Concept

Toggle — where it appears

A configuration in which two links line up, giving a limit of the output's travel and an unbounded ratio between input and output motion. It is used deliberately in clamps and presses, where the unbounded ratio is the point, and it is a limit of the output's travel rather than a jam.

Named by 9 essays across 6 fields — each of them below, with the objects they name alongside it.

A four-bar at 60°, solved. Ground 4, crank 1, coupler 3.5, rocker 3. Every joint position here is the output of a Newton–Raphson solve on the loop-closure equations, converged to 0.0e+0 — not a placement that looked right. Grashof's condition classifies these lengths as a crank rocker, and sweeping the crank through 360° confirms it: 120 of 120 positions assemble. The transmission angle at this instant is 66.9°.

Four bars and four pins

The smallest interesting machine there is. Four lengths decide everything about it — which link can turn all the way round, how hard it pushes, where it stops and whether it can be assembled at all — and every one of those is a number that falls out of a solve rather than a judgement about a drawing.

linkages · Fourbar

Two things that are not the same configuration. The mechanical advantage of a four-bar, from the velocity solution: for a lossless mechanism it is the reciprocal of the output-to-input speed ratio, so wherever the output momentarily stops the force ratio diverges. It reaches 1673 at 222° — a toggle, where crank and coupler line up, and the reason a knee-joint clamp holds with almost no effort. The transmission angle is at its worst somewhere else entirely: 46.5° at 0°, 222° away, where coupler and rocker line up instead. Both get called "the mechanism jamming" and they are opposite situations — one is enormous force output, the other is force going into the bearings.

Two things called jamming

A four-bar's mechanical advantage peaks at 1,673 in one configuration and its transmission angle collapses in another, 222° away. Both get described as the mechanism jamming. One is enormous force output and the other is force disappearing into the bearings, and they are opposite situations.

wrong · Misconception

Of 1176 exactly correct syntheses, 176 could be built. Every pair of points on a 7×7 grid over the moving body, each pair synthesised into a four-bar and each four-bar verified by the forward solver as reaching all three prescribed poses. 1176 of them do, exactly. Then each is swept from the first pose in both directions, carrying the branch the way a built mechanism must: 810 cannot reach all three without being taken apart and reassembled, and 190 reach them in the wrong order. 176 — 15% — are mechanisms rather than theorems. Nothing in the construction distinguishes them.

Exactly right, and unbuildable

A linkage synthesised through three prescribed positions reaches all three. That is a theorem and it holds exactly. Whether it reaches them in one piece, without being taken apart, and in the order asked for, are separate questions the construction says nothing about — and of 1,176 exactly correct solutions, 176 could be built.

wrong · Misconception

The transmission angle

The angle at which the coupler meets the rocker decides how much of an applied force becomes useful output torque and how much goes into the bearings. It is pure geometry, it is computed here from every solved position rather than from a formula, and it is the number a linkage is judged by after Grashof has said it turns.

linkages · Fourbar

Where the output stops, and why the return is quicker. A crank-rocker's output reaches an extreme exactly when the crank and coupler line up — stretched out, so O₂ to B is 4.50, or folded back, so it is 2.50. Nothing about the rocker enters the condition, which is why the limits can be written down rather than searched for. Those two crank angles are 40.8° and 228.5°, so the crank spends 187.7° going one way and 172.3° coming back while the rocker covers the same 40.0° both times. The ratio is 1.0894 predicted and 1.0894 measured over 7200 swept positions — a shaper cuts on the slow stroke and returns on the fast one, and this number is what the proportions are chosen to get.

The return stroke is quicker

A crank-rocker's output stops at two definite places, and the crank angles at which it does are calculable without touching a solver. The interesting number is not where they are but how far apart — because the crank turns at a constant speed and the output covers the same swing twice in unequal times.

linkages · Fourbar

Where a tolerance stack-up stops meaning anything. The ratio between the first-order tolerance estimate and the band measured by building every corner linkage, for two four-bars at ±0.002 on each length. The crank-rocker's ratio is 1 at all 180 positions — a stack-up is exactly right for it, everywhere. The parallelogram is a change-point linkage, where all four bars can lie on one line, and at that position the estimate exceeds the measurement by a factor of 4.8e+5. The difference is not in the arithmetic, which is identical; it is that a derivative describes a map that can be inverted, and at a change point the map cannot.

Where a stack-up stops working

On a crank-rocker the first-order tolerance estimate matches the measured band at every one of 180 positions, to eight parts in ten thousand. On a parallelogram it exceeds it by a factor of 475,512. Same arithmetic, same tolerance, two linkages that differ only in their proportions — and nothing in the calculation says which one it is being run on.

practice · Tolerance

The slider turns round at the dead centre. The slider's position against the crank angle, through the dead centre. The curve has a maximum there — that is what a dead centre is — so the slider retreats on both sides of it, and the latch works because a mechanism resting past the top of this curve has to be pushed back up it before anything can move. Set 4° past, the slider is 71 µm below the peak, and because the curve is quadratic there, doubling the setting quadruples the depth.

Locked on purpose

A toggle clamp, a landing-gear downlock and the catch on a folding table are all the same mechanism parked a few degrees past its dead centre, where the slider's motion is second order in the crank's. Seventy-one microns of slider travel undoes a latch set four degrees over — and setting it eight degrees over does not double that, it quadruples it.

applied · Fourbar

One angle, read twice. Draw against the angle the locking face is tilted by. It is not a separate design quantity from recoil: the pallet's moment per unit of wheel torque is minus the rate at which the wheel is driven backwards, which is virtual work and holds to nine figures. So an escapement cannot be made to hold its own lock without also being made to push its train back — and at δ = 0 the arc has neither, which is a lock that any disturbance opens. The flat face starts above zero because the tooth rests below the corner, where a straight face is no longer tangent to anything.

One test, three mechanisms

Whether a pawl holds, whether an escapement's lock draws itself deeper, and how much a four-bar's coupler can do for its rocker are the same question asked three times: on which side of a pivot does a contact normal pass? All three are one cross product, none evaluates a force, and the three answers are used for completely different things.

timing · Intermittent

The transmission angle has no size

The geometric half of force transmission is an angle in a triangle whose three sides scale together, so it is the same at every size — 54.31° at its worst on this machine, whatever units the drawing is in. Which means a measurement that cannot recover a single length recovers the whole of what this field computes.

transmission · Transmission

Named alongside it

The objects these essays reach for when they reach for this one.

Transmission angle Grashof's condition Constraint Dead centre Mechanical advantage Ratio Singularity Stroke Tolerance Assembly branch Constraint jacobian Four-bar

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