Mechanics of Machines

MDB3043
Lecture 07: Mechanism Design
Outline

Mechanism Design
 Synthesis vs Analysis

 Slider-Crank Design (Inline & Offset)

 Rocker Design
Synthesis vs Analysis

Given … determine
Dynamic
Mechanism
Properties
ANALYSIS

Given
… determine
Dynamic Mechanism
Properties
SYNTHESIS (design)
Slider-Crank Design

In-line

Offset
Categories of Slider-Crank Mechanisms

In-line

Offset
offset
Sliding axis does not pass through the crank centre.
Limiting Positions for In-Line
Slider-Crank Mechanisms
limiting
position 2

limiting STROKE
position 1
 In-line Slider-Crank Design
L1 L2 Stroke = 2 x crank radius

Slider motion in one

direction == half
L1 + L2
revolution of the crank

Motion of slider to
the left and right
L2 – L1 2 L1
are equal, provided
crank is at
constant speed
Offset Slider-Crank Design

 In many mechanisms, the working stroke is in one

direction only. Some examples: cutting, material
handling.
 In these mechanisms, the working stroke is
controlled against load and normally slower than the
non-working stroke (or sometimes referred to as the
return stroke). These mechanisms are called quick-
return mechanisms because the return stroke is
quicker.
 Quick-return mechanisms can be achieved through
offset slider crank design.
 155 mm

125 mm

Working Return
stroke stroke
(cutting)
 Quick-Return Mechanisms
L2
L3
L1

If the crank is rotating counterclockwise,

stroke to the right  crank angle of 180o + β β
stroke to the left  crank angle of 180o - β Imbalance angle
At constant speed
180o +β Time of slower stroke
o
180 -β = Time of quicker stroke =
Quick-Return Mechanisms
L2
L3
L1

180   β
Time Ratio, Q 
180   Imbalance angle
Q 1
Imbalance Angle   180
Q 1
 Problem 5-2
A quick-return mechanism is to be designed where the
working stroke takes 0.35 s and the return stroke takes
0.20 s. Determine the time ratio, the imbalance angle and
the speed at which the mechanism should be driven.
0.35
Time Ratio, Q  0.2  1.75
1.75  1
Imbalance Angle,   180  49.1
1.75  1
tcycle  0.20  0.35  0.55 s / rev
60 s/min
  109.1 rpm
0.55 s/rev
Sizing the Connecting Arm
L2
L3
L1

Slider
acceleration
L3
(Coupler Ratio)
L2
The connecting arm (L3) should be made as long as
possible to reduce slider acceleration and joint forces.
L3
Rule of thumb in selecting the coupler ratio : 3
L2
Space limitation will restrict the practicality of large L3
Offset Slider-Crank Design Task
Design a mechanism which produce a reciprocating
linear motion with a stroke of 30 mm. The working stroke
is to be completed within 0.5 seconds. There should be
at least 65 working strokes per minute.
Assuming a slider-crank mechanism has been selected, the
design task is to determine
• the offset L1,
• the crank radius L2 and
• the connecting arm length L3.

L2
L3
L1
Cycle Time Calculation

 65 working strokes per minute  65 cycles per minute

 1.08 cycle per second
 Cycle time = 1/1.08 = 0.92 sec
 Working stroke time + Return stroke time < Cycle time
 0.5 sec + treturn < 0.92
 Pick treturn = 0.4 sec
 treturn < tworking  offset slider-crank
 Note: this design is not unique.
 L2
Offset Slider-Crank
L3 Design
L1

β
Time Ratio
180o +β 1.25  1
= 1.25 
0.5
=   180   20 
180o -β 0.4 1.25  1
Cycle time: 0.5+0.4 = 0.9 sec. Cycle speed = 1/0.9 stroke/sec
= 66.7 strokes/min
 Slider-Crank Design : Graphical
Measuring L1, AC1 and AC2 :
A
30 mm
L1 C2
C1
AC1 = L3 - L2
AC2 = L3 + L2 β = 20o
L2 = ½(AC2 - AC1)
Options 1 2 3 4
L3= AC1 + L2 L1 57 33 21 13
AC2 81 68 60.4 50
Different design parameters AC1 63 45 34 23
due to arbitrary angle of the
line AC1 relative to the L3 72.0 56.5 47.2 36.5
sliding axis. L2 9.0 11.5 13.2 13.5
 Offset Slider-Crank Design
21 mm Check
L3 >3
L2
Check overall dimension:
Heavily influenced by offset L1 and
coupler length L3.

20°
Options 1 2 3 4
L1 57 33 21 13
AC2 81 68 60.4 50
AC1 63 45 34 23 Option 3 is the best
L3 72.0 56.5 47.2 36.5 choice by considering
L2 9.0 11.5 13.2 13.5 size and accelerations
L3 / L2 8 4.91 3.58 2.70
Rocker Design
 Rocker Design
An application requires a rocking motion
of a link with a throw angle of . 

Normally, a design task only specify the

output motion desired. It is left to the
designer creativity in satisfying other design
criteria such as
• cost (capital & operational), A common approach in cutting
down the cost is by using an
• performance electric motor to drive a crank at
• size a constant speed and direction.
• maintenance
• reliability
Kinematic Design of a Crank-Rocker

The kinematic design of the crank rocker specifies

the length of the links and the relative positions of
the joints .

L3

L4

L2 L1
Transmission Angle
The transmission angle, γ (gamma), of the crank rocker varies
throughout the cycle of the crank rocker. The forces transmitted
at the joints can become very large if it is not close to 90°. The
rule of thumb is to limit γ to vary between 45° and 135° only.

L3

L4

L2 L1
limiting position 1
 limiting position 1
limiting position 2
 limiting position 1
faster
limiting position 2
slower

 - Imbalance
angle
180o +  

180o - 
180o +β Time of slower stroke
180o -β
= Time of quicker stroke = Time Ratio
Step-by-Step Rocker Design
A rocking mechanism with a throw of Φ is to be designed. The actuator
to be used is a motor turning at constant speed and direction.

AC2=L3+ L2
AC1 =L3- L2 2L2 E

C2
C1
L3


B A L4
L2

L1
 Rocker Design Example
Prob. 5-18
Design a crank-rocker mechanism with a time cycle of 0.3s, a time
ratio of 1.1 and a throw angle of 112o. Set the coupler to be attached
to the rocker at 40 mm away from its pivot.
2L2 E

180o +β = 1.1 β = 8.6o C2

180o -β C1

ω = 1/0.3 rev/s x 60 sec/min = 200 rpm L3


Setting L4=40 mm 
Measuring from graphics, A L4
L2 = 32 mm, L2 L3 = AC1 + L2

L3 = 110 mm,
L1 = 107 mm L1
Bring these to the Tutorial!