Kinematics of machines

Chapter 8 Cam design

Dr. Jaafar Hallal

1 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

 Chapter 8 Cam Design
 8.1 Cam terminology
Type of follower motion:
• Rotating follower (a)
• Translating follower (b)

2 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

 Chapter 8 Cam Design
 8.1 Cam terminology
Type of joint closure:
• Force closed (Fig 8-1)
• Form closed (Fig 8-2 a-b)
• Conjugate (Fig 8-2 c)

3 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.1 Cam terminology

Type of follower:
• Flat faced (automotive ...)
• Mushroom, curved (custom designed)
• Roller (lower friction, expensive, production machine)
4 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019
Chapter 8 Cam Design
 8.1 Cam terminology Type of Cam
• Radial (Fig 8-1,2,3)
• Axial (Fig 8-4)

5 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.1 Cam terminology

6 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.1 Cam terminology

 Type of motion constraints

• Critical extreme position (CEP): constraint on initial

and final point but not on the path.
• Critical path motion (CPM): more constraints on
path and derivations.

7 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.1 Cam terminology
Type of motion program:

 Dwell : no output motion for a specified period of input motion

• Rise-fall (RF)
• Rise-fall-dwell (RFD)
• Rise-dwell-fall-dwell (RDFD)

• RF CEP motion with no dwell ➔ crank-rocker (ease of construction, lower

cost ...)
 If your needs for compactness outweigh those consideration then cam
follower is justified

 For RFD and RDFD we choose the cam follower. We must study the
Boundary conditions of their functions and their derivatives.

8 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.2 SVAJ diagrams

Mathematical functions defined the motion

Linearize the cam (unwrap it)
9 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019
Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The double dwell case is quite Common
Example in the figure below

10 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Example 8-1

•Acc is 0 during the interval

but -> infinity

•Dirac delta function

•Inacceptable

•Jerk is more critical

11 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The fundamental Law of Cam design
The cam function must be continuous through the first and
second derivative of displacement across the entire interval.

➔ The jerk function must be finite.

The cam cannot be defined by single mathematical expression, but

rather must be defined by several separate functions (piecewise
functions)

Third order continuity functions.

Fifth order polynomial is acceptable ( cubic for acc, parabolic jerk)

12 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Simple Harmonic Motion (SHM)

h: total rise
θ: camshaft angle
β: total angle of rise

0<θ/β<1
0<s<h

• This design is good because it never run out of derivative

• Velocity function is continuous (0 at start and end)
• Acceleration is not continuous (half period cos curve)
• Jerk will tends to infinity at start and end of each segment
Dwell have always zero Acc and zero velocity ➔ we should
have zero v and zero a at the start and the end of each segment
13 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019
Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Simple Harmonic Motion (SHM)
The only harmonic displacement function that satisfy is the non-quick-return RF

14 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Cycloidal displacement
It’s better to start with acceleration:
Full period acceleration (start and end with 0)

Then integrate to obtain velocity

BC:
v=0 when θ=0

15 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Cycloidal displacement

Then integrate the velocity to obtain displacement

BC:
s=0 when θ=0
s=h when θ=β

16 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

 Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Cycloidal displacement
Displacement is the sum of a straight line
with slope h and negative sine

Velocity is a sum of scalar and a negative

cosine
It start and end at 0, maximum at β/2

Cycloidal displacement <=> sin acceleration

Displacement is acceptable
Jerk is discontinuous but finite and this is acceptable
Smooth velocity
Disadvantage: large peak velocity and acceleration

17 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Combined functions

Dynamic force is proportional to the acceleration.

 Objective is to reduce the acceleration to the min but should always be
continuous

Kinetic Energy is proportional to the velocity^2.

 Objective is to reduce the velocity

18 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Constant Acceleration
Minimize the peak value for a given area
But the Jerk is infinite
➔ Unacceptable

19 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

 Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Trapezoidal Acceleration
 Jerk is finite

Trapezoidal Sin Acc

Acc (cycloidal disp)
Jerk Very 2 discontinuous
discontinuous (smoother)
Peak Peak < Peak >

Trades-offs??

20 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design
choosing SVAJ functions
Modified trapezoidal Acceleration

 Improvements:
sine (A,B,C,D) + constant Acceleration (E,F)

 Advantages:
• low peak acceleration
• Smooth transition (begin-end)

21 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design
choosing SVAJ functions
Modified sinusoidal acceleration

 Sine acceleration is smoother than the

modified trapezoidal but higher
acceleration peak.

 2 sine (2 frequencies) ➔
• we can retain some of the smoothness of
the cycloid
• and also reduce the peak acceleration

22 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

 Acceleration functions includes:

• Constant
• Simple harmonic
• Modified trapezoid
• Modified sine
• Cycloidal curves

Use the same equations with different numerical parameters (a,b,c,d)

23 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

24 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

25 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

26 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

27 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

28 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

29 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration

30 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
Sine Constant Cosine Acceleration
Acceleration peak

Velocity peak

Jerk peak

31 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
The SCCA family of double-dwell functions
To apply the SCCA function to an actual cam design:

For the fall function change BC

32 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Polynomial functions

 s: follower displacement
 x: independent variable x=θ/β
 Cn: constant coefficient to be determined

The order of the polynomial is defined based on the

number of B.C.:
n=k-1 where k is the number of B.C.
33 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019
 Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Polynomial functions
Example 8-5
θ=0; s=0, v=0, a=0
6 BC ➔ n=5
θ=β; s=h, v=0, a=0

Using BC: =>

34 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Polynomial functions (3-4-5 polynomial functions)
Example 8-5
It give us the 3-4-5 polynomial functions

35 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.3 Double dwell Cam design choosing SVAJ functions
Polynomial functions (4-5-6-7 Polynomial Functions)
If we add constraints on Jerk
θ=0; s=0, v=0, a=0, j=0 8 BC ➔ n=7
θ=β; s=h, v=0, a=0, j=0

Acc start slowly with 0 slop

4-5-6-7 has smoother Jerk ➔ better vibration behaviour

36 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Comparison

37 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Comparison

38 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Comparison

39 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Comparison

40 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.3 Double dwell Cam design choosing SVAJ functions
Comparison

41 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Cycloidal motion (Example 8-6) NOK
If we follow the same
procedure as the double dwell.

=>3 segments: RFD

42 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.4 Single dwell Cam design choosing SVAJ functions
Double harmonic motion (2 cosine functions)
Function of the fall should begin with the same nonzero acceleration value
ended the rise and then be zero at it’s terminus.

NOK
•Acc peak is too high
(twice cycloidal)

•Can be used only for

equal time of rise and fall
(sym)

43 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Polynomial
 As a general rules:
• We would like to minimize the number of segments in our polynomial cam
functions.
• We would like to minimize the number of boundary conditions. (high
degree function may have undesirable oscillations between its BCs)

Use only 2 segments (RF, dwell)➔ polynomial functions

Single RF ➔ 7 BC are needed (2 disp, 2 vel, 2 acc, and 1 for the maximum
value of disp)
➔ n=6

45 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Polynomial

46 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Polynomial

OK
• Smooth as the double
harmonic function
• No necessary return to zero
• But it’s symmetrical

47 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
Example 8-9 (R 45˚, F 135˚, D 180˚)
7 BCs (s, v and a = 0 at 0 and 180) and s=1 at 45˚

3-4-5-6 polynomial function solution is:

48 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
Example 8-9 (R 45˚, F 135˚, D 180˚)
NOK
We should add condition
v=0 when theta=45˚ to
ensure that 1 is the max

49 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
NOK
• Fall is not acceptable
• We should consider 3 functions
(Rise, Fall, dwell)

50 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
Example 8-10 (3 segments RFD)
Rise Fall
S=V=A=0 at the start S=1, V=0, A=-4377.11 at the start
S=1, V=0 at the end (A to match the rise end)
5BCs ➔ n=4 S=V=A=0 at the end
6BCs ➔ n=5

Evaluating the acceleration at the

end (Aend= -4377.11 in/sec2)
This will become a BC for the fall
51 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019
Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
Example 8-10 (3 segments RFD)
It’s important to note that you
should first calculate the
segment with the smaller acc
(here it’s the second one!)
because of it’s larger duration
angle (beta). Then use its
smaller acceleration value as a
boundary condition for the other
segment.

52 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
Example 8-10 (3 segments RFD)
Segment2: Fall Segment1: Rise
S=1, V=0 S=V=A=0
S=V=A=0 S=1, V=0, A=-486.4
(to match the dwell) (to match the fall)

Evaluating the acceleration at the start

(Astart2= -486.4 in/sec2)
This will become a BS for the Rise

53 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.4 Single dwell Cam design choosing SVAJ functions
Effect of Asymmetry on the Rise-Fall polynomial
solution
Example 8-10 (3 segments RFD)
OK

54 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM

Most common application in production machinery design is the

need of constant velocity motion.

Two general types of automated production machinery :

• Intermitted motion
• continuous motion

55 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
Ex 8-11 Design a polynomial for constant velocity critical path motion

 Need a constant speed of 10 in/s for 0.5 sec

 All other length are arbitrary

56 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM

Possible set of BC’s

Start here

57 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
First segment

4 Bc’s ➔ n=3

Disp at theta=30 will be used

as BC for segment 2

58 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
Second segment
2 BC ➔ n=1
 In this segment function we can only choose 2 BC.
 If more than 2 BC ➔ n>1 ➔ disp and vel will oscillate

Acc and Jerk at end are both zeros

Disp when theta= 210 is 5.556

59 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
Segment 3

4 Bc’s ➔ n=3

Bc’s of segment 4 must match those at the end of segment 3

60 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
Segment 4

6 Bc’s ➔ n=5

61 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
 Ex 8-11 Design a polynomial for constant velocity critical path motion

62 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
 Ex 8-12 Design an optimum polynomial for constant velocity critical path
motion

 Maintain a constant velocity

of 10 in/sec for 0.5 sec

 Decelerate and accelerate

follower to constant velocity

 Cycle time exactly 1 sec

63 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
 Ex 8-12 Design an optimum polynomial for constant velocity critical path
motion

 Segment 1:

2 Bc’s ➔ n=1

 Segment 2:

6 Bc’s ➔ n=5

64 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.5 Critical path motion CPM
 Ex 8-12 Design an optimum polynomial for constant velocity critical path
motion

65 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Base circle: smallest circle that can
be drawn tangent to the physical
cam.

Prime circle: smallest circle that

can be drawn tangent to the locus
of the centreline of the follower.

Pitch curve: locus of the centreline

of the follower.

66 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Pressure angle (φ): Angle between the
direction of motion of the follower and
the direction of the axis of transmission.

φ=0 all forces == velocity

φ=90 No motion

0<φ<30 for translating follower

67 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Eccentricity: The geometry of the cam can be
translated.

ε = distance between the follower axis of

motion and the centre of the cam.

68 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Choosing a prime circle radius using eccentricity
If a suitable small cam cannot be obtained with acceptable pressure angle, then
we can use eccentricity to change pressure angle (find the smallest one).

For positive w
ε >0 ➔
 φ << decreased on rise
 φ >> increased on fall

• ε <0 ➔
 φ >> increased on rise
 φ << decreased on fall

69 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
8.6 Sizing the Cam, pressure angle and radius of curvature
Overturning moment (translating flat faced follower)
φ=0 in the figure
But contact point moves ➔ point of application
of the force moves.

Moment works here as the pressure angle

We should minimize the moment arm in order

to minimize the moment

70 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Radius of curvature (translating roller follower)
Rf> ρmin

71 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Radius of curvature (translating roller follower)
Rf=ρmin

This can cause a

problem when
undercutting

72 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Radius of curvature (translating roller follower)

Rule of thumb:

ρmin>> Rf by 2 to 3 times

73 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Radius of curvature (translating roller follower)

4 dwell
ρmin=1.7 Rf
φ=30

Acceptable

74 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Radius of curvature (translating roller follower)

4 dwell
ρmin=Rf
➔ Undercutting

Unacceptable

75 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019

Chapter 8 Cam Design
 8.6 Sizing the Cam, pressure angle and radius of curvature
Radius of curvature (translating roller follower)

ρ<0 is not acceptable here

The flat follower cannot
follow a concave cam.

76 Kinematics of machines - Dr. Jaafar Hallal Monday, November 18, 2019