Theory of Machines Project Report

Robotic Arm Attachment Using a Four-Bar

Mechanism and Gear Train

Saleem Al Daken 20219105001

Introduction:
Modern automation and robotics demand compact, efficient, and precise
mechanical systems that can replicate or enhance human actions. The aim of
this project is to design and analyze a robotic arm mechanism that mimics
controlled human arm movement by integrating fundamental kinematic
components studied in the Theory of Machines course. The mechanism
combines a four-bar linkage with a gear train system, specifically involving a
worm gear and a wheel gear, to convert rotary motion from a motor into
guided movement of a robotic arm.

The project is motivated by real-world applications such as pick-and-place

robots, CNC arms, and automated assembly systems. These systems often
require the transformation of high-speed, low-torque input from motors into
slow, high-torque, and controlled motion at the end-effector. The worm gear
in this project enables torque multiplication and directional control, while the
four-bar mechanism translates rotational input into smooth oscillating or
linear-like motion.

Goals and Objectives:

 To design a mechanical robotic arm attachment using fundamental
kinematic mechanisms.
 To employ a worm gear and wheel gear system for motion input and
control.
 To utilize a four-bar linkage for motion transmission within the robotic
arm.
 To simulate the design using SolidWorks, ensuring correct motion
constraints.
 To conduct analytical velocity and acceleration analysis on the
mechanism.
 To assess the mechanical logic and validity of the results.
Literature Review:
The Four-Bar Mechanism:
The four-bar mechanism is one of the most fundamental and widely used
planar linkages in mechanical engineering. It consists of four rigid links
connected by four revolute pairs (pin joints) to form a closed kinematic
chain. The four links are commonly referred to as:

1. Crank (Input Link): The link that receives the input motion, usually
rotational.
2. Coupler: The intermediate link that connects the crank to the output
link.
3. Rocker or Output Link: The link that delivers the output motion.
4. Frame (Fixed Link): The stationary link that connects the two fixed
pivots.

The configuration and relative lengths of the links determine the type of
motion produced—whether it is a crank-rocker (one link fully rotates while
the other oscillates), double-crank (both input and output rotate), or double-
rocker (both input and output oscillate).
Four-bar linkages are extensively used in engineering applications due to
their versatility and simple mechanical design. They are found in devices
such as engine valve systems, bicycle suspensions, folding mechanisms, and
robotic arms. Their utility lies in the ability to convert rotational motion into
controlled oscillatory or reciprocating motion with a single degree of
freedom.

Kinematic analysis of the four-bar mechanism involves determining angular

positions, velocities, and accelerations of all links based on input conditions.
This analysis is foundational in understanding complex motion systems and
designing mechanisms for specific motion paths or force requirements.

Gears and Gear Trains:

Gears are toothed mechanical components designed to transmit rotational
motion and torque between shafts. They work through meshing teeth that
allow the input motion of one shaft to drive the motion of another, with
varying speed and torque based on the gear ratio. Gear trains are
arrangements of two or more gears used to achieve desired motion
characteristics, including speed reduction or amplification, torque
conversion, and direction reversal.

Spur (Wheel) Gears:

Spur gears are the simplest and most common type of gear, characterized by
straight teeth that are parallel to the gear axis. They are typically used to
transmit motion and power between parallel shafts. Key advantages include:

 High efficiency and reliability.

 Constant velocity ratio.
 Ease of design and manufacturing.

Spur gears are commonly referred to as "wheel gears" when used in broader
mechanical assemblies. They are widely used in machines, clocks,
gearboxes, and various mechanical linkages where linear, predictable motion
transfer is needed.

Worm Gears:
Worm gears consist of a worm (a screw-like cylindrical gear) that meshes
with a worm wheel (a toothed gear resembling a spur gear). This gear
arrangement is unique in that it transfers motion between non-parallel, non-
intersecting shafts, typically at a 90° angle. Important characteristics of
worm gear systems include:

 High gear reduction: A single stage can achieve reduction ratios of

20:1 or higher.
 Compact design: Suitable for systems where space is limited.
 Self-locking feature: Under certain conditions, the worm gear cannot
be driven backward, providing a mechanical braking effect.
 Smooth and quiet operation: Due to continuous sliding contact
between gear teeth.
Worm gears are commonly used in applications requiring high torque at low
speeds, such as conveyor systems, hoisting machinery, and tuning
mechanisms in instruments. The sliding nature of the contact, however,
results in lower mechanical efficiency and increased heat generation
compared to other gear types.

Methodology:
The methodology followed in this project involves both the design and
analytical evaluation of a mechanical system composed of a gear train
and a four-bar linkage. The process can be divided into the following key
stages:

1. SolidWorks Modeling and Design

 A complete 3D model of the robotic arm mechanism will be developed
using SolidWorks.
 The model includes:
o A worm gear connected to a motor that serves as the primary
input.
o A wheel gear driven by the worm gear.
o A four-bar mechanism connected to the wheel gear that drives
the output motion.
 Multiple views of the mechanism will be captured, showing:
o Front, top, and side angles.
o The linkage arrangement.
 o Dimensional measurements of all critical components (link
lengths, gear diameters, distances between pivots, etc.).
 Motion simulation will be conducted to verify that the mechanism
behaves as expected and to identify the range of motion.

2. Numerical Analysis
 A comprehensive numerical analysis will be performed to evaluate the
kinematics of the mechanism.
 Input angular velocity will be assumed at the worm gear.
 Using this input, the following will be calculated:
o Angular velocities of the crank, coupler, and rocker in the four-
bar linkage.
o Linear velocities of key points on the mechanism.
o Angular accelerations of each link using analytical methods such
as the method of instantaneous centers or relative acceleration
analysis.
 Linkage dimensions and gear ratios obtained from the SolidWorks
model will be used in all calculations.
 The analysis will be performed both manually (analytically)
For all the calculations I Will be using the following values:
For linkage lengths:
l 1=270 mm , l 2=500 mm , l 3=400 mm, l 4 =400 mm

For angles:
θ1=0, θ2=66.60, θ3 =−26.64, θ 4=44.43

ω worm=250 RPM , this speed is set by the motor controlling the worm gear
ωworm 2 π 250 2 π
ω ¿, wheel = x = x =0.65 rad /s
gear ratio 60 40 60

Velocity Analysis:
Determine the angular velocity of the coupler and the fourth link (output
link), ω 3 and ω 4.

The link lengths l 2 ,l 3 ,l 4 ,l 1 are represented by four vectors as r⃗ 2 , ⃗r 3 , r⃗ 4 , r⃗ 1 Assume

that these vectors make with the x -axis the angles shown in the figure:

r⃗ 2 + r⃗ 3 =⃗r 1+ ⃗r 4 (Equal to zero because it is closed loop) ... equation (1)

To analyze this equation, we write it in terms of complex exponential

notation:
iθ2 i θ3
r⃗ 2=l 2 e ... equation (2)⃗r 3=l3 e ... equation (3)

iθ1
r⃗ 1=l 1 e =l1 (because θ 1=0)... equation (4)
i θ4
r⃗ 4=l 4 e ... equation (5)
From equations (2-5), substitute into equation (1):
i θ2 i θ3 i θ4
l 2 e +l 3 e −l 1−l 4 e =0... equation (6)

Now we can derive equation (6) with respect to time in order to find the
angular velocity:
i θ2 i θ3 i θ4
l 2 θ̇ 2 i e +l 3 θ̇ 3 i e −l 4 θ̇ 4 ie =0 ... equation (7)

We know that i eiθ =cos θ+isin θ (Euler’s formula) So substitute all these angles
in terms of sin and cos and equate separately to zero:

l 2 ω2 ( cos θ2 +i sinθ 2 ) +l 3 ω 3 ( cos θ3 +i sinθ 3 )−l 4 ω 4 ( cos θ 4 +isin θ 4 ) =0 ... equation (8)

From equation (8):

Real part:

l 2 ω2 cos θ2 +l 3 ω3 cos θ3−l 4 ω4 cos θ 4=0...equation (9)

Imaginary part:

l 2 ω2 sinθ 2+ l3 ω 3 sin θ3 −l 4 ω 4 sin θ 4=0 ...equation (10)

We can solve equations 9 & 10 numerically. We have to construct the

following matrix:

[ ][ ] [
−l 3 sin θ3 l 4 sin θ4 ω 3
l3 cos θ 3 −l 4 cos θ 4 ω 4
l sinθ 2
= 2
l 2 cos θ2
ω2
]
Now:
 ( l 2 sinθ 2 )( l 4 cos θ4 )+ ( l 2 cos θ 2 )( l 4 sinθ 4 )
ω 3= ω2
(−l 3 sin θ3 ) ( l 4 cos θ4 ) −( l 3 cos θ3 ) ( l 4 sin θ4 )
(−l 3 sin θ3 ) ( l2 cos θ2 )−( l3 cos θ 3 )( l 2 sin θ2 )
ω 4= ω2
(−l3 sin θ3 ) ( l4 cos θ 4 )−( l3 cos θ 3 )( l 4 sin θ 4 )

Substituting values gives:

 ω 3=0.802 rad/s

 ω 4=0.552 rad/s

Acceleration Analysis:
Determine the angular accelerations α 3 and α 4 of the coupler and output link.

We begin by differentiating the velocity equation again with respect to

time:

From equation (7) of the velocity analysis:

i θ2 i θ3 i θ4
l 2 ω2 i e +l 3 ω3 i e −l 4 ω 4 i e =0

Differentiating again with respect to time:

l 2 ( α 2 i−ω 22 ) ei θ +l 3 ( α 3 i−ω23 ) e i θ −l 4 ( α 4 i−ω 24 ) e i θ =0... equation (11)

2 3 4

Separate into real and imaginary parts using Euler's identity:

Real Part:
 2 2 2
−l 2 ω2 cos θ2−l 3 ω3 cos θ 3+l 4 ω4 cos θ 4−l 3 α 3 sin θ 3+l 4 α 4 sin θ 4=l 2 α 2 sin θ2 ... equation (12)

Imaginary Part:
2 2 2
−l 2 ω2 sinθ 2−l 3 ω3 sin θ3 +l 4 ω 4 sin θ 4 +l 3 α 3 cos θ3 −l 4 α 4 cos θ4 =−l 2 α 2 cos θ2 ... equation (13)

Given α 2=0 (since ω 2 is constant), simplify equations (12) and (13):

Equation (12):
2 2 2
−l 2 ω2 cos θ2−l 3 ω3 cos θ 3+l 4 ω4 cos θ 4−l 3 α 3 sin θ 3+l 4 α 4 sin θ 4=0

Equation (13):
2 2 2
−l 2 ω2 sinθ 2−l 3 ω3 sin θ3 +l 4 ω 4 sin θ 4 +l 3 α 3 cos θ3 −l 4 α 4 cos θ4 =0

Construct the matrix:

[ ][ ] [ ]
2 2 2
−l 3 sin θ3 l 4 sin θ4 α 3 l ω cos θ2 +l 3 ω3 cos θ3−l 4 ω4 cos θ 4
= 2 22 2 2
l3 cos θ 3 −l 4 cos θ 4 α 4 l2 ω 2 sin θ2 +l 3 ω3 sin θ3−l 4 ω 4 sin θ4

Substituting values gives:

2
 α 3=0.865 rad/s
2
 α 4 =0.594 rad/s

Results
Results rad rad
ω( ) α( )
s s
2

3 0.802 0.865
4 0.552 0.594

The velocity and acceleration analysis yielded logical values for the angular
velocities and accelerations of the coupler and output links. These results
were obtained using complex exponential notation, applying Euler’s formulas
to separate real and imaginary components, and solving the resulting matrix
equations numerically.
 Angular velocity of the coupler and output links were computed
relative to the crank input.
 Linear velocities at joints were derived from these angular values.
  The angular accelerations were determined by differentiating the
velocity equations and solving the corresponding matrix system.
 The calculations respected the input constraints (motor speed, gear
ratio) and linkage dimensions from SolidWorks.

Validation of Results:
The obtained results align well with the expected mechanical behavior of a
four-bar linkage and gear train system. The logical progression of angular
and linear velocities, followed by consistent acceleration results, supports
the assumption that the system is dynamically coherent.

Conclusion
Summary and Knowledge Gained
This project successfully demonstrates the application of theoretical
kinematics to a real-world robotic mechanism. The four-bar linkage and gear
train system offer a controlled means of motion transformation, ideal for
robotic applications that mimic human arm movements.
Key takeaways include:
 Gaining a strong understanding of the kinematic behavior of four-bar
mechanisms and gear trains.
 Learning how angular input from a motor translates through a series of
mechanical linkages into useful motion at an output.
 Performing analytical calculations for velocity and acceleration using
vector and matrix methods.
 Appreciating the importance of gear ratios in torque and speed control,
specifically in worm-wheel systems which offer self-locking features
and high torque transfer.
These insights enhance both mechanical intuition and problem-solving skills
in motion analysis.

Future Work
To extend this project and enhance its real-world application, the following
improvements are proposed:
 Dynamic Analysis: Incorporate force and torque calculations to
understand mechanical stresses on joints and links. This can guide
motor selection and ensure safe operation.
 Material Optimization: Study material choices for lightweight yet
strong components to improve the performance of the arm in dynamic
environments.
 Control Integration: Develop electronic control logic (using
microcontrollers or PLCs) to automate motion with sensors and
actuators.
 Multi-DOF Systems: Expand from a single degree-of-freedom four-
bar to more complex articulated systems with multiple joints for
greater mobility and range.
 Prototype Fabrication: Create a physical prototype using 3D printing
or CNC machining to validate simulated performance through real-
world testing.