dimensional synthesis ..................................................................................................................... 5
3.1 Definition: ................................................................................................................................ 5
3.1.1 Function generation: ....................................................................................................... 5
3.1.2 Path generation: .............................................................................................................. 5
3.1.3 Motion generation: ......................................................................................................... 5
3.2 Example 1: ............................................................................................................................... 5
3.3 Example 2: ............................................................................................................................... 6
3.4 Example 3: ............................................................................................................................... 7
3.5 Example 4: ............................................................................................................................... 8

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 Fourbar linkage
1 Definition:
A planar fourbar linkage is composed of four bars or links connected to each other by revolute joints
to form a single closed loop chain. The fourbar linkage has been shown to be the simplest mechanism
for single-degree-of-freedom controlled motion.

𝐶𝑜𝑢𝑝𝑙𝑒𝑟

𝑅𝑜𝑐𝑘𝑒𝑟
𝐶𝑟𝑎𝑛𝑘

Ground

Figure 1 : Fourbar linkage

The link grounded is named "Ground". The link that can make a full rotation is called “Crank”
(manivelle). The link that makes a limited rotation is called “Rocker” (oscillant) and the link that makes
a complex motion is called “Coupler”.

2 Grashof condition:
This condition predicts the rotation behavior or rotatability of a fourbar linkage’s inversions based only
on link lengths.

Let S= length of shortest length

L=length of longest link
P, Q=length of the two-remaining links
Then if 𝑆 + 𝐿 ≤ 𝑃 + 𝑄, the linkage is Grashof and at least one link will be capable of making a full
revolution with respect to ground plane. This is called a class I kinematic chain. If the inequality is not
true, then the linkage is a non-Grashof, and no link will be capable of a complete revolution relative to
any other link. This is a class II kinematic chain.

There are three cases, noted classes. Class I: 𝑆 + 𝐿 < 𝑃 + 𝑄, Class II: 𝑆 + 𝐿 > 𝑃 + 𝑄 and Class III: 𝑆 +
𝐿 =𝑃+𝑄

2.1 Class I: Grashof-linkage 𝑺+𝑳<𝑷+𝑸

• Ground either link adjacent to the shortest and you get a crank-rocker (Figure 2)

𝐿
𝑆
Q
Q 𝑆
P
P

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 Figure 2 : crank-rocker fourbar linkage

• Ground the shortest link and you will get a double crank (Figure 3-a).
• Ground the link opposite the shortest and you will get a Grashof double-rocker (Figure 3-b).

Figure 3 : (a) double crank four bar linkage. (b) double rocker fourbar linkage

• The slider-crank mechanism is a particular case of a Grashof fourbar linkage (Figure 4)

The center of
rotation is at
infinity.

Figure 4 : case of slider-crank mechanism

2.2 class II: Non-Grashof linkage 𝑺+𝑳>𝑷+𝑸

All inversions will be triple rockers in which no link can fully rotate (Figure 5)
(an inversion is created by grounding a different link in the kinematic chain)

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 Figure 5 : non-Grashof fourbar linkage

2.3 class III: Particular case of Grashof linkage (𝑺 + 𝑳 = 𝑷 + 𝑸)

We have three well-known configurations, the parallelogram linkage (Figure 6-a), the
antiparallelogram linkage(Figure 6-b) and the isoceles linkage also called Deltoid or kite configurations
(Figure 6-c)).

(a) : Parallelogram linkage (b) : Antiparallelogram linkage

(c) : Isoceles linkage

Figure 6 : Class III fourbar linkage configurations.

all inversions will be either double-cranks or crank-rockers but will have "change points" twice by
revolution of the input crank when the links all become colinear. The change point allows the linkage
to switch unpredictably between the parallelogram and antiparallelogram from every 180° unless
some additional links are provided to carry it through those position. This can be achieved by adding
an-out of-phase companion linkage coupled to the same crank as the double-parallelogram linkage
(Figure 7). The double-parallelogram arrangement is quite useful as it gives a translating coupler that
remains horizontal in all positions.

Figure 7 : Double parallelogram linkage

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3 Dimensional synthesis
3.1 Definition:
The dimensional synthesis is the determination of the dimensions (lengths) of the links necessary to
accomplish the desired motion. Through this dimensional synthesis we can have three purposes,
function generation, path generation or motion generation.

3.1.1 Function generation:

is defined as the correlation of an input motion with an output motion in a mechanism.
Typically, a double-rocker or crank-rocker is the result, with pure rotation input and
pure rotation output.

3.1.2 Path generation:

is defined as a control of a point in the plane such as that it follows some prescribed
path. This is typically accomplished with a least four bars, wherein a point on the
coupler traces the desired path.

3.1.3 Motion generation:

is defined as the control of a line in the plane such that it assumes some sequential set
of prescribed positions.

In the following, we will see some examples of graphical synthesis of fourbar linkages as solutions to
different problems.

3.2 Graphical Synthesis

3.2.1 Example 1:

In this example, the problem is to design a fourbar Grashof crank-rocker to give 45° of rocker rotation
with equal time forward and back, from a constant speed motor input. (see Figure 8)

1. Draw the output link 𝑂4 𝐵 in both extreme positions, 𝐵1 and 𝐵2 in any convenient
location, such that the desired angle of rotation 𝜃4 is subtended.
2. Draw the cord 𝐵1 𝐵2 .
3. Select a convenient point 𝑂2 on line 𝐵1 𝐵2 extended.
4. Bisect line segment 𝐵1 𝐵2 , and draw a circle of that radius about 𝑂2 .
5. Label the two intersections of the circle and the line 𝐵1 𝐵2 , 𝐴1 and 𝐴2
6. Measure the length of the coupler as 𝐴1 to 𝐵1 and 𝐴2 to 𝐵2
7. Measure ground length 1, crank length 2 and rocker length 4.
8. Find the Grashof condition. If non-Grashof, redo steps 3 to 8 with 𝑂2 farther from 𝑂4
9. Check function and transmission angles.

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 𝑟
𝐴2 𝑟 𝐵2
𝐴1 𝐵1

45°

68°

Figure 8 : Two-positions function synthesis with rocker output

For the first example we obtain: S (Link 2) =10; L (Link 1) =82; P (Link 3) =79; Q (Link 4) =26. The Grashof
condition is verified. The input is a full rotation (crank) and the output is a rocker rotation of 45°. The
transmission angle is 68°.

3.2.2 Example 2:

In this second example the problem is to design a Grashof fourbar linkage to move link 𝐶𝐷 from
position 𝐶1 𝐷1to 𝐶2 𝐷2 (see Figure 9 ).

1. Draw the link 𝐶𝐷 in the two desired positions 𝐶1 𝐷1 and 𝐶2 𝐷2 .

2. Draw construction lines from point 𝐶1 to 𝐶2 from point 𝐷1to 𝐷2.
3. Bisect line 𝐶1 𝐶2 and line 𝐷1 𝐷2 and extend their perpendicular bisectors to intersect
at 𝑂4 . Their intersection is the rotopole.
4. Select a convenient radius and draw an arc about the rotopole to intersect both lines
𝑂4 𝐶1 and 𝑂4 𝐶2 . Label the intersections 𝐵1 and 𝐵2 .
5. Do steps 2 to 8 of example 1 to complete the linkage.
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 6. Make a model of the linkage and articulate it to check its function.

𝐷1

𝐶1 𝐶2
𝐴1 𝑂2
𝐴2
𝐵1 𝐷2
𝐵2

𝑂4

Figure 9 : Two-position motion synthesis with rocker output

3.2.3 Example 3:
The problem of the third example is to design a fourbar linkage to move the link 𝐶𝐷 shown from
position 𝐶1 𝐷1to 𝐶2 𝐷2, with moving pivots at 𝐶 and 𝐷 (see Figure 10).

1. Draw the link 𝐶𝐷 in the two desired positions 𝐶1 𝐷1 and 𝐶2 𝐷2 .

2. Draw construction lines from point 𝐶1 to 𝐶2 from point 𝐷1to 𝐷2.
3. Bisect line 𝐶1 𝐶2 and line 𝐷1 𝐷2 and extend the perpendicular bisectors in convenient
directions.
4. Select any convenient point on each bisector as the fixed pivots 𝑂2 and 𝑂4 ,
respectively.
5. Connect 𝑂2 with 𝐶1 and call it link 2. Connect 𝑂4 with 𝐷1 and call it link 4.
6. Line 𝐶1 𝐷1is link 3. Line 𝑂2 𝑂4 is link 1.
7. Make a model of the linkage and articulate it to check its function.

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 𝐷1
Link 3 Link 3
𝐶1 𝐶2 𝐶1 𝐶2
Link 4 𝐷2 Link 4
𝐷2
Link 2 𝑂4 𝑂4
Link 2
Link 1

𝑂2 𝑂2

Figure 10 : Two-position motion synthesis with coupler output

3.2.4 Example 4:
design a dyad to control and limit the extremes of motion of the linkage in example 3 to its two design
positions (see Figure 11).

1. Select a convenient point on link 2 of the that it need not be on the line linkage
designed in example 3. Note that it need not be on the line 𝑂2 𝐶. Label this point 𝐵1
2. Draw an arc about center 𝑂2 through 𝐵1 to intersect the corresponding line 𝑂2 𝐵2 in
the second position of link 2. Label this point 𝐵2 . The chord 𝐵1 𝐵2 provides us with the
same problem of example 3.
3. Do steps 2 to 9 of example 1 to complete the linkage.

The obtain result is a sixbar Watt mechanism.

𝐷1

𝐶1 𝐶2
𝐴1 𝐴2
𝐵1 𝐷2
𝐵2
𝑂4

𝑂2
3
5 𝐶1 𝐶2
6 4
𝐷2

𝑂4
2

𝑂2

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 Figure 11 : driving a non-Grashof linkage with a dyad.

3.3 Analytical synthesis:

The analytical synthesis procedure is algebraic rather than graphical and is less intuitive. We will see
the analytical synthesis solution of the two-position synthesis for rocker output problem of example 1
(Figure 8).

Link 4 is the output link to be driven by the two links 2 and 3, whose lengths, along with that of the
ground link 1 and its pivot location 𝑂2 , are to be determined. 𝑂4 , the initial angle 𝜃4 and the excursion
angle 𝛽 are given (Figure 12).

𝜃4
𝑅𝑂4 𝑂4

Figure 12 : Given parameters of the rocker link.

The procedure is as follows:

First choose a suitable location on link 4 to attach link 3, here labeled 𝐵1 and 𝐵2 in its extreme locations
(Figure 13).

𝑙4

𝜃4
𝑂2 𝑂4
𝑙1

Figure 13 : analytical synthesis of the four-bar mechanism.

𝑂

This defines 𝑙4 , the length of link 4. These points can be defined in the chosen coordinate systems as:

𝑂𝐵1𝑥 = 𝑂𝑂4𝑥 + 𝑙4 𝑐𝑜𝑠𝜃4 𝑂𝐵1𝑦 = 𝑂𝑂4𝑦 + 𝑙4 𝑠𝑖𝑛𝜃4

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𝑂𝐵2𝑥 = 𝑂𝑂4𝑥 + 𝑙4 𝑐𝑜𝑠(𝜃4 + 𝛽) 𝑂𝐵2𝑦 = 𝑂𝑂4𝑦 + 𝑙4 𝑠𝑖𝑛(𝜃4 + 𝛽)

⃗⃗ = 𝐵
𝑀 ⃗⃗⃗⃗⃗⃗⃗⃗⃗ ⃗⃗⃗⃗⃗⃗⃗⃗ ⃗⃗⃗⃗⃗⃗⃗⃗
1 𝐵2 = 𝑂𝐵2 − 𝑂𝐵1

We want the resulting linkage to be a Grashof crank rocker. We can achieve this by placing the crank
pivot 𝑂2 suitably far from 𝐵1 along line L. A reasonable range for 𝐵1 𝑂2 seems to be two to three times
𝑀 = ‖𝑀 ⃗⃗⃗⃗⃗⃗⃗⃗2 = 𝑂𝐵
⃗⃗ ‖. Let 𝑂𝑂 ⃗⃗⃗⃗⃗⃗⃗⃗1 ± 𝐾𝑀
⃗⃗ 2 ≤ 𝐾 ≤ 3

⃗⃗ ⟹ 𝑙2 = 0.5 𝑀 =
As shown in example 1, the length of the crank must be half the length of vector 𝑀
𝛽
𝑙4 sin( 2 ).

The lengths of Link 3 and link 1 can be determined as follows:

⃗⃗⃗⃗⃗⃗⃗⃗1 − ⃗⃗⃗⃗⃗⃗⃗⃗
𝑙3 = ‖𝑂𝐵 𝑂𝑂2 ‖ − 𝑙2 ⃗⃗⃗⃗⃗⃗⃗⃗4 − ⃗⃗⃗⃗⃗⃗⃗⃗
𝑙1 = ‖𝑂𝑂 𝑂𝑂2 ‖

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