The Mechanism Design skill provides capabilities for mechanism kinematics, dynamics, and motion analysis, enabling systematic design and optimization of mechanical motion systems.
Capabilities
Linkage synthesis and analysis
Cam profile design
Gear train design and analysis
Kinematic simulation
Dynamic force analysis
Motion optimization
ADAMS/RecurDyn integration
Mechanism specification documentation
Usage Guidelines
Kinematic Analysis
Degrees of Freedom
Gruebler's Equation (planar):
DOF = 3(n-1) - 2j1 - j2
Where:
n = number of links (including ground)
j1 = number of full joints (pin, slider)
j2 = number of half joints (cam, gear)
DOF = 1: Constrained mechanism
DOF = 0: Structure
DOF < 0: Over-constrained
Common Mechanisms
Mechanism
Links
Joints
DOF
Application
Four-bar
4
4 pins
1
Motion generation
Slider-crank
4
3 pins + 1 slider
1
Reciprocating motion
Scotch yoke
4
2 pins + 2 sliders
1
Exact sinusoidal
Quick return
4
3 pins + 1 slider
1
Unequal stroke times
Geneva
2
Cam joint
Intermittent
Indexing
Linkage Design
Four-Bar Linkage Types
Grashof criterion:
s + l <= p + q
Where:
s = shortest link
l = longest link
p, q = intermediate links
If satisfied: At least one link can rotate fully
Types:
- Crank-rocker: Shortest link is crank
- Double-crank: Shortest link is ground
- Double-rocker: No full rotation
mu = angle between coupler and output link
Ideal: mu = 90 degrees
Acceptable: 40 < mu < 140 degrees
Poor: mu < 30 or mu > 150 degrees
Cam Design
Cam Profile Types
Type
Motion
Application
Plate cam
Translating or oscillating follower
High speed
Cylindrical cam
Oscillating follower
Indexing
Face cam
Translating follower
Compact
Globoidal cam
Oscillating follower
High accuracy
Motion Profiles
Common profiles:
1. Parabolic (constant acceleration)
s = (1/2) * a * t^2 for first half
Good: Simple, smooth
Bad: Infinite jerk at transition
2. Simple harmonic
s = (h/2) * (1 - cos(pi*t/T))
Good: Zero velocity at ends
Bad: Finite acceleration at ends
3. Cycloidal
s = h * (t/T - sin(2*pi*t/T)/(2*pi))
Good: Zero acceleration at ends
Bad: Higher peak acceleration
4. Modified trapezoid
Combines constant acceleration with transitions
Good: Low peak acceleration
Bad: More complex
Pressure Angle
tan(alpha) = (dy/dtheta) / (rb + y)
Where:
alpha = pressure angle
dy/dtheta = slope of displacement curve
rb = base circle radius
y = follower displacement
Limit: alpha < 30 degrees (typically)
Gear Train Design
Gear Types
Type
Application
Efficiency
Spur
Parallel shafts
98-99%
Helical
Parallel shafts, quieter
97-99%
Bevel
Intersecting shafts
97-98%
Worm
High ratio, non-reversing
50-90%
Planetary
Compact, high ratio
97-98%
Gear Ratios
Simple gear train:
i = N2/N1 = omega1/omega2
Compound gear train:
i_total = product of individual ratios
Planetary gear train:
i = 1 + Nring/Nsun (sun fixed)
i = 1/(1 + Nsun/Nring) (ring fixed)
Gear Geometry
Module: m = d/N
Pitch: p = pi * m
Addendum: a = m
Dedendum: b = 1.25 * m
Center distance: C = m * (N1 + N2) / 2
Contact ratio:
CR = (Arc of action) / (Circular pitch)
Minimum CR > 1.2 recommended
Dynamic Analysis
Force Analysis
Newton-Euler method:
Sum F = m * a_g (for each link)
Sum M_g = I_g * alpha (about mass center)
D'Alembert approach:
Add inertia forces: -m*a, -I*alpha
Solve as static equilibrium
Shaking Forces and Moments
Shaking force = -Sum(m_i * a_i)
Shaking moment = -Sum(I_i * alpha_i + r_i x m_i * a_i)
Balancing strategies:
1. Add counterweights
2. Optimize mass distribution
3. Use multiple cylinders (phase)
Process Integration
Cross-cutting for mechanical system design processes
Input Schema
{"mechanism_type":"linkage|cam|gear|custom","motion_requirements":{"input_motion":"rotation|translation","output_motion":"rotation|translation","motion_profile":"string or array","speed":"number (RPM or m/s)"},"constraints":{"space_envelope":"object","force_requirements":"number","accuracy":"number"},"operating_conditions":{"load":"number","speed_range":"array [min, max]","duty_cycle":"string"}}
Output Schema
{"mechanism_design":{"type":"string","configuration":"object","link_dimensions":"array"},"kinematic_results":{"position_analysis":"array or function","velocity_analysis":"array or function","acceleration_analysis":"array or function","transmission_angle":"number"},"dynamic_results":{"forces":"array","torques":"array","shaking_forces":"object"},"performance_metrics":{"pressure_angle":"number (cams)","contact_ratio":"number (gears)","efficiency":"number"},"design_documentation":"reference"}