249~257()

Journal of the Chinese Society of Mechanical Engineers, Vol.30, No.3, pp.249~257 (2009)

Design of Variable Coupler Curve Four-bar

Mechanisms
Ren-Chung Soong * and Sun-Li Wu **

Keywords: Variable coupler curve, Four-bar

mechanism,
Continuous
path
generation.

ABSTRACT

One way of doing this is to replace the normal links

with screw-nut links driven by servomotors, as shown
in Fig. 1. The different desired coupler curves can
then be obtained by controlling the length of the
adjustable links and the angular displacement of the
driving link.

This paper presents a method for designing a

variable coupler curve four-bar mechanism with one
link replaced by an adjustable screw-nut link and
driven by a servomotor. Different desired coupler
curves can be generated by controlling the angular
displacement of the driving link and adjusting the
length of the adjustable links for continuous path
generation. This paper also presents a derivation of
the adjustable link lengths and the specified angular
displacement of the driving link corresponding to the
desired coupler curves. The conditions for generable
desired coupler curves are also described. The
examples and experiments described in this paper
confirm the feasibility and effectiveness of the
proposed method.

P
4

3
5

INTRODUCTION

(b)

Paper Received February, 2009. Revised April, 2009.

Accepted May, 2009. Author for Correspondence: Ren-Chung
Soong

** Assistant Professor, Department of Electrical Engineering,

Kao Yuan University, Kaohsiung 82141, TAIWAIN, R.O.C.

There are two types of path generation. One is

point-to-point path generation, in which the coupler
curves only specify discrete points on the desired
path. The other is continuous path generation, in
which the coupler curves specify the entire path, or at
least many points on it. Because the coupler curves of
linkage mechanisms are functions of their link
lengths, the only way to generate different continuous
coupler curves with a single linkage mechanism is to
make the length of at least one of its links adjustable.

* Associate Professor, Department of Mechanical and

Automation Engineering, Kao Yuan University, Kaohsiung
82141, TAIWAIN, R.O.C.

(a)

Fig. 1. Adjustable mechanisms

The investigation of new synthesis methods for
path generation using linkage mechanisms has been
the subject of some research attention in recent years.
Tao and Krishnamoothy (1978) developed graphical
synthesis procedures of adjustable mechanisms for
generating variable coupler curves with cusps and
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J. CSME Vol.30, No.3 (2009)

symmetrical coupler curves with a double point.
McGovern and Sandor (1973) used complex number
methods to synthesize adjustable mechanisms for
path generation. Kay and Haws (1975) developed a
design procedure for a path generation mechanism
with a cam link, which provided accuracy over a
range of motion. Angeles et al. (1998) proposed an
unconstrained nonlinear least-square optimal
synthesis method for RRRR planar path generators.
Hoeltzel and Chieng (1990) proposed a pattern
matching synthesis method based on the
classification of coupler curves according to moment
variants. Watanabe (1992) presented a natural
equation that expressed the curvature of the path as
an equation of the arc length and was independent of
the location and orientation of the path. Ullah and
Kota (1994, 1997) presented an optimal synthesis
method in which the objective function was
expressed as Fourier descriptors. Shimojima et al.
(1983) developed a synthesis method for straight-line
and L-shaped path generation using fixed pivot
positions as adjustable parameters. Unruh and
Krishnaswami (1995) proposed a computer-aided
design technique for infinite point coupler curve
synthesis of four-bar linkages. Kim and Sodhi (1996)
introduced a method of path generation that made the
desired path pass exactly through five specified
points and close to other points. Chuenchom and
Kota (1997) presented a synthesis method for
programmable mechanisms using adjustable dyads.
Chang (2001) proposed a synthesis method for
adjustable mechanisms to trace variable arcs with
prescribed velocities. Zhou et al. (2002) proposed an
optimal synthesis method with modified genetic
optimization algorithms by adjusting the position of
the driven side link for continuous path generation.
Russell and Sodhi (2005) presented a design method
for slider-crank mechanisms to achieve multiphase
path and function generation.
In this paper, we propose a new design method for
continuous path generation by four-bar mechanisms
that incorporates a screw-nut link called an adjustable
link. Different desired coupler curves can be
generated by appropriately adjusting the length of the
adjustable link and controlling the angular
displacement of the driving link. Examples and
experiments are provided to demonstrate this design
method.

REQUIRED DRIVING LINK

ANGULAR DISPLACEMENT
CORRESPONDING TO THE DESIRED
COUPLER CURVE

Y
P

r5 R5
RP

rp

R3

r3

R4

R2

r2

2
R1

r1

Fig. 2. The coordinate system of a four-bar linkage

The speed trajectory of the driving link, and the
lengths of links 1 or 4 can be adjusted to generate
new coupler curves. Figure 2 shows that the
relationship between the angular displacement of the
driving link 2 and the coordinate of the coupler
point ( Px , Py ) can be written as

Py
( 2 + ) = tan 1
Px

(1)

and the vector loop equation can be written as

R2 + R5 RP = 0.

(2)

Separating Eq. (2) into two scalar component

equations in the x- and y-directions yields

r2 cos 2 + r5 cos( 3 + ) Px = 0 and

(3)

r2 sin 2 + r5 sin( 3 + ) Py = 0

(4)

where ri and i represent the length and angular

displacement of the ith link, respectively. Adding Eqs.
(3) and (4) after squaring both sides gives
2
2
2
2
r5 = Px + Py 2r2 ( Px cos 2 + Py sin 2 ) + r2 ,

(5)
which, after rearrangement, gives

The coordinate system of a four-bar linkage is

shown in Fig. 2.

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R.C. Soong and S.L. Wu: Design of Variable Coupler Curve Four-bar Mechanisms.

r5 2 Px 2 Py 2 r2 2
= 0.
( Px cos 2 + Py sin 2 ) +

2
r
2

(6)
To reduce Eq. (6) to a form that can be solved more
easily, we substitute the half angle identities to
convert the cos 2 and sin 2 terms to

tan 2 terms:

2
1 tan ( 2 )
2
cos 2 =

2 2
1 + tan ( )
2

2 tan( 2 )
2

sin 2 =

2 2
1 + tan ( )
2

) + B tan(

2
2

(10)

(r4 + r4 ) sin 4 = r2 sin 2 + r3 sin 3 r1 sin 1

(11)
where r4 is the length of adjustable link 4.
By dividing Eq. (11) by Eq. (10) to
eliminate (r4 + r4 ) , the angular displacement of link

4 , can be expressed as

4 = tan 1 (

( Px , Py ) terms have been collected as constants A, B,

(r4 + r4 ) cos 4 = r2 cos 2 + r3 cos 3 r1 cos 1

4,

This results in the following simplified form, where

the link lengths ( r2 and r5 ) and the known value

and C: A tan 2 (

If we assume that the length of link 4 can be

adjusted, then we separate Eq. (9) into two scalar
component equations and rearrange as follows:

r2 sin 2 + r3 sin 3 r1 sin 1

) (12)
r2 cos 2 + r3 cos 3 r1 cos1

Then r4 can be calculated as

r cos 2 + r3 cos 3 r1 cos1

r4 (13)
r4 = 2
cos 4

) + C = 0 where

r5 2 Px 2 Py 2 r2 2
P , B = 2 Py , and
A=
x

r
2
2

2
2
2
2
r5 Px Py r2
+ P . The angular
C =
x

2
r
2

Assuming that the length of link 1 can be adjusted,

we separate Eq. 9 into two scalar component
equations and rearrange them as follows:

r4 cos 4 = r2 cos 2 + r3 cos 3 (r1 + r1 ) cos 1

(14)

displacement of the driving link can then be

calculated as

and

B B 2 4 AC

2 = 2 tan

2
A

r4 sin 4 = r2 sin 2 + r3 sin 3 (r1 + r1 ) sin 1

(7)

(15)

and the corresponding 3 can be obtained from Eq.

We then square both equations and add them to

eliminate one unknown, say 4. The adjustable length
of link 1, denoted as r1 , can then be expressed as

(4):

3 = tan 1 (

Px r2 cos 2
) .
Py r2 sin 2

(8)

r1 =

where

ADJUSTABLE LENGTH OF LINKS 1

AND 4

B B 2 4C
r1
2
B = 2r2 (cos1 cos 2 + sin 1 sin 2 )
2r3 (cos1 cos 3 + sin 1 sin 3 )

C = r42 + r22 + r32

+ 2r2 r3 (cos 2 cos 3 + sin 2 sin 3 )

From Figure 2, the vector loop equation can be

written as

corresponding

R2 + R3 R1 R4 =0 .

(9)

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(16)

is

and

The

J. CSME Vol.30, No.3 (2009)

4 = tan 1 (

r2 sin 2 + r3 sin 3 (r1 + r1 ) sin 1

)
r2 cos 2 + r3 cos 3 (r1 + r1 ) cos 1
(17)

CONDITIONS FOR GENERABLE

COUPLER CURVES
The coupler curves that can be generated must
satisfy both the following conditions:

r5 r2 rp r5 + r2

(b)

and

(Px r2 cos 2 )2 + (Py r2 sin 2 )2 = r5 2

where rp =

(18)
(19)

2
2
Px + PY . In Fig. 2, we assume that

r2 and r5 are not adjustable. Therefore, as long as

the desired continuous coupler curves are in the area
between the two concentric circles with radii
r5 r2 and r5 + r2 , they can be generated by
controlling the angular displacement of the driving
link and adjusting the length of links l or 4.

(c)

EXAMPLES
Burrs have always been a problem for steel pipe
manufacturers.
Burrs
frequently
form
on
cross-sections when pipes, especially thick ones, are
cut, as shown in Fig. 3. Eliminating burrs in pipes
with circular cross-sections is relatively easy, but this
is much more difficult for non-circular cross-sections.
Since pipe manufacturers generally produce pipes
with various different cross-sections, clearing burrs
from pipes is very important.

(c)

(d)
Fig. 3. Burrs on the cross-section of steel pipes
In following examples, we use the four-bar linkage
shown in Fig. 2 with the dimensions shown in Table 1
to generate the coupler curves shown in Fig. 4 by
controlling the angular position of the input link and
the length of links 1 or 4. The intended application is
the removal of burrs from pipes.
Table 1 Four-bar linkage dimensions

r1

(a)

r2

r3

r4

r5

dimension 22.2 cm 10 cm 20.6 cm 23.3 cm 30.6 cm

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R.C. Soong and S.L. Wu: Design of Variable Coupler Curve Four-bar Mechanisms.

20
Angular displacement of the driving link (degree)

The quarter circle with diameter(r5-r2)

45

The quarter circle with diameter(r5+r2)

40

Desired circle curve

Desired ellipse coupler curve
Desired square coupler curve

35
30
25
20
15
10
5
0

-20

-40

-60

-80

10
15
20
25
30
35
40
The X coordinate of the desired coupler curves(cm)

45

Example 1
Example 2
Example 3

-100

-120

10

50

20
30
40
50
60
The number of points on the coupler curve

70

80

Fig. 6. The required angular displacement of the

driving link for all examples

Fig. 4. The desired coupler curves for examples

Example 1.
Generation of a circular coupler curve with the
center at (25, 18.5) and radius = 8.5 cm, as shown in
Fig. 4.
Example 2.
Generation of an elliptical coupler curve with the
center at (25, 18.5), long axis = 10 cm, and short axis
= 6 cm, as shown in Fig. 4.
Example 3.
Generation of a square coupler curve with four
vertexes p1 (17.5, 22.5), p2 (17.5, 13), p3 (27.5, 13),
and p4 (27.5, 23), as shown in Fig 4.

12
The length-adjustable magnitude of the link 1 (cm)

The Y coordinate of the desired coupler curves(cm)

50

Figure 5 shows the desired coupler curves

generated for all examples and Fig. 6 shows the
required angular displacements of the driving link
corresponding to the desired coupler curves. Figures
7 and 8 show the required lengths of links 1 and 4,
respectively, corresponding to the desired coupler
curves for all examples.

Example 1
Example 2
Example 3

10

-2
0

10

20
30
40
50
60
The number of points on the coupler curve

70

80

Fig. 7. The length-adjustable magnitude of the link

1 for all examples
2
The length-adjustable magnitude of the link 4 (cm)

30

Y coordinate of coupler point (cm)

Example 1
Example 2
Example 3
25

20

15

10

1
0
-1
-2
-3
-4
-5
-6
-7
-8

5
10

15

20
25
30
X coordinate of coupler point (cm)

35

40

Fig. 5. The desired coupler curves in all examples

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Example 1
Example 2
Example 3
0

10

20
30
40
50
60
The number of points on the coupler curve

70

80

Fig. 8. The length-adjustable magnitude of the link 4

for all examples

1 Experimental Setup
Figure 9 shows the schematic of a planar
PC-based controlled variable coupler curve four-bar
mechanism used in our experiments. The setup
included the four-bar mechanism, two AC
servomotors with encoders and drivers, and a belt.
One AC servomotor was used to control the angular
displacement of the driving link while the other drove
the screw to adjust the length of link 1
simultaneously.
The hardware specifications of the control system
were as follows:
(1) Intel Pentium IV 400-MHz microcomputer
with 512 MB RAM;
(2) Motion control card (PCI-8164; Adlink
Technology, Inc.);
(3) AC servomotors (400 W; Mitsubishi Co.) and
drivers (MR-J2S-A; Mitsubishi Co.); and
(4) Incremental encoder (10,000 pulses per
revolution).

20

Command
Actual

-20

-40

-60

-80

-100
0

10

15

20

25

30

35

Time (s)

(a) Angular displacement of the driving link

The length-adjustable magnitude of the link 1 (cm)

EXPERIMENTS

The angular displacement of the driving link (degree)

J. CSME Vol.30, No.3 (2009)

12
Command
Actual

10

10

15

20

25

30

35

Time (s)

(b) The length-adjustable magnitude of the link 1

28

2 Implementation
Three experiments corresponding to the examples
listed in Section 6 were conducted, but only link 1
was adjusted. The desired (command) and actual
coupler curves, the angular displacement of the
driving link, and the corresponding length of link 1
are shown in Figs. 10, 11, and 12, respectively. The
experimental results in this section agreed with the
design results in Section EXAMPLES. These
examples and experiments thus confirm the practical
feasibility of the proposed design method.

Y coordinate of coupler point (cm)

26

Fig. 9. The variable coupler curve mechanism

24
22
20

Command
Actual

18
16
14
12
10
16

18

20

22

24

26

28

30

32

34

X coordinate of coupler point (cm)

(c) The coupler curves

Fig. 10. The experimental results of the Example 1
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The angular displacement of the driving link (degree)

The angular displacement of the driving link (degree)

R.C. Soong and S.L. Wu: Design of Variable Coupler Curve Four-bar Mechanisms.

40
20
Command
Actual

0
-20
-40
-60
-80
-100
-120
0

10

15

20

25

30

Command
Actual

-20

-40

-60

-80

-100

-120
0

35

The length-adjustable magnitude of the link 1 (cm)

The length-adjustable magnitude of the link 1 (cm)

14
12
Command
Actual

8
6
4
2
0
-2
-4
0

10

15

12

14

20

25

30

10

Command
Actual

-2
0

35

10

12

14

Time (s)

Time (s)

(b) The length-adjustable magnitude of the link 1

(b) The length-adjustable magnitude of the link 1

24

26

Y coordinate of coupler point (cm)

24

Y coordinate of coupler point (cm)

10

(a) Angular displacement of the driving link

(a) Angular displacement of the driving link

10

Time (s)

Time (S)

22
20
Command
Actual

18
16
14

22

20
Command
Actual

18

16

14

12

12

10
10

15

20

25

30

35

40

16

18

20

22

24

26

28

30

X coordinate of coupler point (cm)

X coordinate of coupler point (cm)

(c) The coupler curves

(c) The coupler curves

Fig. 11. The experimental results of the Example 2
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Fig. 12. The experimental results of the Example 3

J. CSME Vol.30, No.3 (2009)

CONCLUSIONS
The proposed approach was based on a variable
coupler curve four-bar mechanism in which one link
was replaced by a screw-nut link driven by a
servomotor. The different desired couple curves could
be generated by controlling the angular displacement
of the driving link and changing the length of the
adjustable link. The derivations of the adjustable link
length and the specified angular displacement of the
driving link corresponding to the desired coupler
curves were presented along with the conditions
required to achieve the desired generable coupler
curves. The examples and experiments confirmed the
feasibility of this design method, which is suitable for
cases that require several different coupler curves
within a specific area for practical applications.

ACKNOWLEDGMENT
This research was supported by the National
Science Council Taiwan, R.O.C, through the grant
NSC 94-2212-E-244-003.

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R.C. Soong and S.L. Wu: Design of Variable Coupler Curve Four-bar Mechanisms.

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