Machine Kinematics
solved, then drawn
Series

Fourbar — the series

17 essays on one idea, from the one that introduces it to the one that assumes the rest.
  1. 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.

    part 1 · linkages
  2. Grashof's classification, predicted and then swept. Four sets of link lengths. For each, Grashof's condition predicts from the lengths alone whether the input can rotate a full turn, and the solver then attempts all 180 positions and reports how many assembled. The prediction and the measurement agree in every case, which is what licenses quoting the classification for a mechanism nobody has swept.

    Grashof, predicted and then swept

    Add the shortest link to the longest. If the total does not exceed the other two, some link can turn a full revolution. It is a sentence about four numbers, it was published in 1883, and it is the kind of claim this site refuses to print without measuring — so every linkage here is also asked for all 360 positions and required to agree.

    part 2 · linkages
  3. The transmission angle through one turn. μ is the angle at B between coupler and rocker, computed from each solved position rather than from a formula. It runs from 54.3° to 100.3° for these lengths. The shaded band is the usual design rule — keep μ between 40° and 140° — and this linkage stays inside it throughout. The rule is about geometry alone: nothing here knows about friction, and a mechanism with a comfortable μ can still be a poor machine.

    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.

    part 2 · linkages
  4. Slider-crank at 50°. Crank 1, connecting rod 3. The slider's travel is 2.0000 — exactly twice the crank throw, which is the one thing about this mechanism that does not depend on the rod length. Everything else does: the rod length decides how far the piston's motion departs from a sine wave, and that departure is the second harmonic every engine balancer has to deal with.

    The slider-crank

    Replace one pin of a four-bar with a slide and you get the mechanism in every reciprocating engine ever built. Its stroke is exactly twice the crank throw and does not depend on the connecting rod at all. Everything else about the motion depends on the rod, including the part that is always described as a sine wave and is not.

    part 2 · linkages
  5. 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.

    part 3 · linkages
  6. One chain, four mechanisms. The same four bars and the same four pins in every panel. What changes is which link is bolted to the bench, and that is not a property of the chain — it is a decision about where the bench is. The four mechanisms are crank rocker, double crank, crank rocker, double rocker: one input turns fully in some and rocks in others, and what each one is for is different. What cannot change is the shape of the closed loop, and the two diagonals measure that without reference to which link is held still: swept independently, all four visit the same locus of diagonal pairs to within 2.9e-3, half the sampling resolution. This is why the Whitworth quick-return and the oscillating-cylinder engine are not merely similar to a slider-crank; they are one.

    One chain, four mechanisms

    Which link of a four-bar is bolted to the bench is not a property of the chain. It is a decision about where the bench is, and making a different one gives a mechanism that looks and behaves completely differently while being, as a chain, the same object — which is why the Whitworth quick-return and the oscillating-cylinder engine are both a slider-crank.

    part 3 · linkages
  7. The wheel is the coupler — double wishbone. The suspension solved at 0 mm of bump, with the whole travel ghosted behind it. The two arms are the cranks and the upright between them is the coupler; the wheel is bolted to that coupler, so camber is the coupler's rotation and nothing else. Camber here is 0.00° and the contact patch has moved 0.0 mm across the road. The cross is the instantaneous centre of the upright, found from the solved velocity field; the roll centre is where the line from it to the contact patch crosses the car's centreline, and it is at 73 mm here.

    The wheel is the coupler

    A double wishbone is a four-bar standing on end whose coupler carries a wheel, so camber is coupler rotation and scrub is a coupler point's path. Both are computable, and the second one comes out with the opposite sign from the model every suspension book uses — by more than the whole scrub.

    part 4 · applied
  8. The roll centre through the travel — double wishbone. The roll centre is a construction: the instantaneous centre of the upright, joined to the contact patch, extended to the car's centreline. It is quoted as a height. Over 160 mm of travel it moves 54 mm — 52 mm to 106 mm — The number in a specification is the value at one position of a curve, and the curve is steeper than the thing it is a property of.

    A roll centre is not a point

    The roll centre is a construction on the instantaneous centre of the wheel's upright, and every step of it is exact. What it is not is a height: over eighty millimetres of bump and droop it moves 54 mm on a wishbone and 131 mm on a strut, and on the strut it goes below the road.

    part 5 · applied
  9. How wrong the trapezoid is, arm angle 15.6°. The difference between the outer wheel's angle and the angle that would put all four wheels on one circle. It is zero at straight ahead by construction — both wheels point forwards — and it reaches 2.06° at 35° of lock. "One hundred per cent Ackermann" names a condition this linkage meets at 1 angle and nowhere else, and no four-bar can do better than a handful: the condition is not a rational function of the crank angle, and the linkage is.

    The steering that is never right

    For four wheels to roll without scrubbing, the two front wheels must point at different angles, and the relation between them is a cotangent condition no four-bar can satisfy. The trapezoid under every car meets it at straight ahead and, if the arm angle is chosen well, at exactly one other angle — 0.34° out at worst instead of 2.06°.

    part 6 · applied
  10. 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.

    part 7 · applied
  11. Eight four-bars, one from each region the three signed sums cut. One linkage from each of the eight sign patterns of T₁ = g + c − a − b, T₂ = g + b − a − c and T₃ = b + c − a − g, each solved at a crank angle in the middle of its range. The thick arc round the left pivot is where the input's pin can go and the arc round the right pivot is where the output's can: crank-rocker + + +, input 100% of a turn and output 22%; double crank − − +, input 100% of a turn and output 100%; rocker-crank − + −, input 22% of a turn and output 100%; double rocker + − −, input 23% of a turn and output 21%; 0–π rocker + + −, input 76% of a turn and output 72%; π–π rocker + − +, input 84% of a turn and output 51%; π–0 rocker − + +, input 84% of a turn and output 85%; 0–0 rocker − − −, input 67% of a turn and output 91%. Grashof's condition names four of these and calls the other four one thing; the arcs show that the four triple rockers differ in which way along the ground line each rocker swings through.

    Eight kinds of four-bar

    Grashof's condition gives a four-bar one of four names and calls every linkage that fails it a triple rocker. Three signed sums of the lengths give eight, and a census of four thousand random linkages finds every one moving exactly as its signs say — because the planes where those sums vanish are the only places a four-bar's motion can change its kind.

    part 8 · linkages
  12. Every pivot on these arcs gives a 60° swing at a time ratio of 1.2. The rocker's pivot O₄ is fixed and its two limit positions B₁ and B₂ are 60° apart. At a limit the crank and coupler are in line, so the crank pivot sees the chord B₁B₂ at the angle δ = 180°(Q − 1)/(Q + 1) = 16.36°, and the points that see a chord at a fixed angle are arcs of two circles. The thick stretches are the 828 sampled pivots that give a crank-rocker with exactly this swing and ratio; the rest of each circle gives a linkage of another kind. The linkage drawn is the member whose worst transmission angle is largest, at both limits: ground 1.222, crank 0.478, coupler 1.130 and rocker 1, with its worst transmission angle 40.32°.

    A swing and a time ratio

    A shaper's specification gives the rocker's swing and how much quicker the return must be than the cut, and those two numbers do not fix a linkage. They leave a one-parameter family of crank-rockers on the arcs of two circles, every member exactly right, and the transmission angle chooses between them — which is also what decides that a 60° swing cannot return more than 1.207 times as fast and keep 40°.

    part 9 · linkages
  13. Four offset slider-cranks, one from each region the limit leaves. One slider-crank from each region of T₂ = b − a + e and T₃ = b − a − e, with the slide the dashed vertical line a distance e from the crank's pivot and the ground line dashed across. The thick arc round the pivot is where the crank's pin can go and the thick stretch of the slide is where the slider can: crank-rocker + +, crank 1, rod 3.5, offset 0.8, the crank reaching 100% of a turn and the slider between 2.37 and 4.43 on each side of it; double rocker − −, crank 3.5, rod 1.2, offset 0.6, the crank reaching 22% of a turn and the slider between 2.22 and 4.66 on each side of it; 0–π rocker + −, crank 2, rod 2.5, offset 1.6, the crank reaching 65% of a turn and the slider running from −4.21 to 4.21 through the ground line; π–π rocker − +, crank 2, rod 2.5, offset −1.6, the crank reaching 65% of a turn and the slider running from −4.21 to 4.21 through the ground line. These are the four of the eight four-bar kinds in which T₁ is positive.

    Four kinds of slider-crank

    An offset slider-crank is a four-bar whose output bar and ground have grown without bound, and in that limit the three signed sums that sort four-bars into eight kinds lose one of their signs. Four kinds survive. A census of four thousand finds every slider-crank moving as its region predicts, the textbook condition for a full crank turn turns out to be one region exactly, and each of the four kinds that vanish is carried, at a length that can be written down, into the survivor that shares its other two signs.

    part 10 · linkages
  14. A drag link driving a crank-rocker at a phase of 284.8°. A drag link, ground 1, crank 2.5, coupler 2.25, output 1.5, whose output crank carries the crank of a crank-rocker with a 60° swing, ground 1.2223, crank 0.4783, coupler 1.1298, output 1, turned 284.8° ahead of it, drawn at an input angle of 40°. The two cranks on the middle pivot are one rigid part. The thick arc at the right is the rocker's swing. At this phase the whole machine returns 2.71 times as fast as it works; the crank-rocker alone, driven at constant speed, returns 1.2 times as fast.

    A drag link ahead of a crank-rocker

    A crank-rocker with a 60° swing keeps a transmission angle of 40° only up to a time ratio of 1.207, and at a ratio of 2 no crank-rocker keeps even 20°. Drive its crank from the output of a drag link, whose cranks both turn but not at the same speed, and a pair in which each stage keeps 40° returns 2.71 times as fast as it works. The phase between the two stages decides almost all of it: the same two linkages give anything from 1.003 to 2.71.

    part 10 · linkages
  15. Grashof's classification, predicted and then swept. Four sets of link lengths. For each, Grashof's condition predicts from the lengths alone whether the input can rotate a full turn, and the solver then attempts all 180 positions and reports how many assembled. The prediction and the measurement agree in every case, which is what licenses quoting the classification for a mechanism nobody has swept.

    Grashof is a shape test

    The oldest classification in the subject compares sums of lengths, so it is unchanged by making the machine bigger — which means a protractor recovers it exactly without recovering a single length. What it does not recover is the margin, and the margin is what says whether the classification is safe.

    part 11 · linkages
  16. How evenly the rocker is driven through the working stroke. The rocker's speed through the working stroke, divided by its mean over the stroke, against the fraction of the stroke's duration, for a crank-rocker with a 60° swing and a time ratio of 1.2 of its own, ground 1.2223, crank 0.4783, coupler 1.1298, output 1. Every curve must start and end at nought, because the rocker stops to reverse; what differs is the middle. The number after each name is the fastest speed over the slowest while the rocker covers the central 80% of its swing. Driven directly at constant speed the crank-rocker gives 1.91 at a time ratio of 1.20. The drag link that gives the highest time ratio, 2.71, gives 2.77: a hump in the middle of the cut. The most even design that still reaches 2, a drag link of ground 1, crank 5, coupler 4.5, output 2.25, gives 1.21 at a ratio of 2.03 — more even than the crank-rocker alone. Dragging moves that design's phase.

    A quick return that cuts evenly

    A drag link ahead of a crank-rocker buys a shaper its time ratio of 2 with both stages at 40°. The drag link that buys the most ratio drives the cut unevenly — its fastest speed through the middle of the stroke is 2.77 times its slowest — and a different drag link at a different phase reaches 2.03 with a ratio of 1.21, which is more even than the crank-rocker driven alone at constant speed. Up to a ratio of about 2.4 the second stage can improve both specifications at once.

    part 11 · linkages
  17. The chain's whole configuration space, drawn on its two angles. A slider-crank asks one thing of its two angles: a cos θ + b cos φ = e, with θ the crank's angle and φ the rod's. Each panel is the square of those two angles from −π to π, with the curve that equation cuts out, followed by arclength on the equation alone. The number under each panel is how many whole turns θ, φ and φ − θ make around a circuit. A curve that crosses the square from side to side carries a turn in that angle; a closed loop inside the square carries none. The two regions where a member turns have two circuits each and the two where none does have one, which is what the four-bar regions these came from predict.

    Three rotations, and four benches

    The slider-crank chain's four inversions are four famous machines, and they are not four classifications. Four links make six pairs, one of those pairs cannot rotate at all because a slide is a rotation of nought, and the five that are left are three quantities between them. So an inversion chooses which two of the chain's three rotations sit at its bench, and the four regions of length space already say what all three do.

    part 12 · linkages

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