Dynamic Simulation: Constraint Equations

Dynamic Simulation:
Constraint Equations
Objective
The objective of this module is to develop the equations
for ground, revolute, prismatic, and motion constraints
for a planar mechanism.
These equations will be developed for a piston-crank
assembly in a Boxer style engine.
These constraint equations will be used in the next
Module (Module 4) to show how position, velocity, and
accelerations are computed.
Although the equations developed for this module are
for a planar (2D) mechanism, the methods
can be
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Section 4 Dynamic Simulation
Boxer Style Engine
Module 3 Constraint Equations

Page 2
Boxer style engines have

a horizontally opposed
piston configuration.
This has several
advantages
Lower center of gravity

Lower vertical height
Lighter weight
Less vibration
Boxer style engines are

used by Porsche and
Subaru.
Because of their low
vertical profile they are
often called pancake
engines.
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Cross Section View

Page 3
This module will use the piston-crank portion of this

engine to demonstrate how kinematic and motion
constraints are developed.
Counterweight
Cylinder
Liner
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Piston
Connecti
Pin Piston
Beari
Piston ng Rod
ng
Pin
Rod Bolt
Bottom
Bearing
Cap
Crank Shaft
Crank Bearing
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Planar System

Page 4
The boxer engine

rotating assembly
contains four piston
assemblies.
Constraint equations will
be written for one piston
assembly to
demonstrate the
process.
This single assembly can
be represented as a
planar mechanism.
A Dynamic Simulation of
the complete system will
be presented in another
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Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
The planar equations

will be developed for
Cylinder 3.
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Global Coordinate System

Page 5
The constraint equations will

be referenced to the
stationary coordinate system
shown in the figure.
This reference coordinate
system is called the global
coordinate system.
Capital letters are used to
indicate that a coordinate or
vector refers to this
coordinate system.
Lower case letters will be
used to indicate a coordinate
or vector is referred to a
body fixed coordinate system
associated with a part.
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X
Cylinder 3
Y
X
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Part IDs

Page 6
The process of
developing the
constraint equations
is facilitated by
identifying each
component by a
letter.
The five components
shown with letters
make up the basic
system for which the
constraint equations
will be written.
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A
Cylinder
Liner
E
Crank Bearing
(Not Visible)
B
Piston
C
Connectin
g Rod
D
Crank Shaft
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Mobility

Page 7
Grueblers equation can be used to establish the mobility

of the planar mechanism.A
Cylinder
Liner
Bodies (B) = 5
Grounded bodies (G) = 2
Revolute joints (R) = 3
Prismatic joints (P) = 1
Crank Bearing
(Not Visible)
Mobility
DOF 3( B) 2( R ) 2( P) 3(G )
3(5) 2(3) 2(1) 3(2) 1
A mobility of one will
require one motion
constraint.
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B
Piston
C
Connectin
g Rod
D
Crank Shaft
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List of DOFs

Page 8
The DOFs are

associated with a set
of generalized
coordinates.
Each body has 3 DOF
and 3 generalized
coordinates.
The generalized
coordinates for the
planar mechanism are
listed on the right.
Fifteen constraint
equations must be
developed that will
enable each of the
X cgA
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List of Generalized Coordinates
YcgA
A
X cgB
Format
X-coordinate of
the cg of Body
A
Body
A
cg
Capital letter
indicates that
variable is
associated with
the global
coordinate
system.
YcgB
B
X cgC
YcgC
C
X cgD
YcgD
Center of
Gravity
D
X cgE
YcgE
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Ground Joints

Page 9
The cylinder liners

are pressed into the
engine block and do
not move.
The pistons move
relative to the
cylinder liners and
the combination
make a prismatic
joint.
The cylinder liners
must be
mathematically
grounded or fixed in
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Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
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Cylinder Liner Ground Equations

Page 10
The location of the center

of gravity and the
orientation of the principal
axes of inertia are shown
in the figures.
The ground constraint
equations that fix the
position of the c.g. and
orientation of the principal
axes can Abe written as
y
x
y
z
X cg156.8 mm 0
Y cgA 0
cgA 0
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Crank Bearing Ground Joint

Page 11
The crank bearing is fixed in

the engine block and does not
move.
The crank shaft rotation
relative to the crank bearing
can be represented by a
revolute joint.
All of the parts in the planar
system must lie in the global
X-Y plane.
Therefore, a virtual crank
bearing will be placed at the
origin of the global coordinate
system so that the planar
equations can be developed.
Virtual Crank
Bearing Located
at the Origin
Y
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Z
X
Crank Bearing
Constraint Equations
X cgE 0
YcgE 0
cgE 0
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Summary of Ground Joint

Equations
Cylinder Liner

Page 12
Virtual Crank Bearing
X cgA156.8 mm 0
X cgE 0
Y cgA 0
YcgE 0
cgA 0
cgE 0
Each of these equations fix one DOF for

the respective part in space.
None of the equations are a function of
time.
None of the equations involve more than
one part.
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2D Coordinate Transformation
Matrix
In subsequent slides it will
be necessary to transform
the components of a vector
from a body fixed
coordinate system to the
global coordinate system.
This transformation is
accomplished with the
transformation matrix [T()].
From the figure,

Page 13
y cos
X x cos y sin
Y x sin y cos
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y sin
x
x sin
x cos
Matrix Form
X
cos

Y
sin
cos
T
sin
sin x

y cos y
sin
y cos
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Revolute Joint

Page 14
There are three revolute joints

in the piston-crank assembly
Between the piston and

connecting rod
Between the connecting rod
and crankshaft
Between the crankshaft and
crank bearing
The constraint equations for a

revolute joint will be
developed using the two
bodies shown in the figure.
Body A and B have the same
translational motion at the
joint but can have relative
rotation.
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yB
Body B
Body A
yA
xB
xA
Joint
X
Two bodies connected at a
common point that allows
relative rotational motion.
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Revolute Joint

Page 15
The position of Joint 1

on Body A relative to
the global coordinate
system is given by the
A A A
equation
R1 Rcg r1
Joint 1
yA
Body A
A
r1
xA
A
Rcg
The components of
are written with respect
to the global coordinate
A
r
system base vectors
1
and the components of
are written with
respect to the body
fixed coordinate
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A
Rcg
I
cg
RA
A
r1 x1Ai y1A j
A
Rcg X cgA I YcgA J
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Revolute Joint

Page 16
The components of the body

fixed position vector must
be transformed to the global
coordinate system before
the components of the two
vectors can be added.
Position Vector Equation
A A A
R1 Rcg r1
Component Form
X cgA cos A
A A
A
Y
Y
sin
1 cg
X 1A
This is accomplished using

the transformation matrix
introduced earlier.
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sin A
A
cos
x1A
A
1
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Revolute Joint

Page 17
The coordinates of Joint

1 on Body A are
X cgA cos A
A A
A
Y
Y
sin
cg
1

X 1A
sin A x1A

cos A y1A
Similarly, the
coordinates of Joint 1 on
Body BB are
X cg cos
B
B
Y
Y
sin
cg
X
B
1
B
1
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sin
cos B

y
B
1
B
1
In a Revolute Joint the

coordinates of the joint
must be same for each
body.
Thus,
X 1A
X 1B
B
Y
1
Y1
or
X cgA cos A
A
Ycg sin A
sin A x1A

cos A y1A
General Form of the

X cgB cos B sin B x1B 0
B

Constraint
B
B
B
cos y1 0
Ycg sin
Equations for a
Planar Revolute
Joint
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Revolute Joint

Page 18
The general form of the

constraint equations for
a planar revolute joint is
X cgA cos A
A
Ycg sin A
X cgB cos B
B
Ycg sin B
sin B x1B 0

B
B
cos y1 0
The specific equations

for the three revolute
joints in the piston-crank
mechanism will now be
developed
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Joint 1
sin A x1A

cos A y1A
2nd Revolute Joint

Joint 2
Joint 3
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1st Revolute Joint

Page 19
Piston Body B
The location of the joint

relative to the c.g. is
B
B
x
y1
needed to define the
1
parameters
&
For the piston,
28 mm
x 28mm
B
1
y 0
B
1
C.G.
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Joint 1
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1st Revolute Joint

Page 20
The location of the joint

relative to the c.g. is
C
C
x
y1
needed to define the
1
parameters
&
From the picture,
C
x1 102.6mm
Connecting Rod Body C
102.6
y1C 0
y
x
Joint 1
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1st Revolute Joint

Page 21
Using the geometry from

the piston and connecting
rod, the revolute joint
constraint equation
becomes
x1B 28mm
x1C 102.6mm
y1B 0
y1C 0
X cgB cos B
B
Ycg sin B
X cgC cos C
C
Ycg sin C
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sin x1B

cos B y1B
B
sin C x1C 0

C
C
cos y1 0
Joint 1
1st Revolute Joint Constraint Equations
X cgB 28 cos B X cgC 102.6 sin C 0

YcgB 28 sin B YcgC 102.6 cos C 0
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2nd Revolute Joint

Page 22
General Form of
Constraint Equation
X cgC cos C
C
Ycg sin C
X cgD cos D
D
Ycg sin D
sin C x2C
C
C
cos y2
sin D x2D 0

D
D
cos y2 0
The location of the

joint relative to the
C
x2
c.g. is needed to
C
y2
define
the parameters
&
From the
picture,
C
x 41.3
Body C
y
Joint 2
x
41.3 mm
y 0
C
2
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2nd Revolute Joint

Page 23
General Form of
Constraint Equation
X cgC cos C
C
Ycg sin C
sin C x2C
C
C
cos y2
X cgD cos D
D
Ycg sin D
sin D x2D 0

D
D
cos y2 0
The location of the

joint relative to the
D
x2
c.g. is needed to
D
y2
define
the parameters
&
D
From the
x picture,
43
y
x
Joint 2
43 mm
y 0
D
2
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2nd Revolute Joint

Page 24
Using the geometry from

the connecting rod and
crank shaft, the revolute
joint constraint equation
becomes
C
x D 43
x2 41.3
y 0
C
2
X cgC cos C
C
Ycg sin C
X cgD cos D
D
Ycg sin D
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y2D 0
sin C x2C
C
C
cos y2
sin D x2D 0

D
D
cos y2 0
Joint 2
2nd Revolute Joint Constraint Equations
X cgC 41.3 cos C X cgD 43 sin D 0

YcgC 41.3 sin C YcgD 43 cos D 0
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3rd Revolute Joint

Page 25
General Form of
Constraint Equation
X cgD cos D
D
Ycg sin D
X cgE cos E
E
Ycg sin E
sin D x2D
D
D
cos y2
sin E x2E 0

E
E
cos y2 0
The c.g.s of both the

crank and crank shaft
lie at the origin of the
global coordinate
system.
Therefore, the body
fixed coordinates of
the joint relative to the
c.g. are zero.
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Joint 3
3rd Revolute Joint Constraint Equations
X cgD X cgE 0
D E
Ycg Ycg 0
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Summary of Revolute Joint

Equations
Body B
Body C

Page 26
Body C
2nd Revolute Joint
Joint 2
Joint 1
Body D
X cgB 28 cos B X cgC 102.6 sin C 0
X cgC 41.3 cos C X cgD 43 sin D 0
YcgB 28 sin B YcgC 102.6 cos C 0
YcgC 41.3 sin C YcgD 43 cos D 0
Joint 3
Body D
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Body E
X cgD X cgE 0
D E
Ycg Ycg 0
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Prismatic Joint

Page 27
In the planar system the

cylindrical joint between the
cylinder liner and the piston
acts like a prismatic joint.
A prismatic joint allows two
bodies to translate relative
to each other along a
common axis.
The two bodies cannot
rotate independent of each
other.
The equations for a planar
prismatic joint are based on
the geometry shown in the
figure.
yA
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Common
Axis
Body B
Body A
yA
x
xA
X
Two bodies A & B that
translate relative to one
another along a common
axis.
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Prismatic Joint Constraint

Equations
The points P and Q in
Body A lie on the
common axis and are
connected by the vector
PQ.
The points R and S in
Body B lie on the
common axis and are
connected by the vector
RS.
The vector PR also lies on
the common axis and
connects the points PPQ

and
R.
The three vectors must
be parallel.

Page 28
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yA
Y
Common
Axis
Body B
R
Body A
yA
PQ
xA
X
axis.
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Equations
The vector PQ with

components written with
respect to the body fixed
coordinate system of
Body AareA
A
PQ xPQ i y PQ j

Page 29
yA
Y
Body B
R
Body A
yA
PQ
xA
The components of the

vector PQ with respect to
X
cos
sin x
system
are

A
PQ
A
PQ
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A
sin
A
PQ
A
PQ
cos A y
X
axis.
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Equations
The vector RS with

components written with
respect to the body fixed
coordinate system of
Body B areB
B
RS xRS i y RS j

Page 30
yA
Y
Body B
R
Body A
yA
PQ
xA
The components of the

vector RS with respect to
X are
cos
sin x
system

B
RS
B
RS
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B
sin
B
RS
B
RS
cos B y
X
axis.
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Equations
The third vector is
directed from point P to
point R.
Point
X P
costhe
X has
sin x

y
Y
Y
sin
cos
coordinates


Page 31
A
P
A
P
A
CG
A
CG
A
p
A
p
yA
Y
Body B
R
Body A
yA
PQ
xA
B
X RB X CG
cos B
B B
B
YR YCG sin
sin B xRB

cos B y RB
Point R has the

coordinates
B
cos B
X PR X CG
B
B
YPR YCG sin
sin B xRB

cos B y RB
X vector
cos
has
sin
The

Y
sin
cos

components
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A
CG
A
CG
xPA
y PA
X
axis.
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Equations
The vector perpendicular

to PQ has components
A
X PQ

A
Y
PQ
cos A

A
sin
sin A
cos A
A
0 1 xPQ
1 0 yA
PQ

Page 32
yA
Y

A
PQ PR X PQ
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X PR
0
First
YPR
A
X PQ

A
X PQ
Body A
yA
PQ
The dot product of two

vectors that are
perpendicular to each
other is zero.

A
PQ PR X PQ
Body B
xA
Constraint Eq.

X
0
Second
Constraint
Eq.
Y
axis.
B
RS
B
RS
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Equations
Page 33
Substituting the vector components from the previous

slides into the first constraint equation yields

A
PQ PR X PQ
A
PQ
A
PQ
0 1 cos
1 0
A
sin
X PR
0
YPR
A
X PQ

A T
B
cos B
sin X CG
B
A
cos YCG sin B
A
cos A
sin B xRB X CG
A
B
B
cos y R YCG sin A
sin A xPA
0
A
A
cos y P
Substituting the vector components from the previous

slides into the second constraint equation yields

A
PQ PR X PQ
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A
PQ
A
PQ
0 1 cos A
1 0
A
sin
A
X PQ
sin A
cos A
B
X RS
B 0
YRS
cos B

sin B
sin B xRS
B
cos B y RS
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Summary of Prismatic Constraint

Equations

Page 34
The two constraint equations for a planar prismatic joint

are
1st Constraint Equation
T
A
PQ
A
PQ
B
cos B
sin A X CG
B
A
cos YCG sin B
0 1 cos A
1 0
A
sin
A
cos A
sin B xRB X CG
A
B
B
cos y R YCG sin A
sin A xPA
0
A
A
cos y P
2nd Constraint Equation

T
A
PQ
A
PQ
0 1 cos A
1 0
A
sin
sin A
cos A
cos B

sin B
sin B xRS
B
cos B y RS
The vector components at the beginning and end of each

equation are based on the body fixed coordinate systems and
are constant. The only variables are the generalized
coordinates of Body A and B.
These equations are easily evaluated in a computer program.
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Prismatic Joint

Page 35
The prismatic joint

formed by the cylinder
liner and the piston lies
along the global X-axis.
Point P is chosen to lie at
the c.g. of the cylinder
liner.
Point Q is chosen to lie 1
mm to the right on the xaxis.
Point R is chosen to lie at
the c.g. of the piston.
Point S is chosen to lie 1
mm to the right on the xaxis.
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x
P Q
Vector
compone
nts of PQ
R S
Vector
compone
nts of RS
A
xPQ
1
B
xRS
1
A
y PQ
0
B
y RS
0
Point Coordinates
B
xPA 0 xR 0
B
y PA 0 y R 0
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Prismatic Joint

Page 36
Substitution of the vector components and point

coordinates into the two prismatic joint equations yields
1st Constraint Equation
T
0 1 cos A
1 0

A
1 0 sin
sin A
cos A
B
X CG
cos B
B
YCG sin B
sin B
cos B
A
cos A
0 X CG
A
A
0 YCG sin
sin A
cos A
0
0
0
which reduces to
T
0 1 cos A
1 0

A
1
0
sin
sin A
cos A
B
A
X CG
X CG
B A
YCG YCG
2nd Constraint Equation

T
0 1 cos
1 0

A
1
0
sin
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A T
sin cos B

cos A sin B
sin B
cos B
1

0
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Motion Constraint

Page 37
One motion constraint is

required to make the
mechanism stable.
The rotation of the
crankshaft (Body D) will be
given an angular speed of
3,000 rpm.
A 3,000 rpm engine speed
is equal to 314 rad/sec.
Although all fifteen
generalized coordinates
are a function of time, this
is the only constraint
equation that explicitly
contains time as a
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Motion Constraint
D 314 t 0
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Summary of Constraint
Equations

Page 38
There are five planar bodies each having three DOF giving a
total of fifteen DOF. Fifteen unknowns requires fifteen
equations.
Revolute Joint 3
Revolute Joint 1
Ground Constraint 1
1) X 156.8 0
7) X 41.3 cos X 43 sin 0
2)Y 0
8)Y 41.3 sin Y 43 cos 0
A
cg
A
cg
C
cg
C
cg
D
cg
11) X cgD X cgE 0
D
cg
12)YcgD YcgE 0
3) cgA 0
Ground Constraint 2
Revolute Joint 2
4) X cgE 0
9) X cgB 28 cos B X cgC 102.6 sin C 0
5)YcgE 0
10)YcgB 28 sin B YcgC 102.6 cos C 0
6) cgE 0
Prismatic Joint
T
0 1 cos A
13) 1 0

A
1
0
sin
0 1 cos A
14) 1 0

A
1
0
sin

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Motion Constraint
15) D 314 t 0
sin A
cos A
sin A
cos A
B
A
X CG
X CG
B A
YCG YCG
cos B

sin B
sin B
cos B
1
0
0
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Summary of Constraint
Equations

Page 39
Only one of the constraint equations is time

dependent (Motion Constraint).
Most of the constraint equations are non-linear.
All of the constraints are algebraic equations and
none are differential equations.
Geometric quantities (dimensions and distances)
contained in the constraint equations can be
found from information in a 3D CAD model.
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Module Summary

Page 40
The constraint equations for ground, revolute, and

prismatic joints have been developed for a planar
mechanism.
The constraint equation for a rotational motion
constraint has been developed for a planar mechanism.
These equations were used to determine the fifteen
equations necessary for a piston-crank assembly taken
from a Boxer engine model.
In some cases the constraint equations are very simple
and in other cases they are complex.
Only the motion constraint is an explicit function of
time.
All of the constraint equations are algebraic.
These equations will be applied in the
next
module:
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Dynamic Simulation: Constraint Equations

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Dynamic Simulation: Constraint Equations

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Dynamic Simulation:

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This is accomplished using

Section 4 Dynamic Simulation

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The coordinates of Joint

In a Revolute Joint the