Actuation Systems

Mechanical Actuators
 Mechanism
A mechanism is a set of mechanical elements within a mechanical system
(machine) that functions as a motion converter, transforming motion or force from
one form into another to satisfy a specific functional requirement.
Example:
• Mechanical system: Combustion Engine
• Mechanism Example: Slider-crank, belt drive
• Slider-crank Function: Converts reciprocating (linear up–down)
motion of the piston into rotary motion of the crankshaft.
• Belt-drive function: Transfers rotary motion from the crankshaft to
the camshaft, ensuring synchronized valve and piston movement.

Cut-away view of a Chrysler 2.2 liter four-cylinder engine

Source: [Link]
Mechanical Elements
Links and Joints

Link: A link is a rigid or resistant body that connects with other bodies (via joints) to
form a kinematic pair to transmit motion and force.
A link maybe a single part (e.g. rod, lever) or multiple components rigidly fastened
together.

Types of links based on rigidity:

Rigid, Flexible and Fluid
Types of Link based on Rigidity
Rigid link: A link that does not deform under load; the distance between any two
points on the link remains constant.
Examples: Crank, connecting rod, piston rod etc.

Flexible link: A link that can transmit motion or force only in tension (pull) or
compression (push), but not in bending.
Examples: belt, chain (tension only), rope, cable, wire
 Types of Links based on number of joint
connections
Links can be classified based on the number of joints they connect to in a
mechanism.
1) Binary Link: A link that connects to two other links through two joints.
Example: Connecting Road

Source: [Link]
 Types of Links based on number of joint
connections
2) Trenary Link: A link that connects to three other links through three joints.
Example: Watt mechanism, application of wrist brace

Source: Kinematic synthesis of Stephenson III six-bar function generators

 Types of Links based on number of joint
connections
3) Quaternary Link: A link that connects to four other links through four joints.

Source: [Link]
 Kinematic Pairs
When two kinematic links are connected in such a way that their motion is either
completely or successfully constrained, these two links are said to form a kinematic pair.
The kinematic pairs can be classified as follows:
1) According to nature of contact
i. Lower Pair
ii. Higher Pair
2) According to nature of Mechanical Constraints
i. Closed Pair
ii. Unclosed Pair
3) According to Nature of Relative Motion
i. Sliding Pair
ii. Turning Pair
iii. Rolling Pair
iv. Screw Pair
v. Spherical Pair

[Link]
 Kinematic Pairs According to nature of contact
Lower Pair: A lower pair is a kinematic pair in which the two elements have surface
(area) contact with each other, and relative motion takes place over the entire surface.

Example: Shaft rotating in a bearing (revolute pair), bolt and nut (screw pair), prismatic
pair

Source: [Link] [Link]

[Link]
 Kinematic Pairs According to nature of contact
Higher pair: A higher pair is a kinematic pair in which the two elements have point
contact or line contact with each other, and relative motion occurs at that contact.

Example: ball bearing, toothed gearing

Source: [Link]
 Kinematic Pairs According to nature of Mechanical
Constraints
Closed Pair: A closed pair is a kinematic pair in which the two links are held together
mechanically by direct contact or by a fastening arrangement, so that they cannot be
separated without disassembly. All the lower pairs and some of the higher pairs are
closed pairs.

Unclosed Pair: An unclosed pair is a kinematic pair in which the two links are not
mechanically held together. Example: cam and follower,

Source: [Link]
 Kinematic Pairs According to Nature of Relative
Motion
Sliding Pair: A sliding pair is a kinematic pair in which one link slides linearly over
another link, and the two links have surface contact.
Sliding pair has a completely constrained motion.
The sliding path is defined by the shape of the surfaces (usually prismatic or
cylindrical).
Surface contact, one dimensional sliding.
Example: Piston and cylinder

Source: [Link]
 Kinematic Pairs According to Nature of
Relative Motion
Turning Pair: A turning pair is a kinematic pair in which one link turns (rotates)
relative to another link about a fixed axis.
It is a rotational motion. Rotation is restricted to one axis only.
Example: Shaft in bearing, door hinge

Source: [Link]
[Link]
 Kinematic Pairs According to Nature of
Relative Motion
Rolling Pair: A rolling pair is a kinematic pair in which one link rolls over the
surface of another without slipping.
Line or point contact (so it is a higher pair).
Example: Ball and roller bearings

Source:[Link]
 Kinematic Pairs According to Nature of
Relative Motion
Screw Pair: A screw pair is a kinematic pair in which relative motion between
the two links is a combination of sliding and turning, due to the helical threads
on their contact surfaces.
One link turns relative to the other, and at the same time it slides along the
axis of the screw.
Example: Bolt and nut

Source: [Link]
 Kinematic Pairs According to Nature of
Relative Motion
Spherical Pair: A spherical pair is a kinematic pair in which one link has a
spherical (ball) shape that fits into a hollow spherical socket of another link,
allowing rotation in multiple directions.
The ball can rotate inside the socket → 3 degrees of freedom (rotation about X,
Y, and Z axes).
Example: Ball-and-socket joint machinery

Source: [Link]
Joints
Kinematic pair is type of motion relationship between the links at that joint while the
joint is a physical connector.
Examples of joints: Revolute joint, sliding joint, spherical joint.
Joint Types
Types of Joints:
1) Binary Joint: Connects 2 link
2) Ternary Joint: Connects 3 links at a single point
3) Quaternary Joint: Connects 4 links at one point
Examples
• What type of joints do you see?
Degree of Freedom (DOF)
The degree of freedom (DOF) of a system (or link) is the number of independent
parameters (or independent motions) required to completely define its position in
space.
DOF = 6 – Number of Restraints

y
x
A free rigid body can move:
3 translational motions (along X, Y, Z).
3 rotational motions (about X, Y, Z).
Total DOF is 6

z
 DOF
• Examples:

Source: [Link]
Constrains and Freedom
Orientation and arrangement of the elements and parts in the design of mechanical
systems are important aspects. There are two categories of motion:
1) Constrained Motion
2) Unconstrained Motion
 Constrained Motion
• The motion of a link or body is restricted by joints, guides, or other links, so it can only move in a definite
manner.
1) Completely constrained motion: The motion between elements is restricted to only one definite
direction, regardless of how the force is applied.

2) Incompletely constrained motion: The relative motion between

elements can take place in more than one direction,
depending on how the force is applied.

3) Successfully constrained motion: The relative motion could occur

in more than one direction (like incompletely constrained), but an
external force or arrangement ensures only one kind of motion takes place.

Source: [Link]
Kinematic Chain
A kinematic chain is a series of interconnected links and joints that work together to
transfer motion and forces in a mechanical system. Each link acts as a rigid body,
while the joints provide constraints that define the type of relative motion between the
links (e.g., rotation or translation)
The designs of many mechanisms are based on two basic forms of kinematic chains,
the four-bar chain and the slider–crank chain.
Kinematic Chain (Four-Bar Chain)
The four-bar chain consists of four links connected to give four joints about which
turning can occur.
If the sum of the length of the shortest link plus the length of the longest link is less
than or equal to the sum of the lengths of the other two links then at least one link will
be capable of making a full revolution with respect to the fixed link. If this condition is
not met then no link is capable of a complete revolution.
• Case1: Link3 + Link4 > Link1 + Link2 (no full revolution)
• Case2: Link3 + Link4 < Link1 + Link2 (Link4 is capable of rotating)
• Case3: Link3 + Link4 = Link1 + Link2
Kinematic Chain (Slider–Crank)
Link 3 is fixed; Link 1 is crank which is rotate; Link2 is connecting rod and Link4 is the
sider.
Mobility Criteria
• Mobility criteria of a mechanism is calculated using Gruebler-Kutzbach formula.
𝑔𝑔
M = d(n-g-1) + ∑𝑖𝑖=0 𝑓𝑓𝑖𝑖
d: 6 for spatial mechanism, d=3 for planar
n: number of links including the ground link
g: total number of joints
𝑓𝑓𝑖𝑖 : degrees of freedom in joint i
Power Screw/Ball Screw Linear Actuator
• Cutting tools, 3D printer bed move up-down or horizontally, they require straight-line
motions.
• Power screw and balls screw are designed to convert the rotary motion to linear
motion. Low-friction materials or rolling contact elements are used to produce
smooth motion with low power required.

Ball bearing screw

Different power screw threads
Power Screw
Effort to raise or lower a load based on square thread screw type:
F : Load (mg) 𝑑𝑑𝑚𝑚 : pitch diameter
𝑃𝑃𝑅𝑅 : Force requires to raise the load
𝑃𝑃𝐿𝐿 : Force requires to lower the load
l: lead 𝜆𝜆: lead angle
N: Normal reaction on the thread surface
f: friction coefficient
Power Screw Force Calculation
To raise the Load:
Σ𝐹𝐹𝑥𝑥 = 𝑃𝑃𝑅𝑅 − 𝑁𝑁 sin 𝜆𝜆 − 𝑓𝑓𝑓𝑓 cos 𝜆𝜆 = 0
Σ𝐹𝐹𝑦𝑦 = −F − 𝑓𝑓𝑁𝑁 sin 𝜆𝜆 + 𝑁𝑁 cos 𝜆𝜆 = 0

To lower the Load:

Σ𝐹𝐹𝑥𝑥 = −𝑃𝑃𝐿𝐿 − 𝑁𝑁 sin 𝜆𝜆 + 𝑓𝑓𝑓𝑓 cos 𝜆𝜆 = 0
Σ𝐹𝐹𝑦𝑦 = −F + 𝑓𝑓𝑓𝑓 sin 𝜆𝜆 + 𝑁𝑁 cos 𝜆𝜆 = 0
Power Screw Force Calculation
Solution of the second equation for N using the raising load case:

−F − 𝑓𝑓𝑓𝑓 sin 𝜆𝜆 + 𝑁𝑁 cos 𝜆𝜆 = 0

𝑁𝑁 cos 𝜆𝜆 − 𝑓𝑓sin 𝜆𝜆 = 𝐹𝐹
𝐹𝐹
𝑁𝑁 =
cos 𝜆𝜆−𝑓𝑓sin 𝜆𝜆

Substitute N into the first equation:

𝑃𝑃𝑅𝑅 = 𝑁𝑁 sin 𝜆𝜆 + 𝑓𝑓𝑓𝑓 cos 𝜆𝜆
Factor N
𝑃𝑃𝑅𝑅 = 𝑁𝑁 (sin 𝜆𝜆 + 𝑓𝑓 cos 𝜆𝜆)
Substitute N
𝐹𝐹 𝐹𝐹(sin 𝜆𝜆+𝑓𝑓 cos 𝜆𝜆)
𝑃𝑃𝑅𝑅 = (sin 𝜆𝜆 + 𝑓𝑓 cos 𝜆𝜆) => 𝑃𝑃𝑅𝑅 =
cos 𝜆𝜆−𝑓𝑓sin 𝜆𝜆 cos 𝜆𝜆−𝑓𝑓sin 𝜆𝜆
Power Screw Force Calculation
Similar transition for the Force requires to lower the load, 𝑃𝑃𝐿𝐿 :

𝐹𝐹(𝑓𝑓 cos 𝜆𝜆 − sin 𝜆𝜆)

𝑃𝑃𝐿𝐿 =
cos 𝜆𝜆 + 𝑓𝑓sin 𝜆𝜆

l
Divide numerator and denominator by cos 𝜆𝜆 to use the relation tan 𝜆𝜆 =
π𝑑𝑑𝑚𝑚

l l
𝐹𝐹( + 𝑓𝑓) 𝐹𝐹(𝑓𝑓 − )
π𝑑𝑑𝑚𝑚 π𝑑𝑑𝑚𝑚
𝑃𝑃𝑅𝑅 = 𝑃𝑃𝐿𝐿 =
l l
1 − 𝑓𝑓( ) 1 + 𝑓𝑓( )
π𝑑𝑑𝑚𝑚 π𝑑𝑑𝑚𝑚
Power Screw Torque Calculation
Torque required to move a load up :

𝑑𝑑𝑚𝑚 𝐹𝐹𝑑𝑑𝑚𝑚 𝑙𝑙 + π𝑓𝑓𝑑𝑑𝑚𝑚

𝑇𝑇𝑅𝑅 = 𝑃𝑃𝑅𝑅 ⇒ 𝑇𝑇𝑅𝑅 = ( )
2 2 π𝑑𝑑𝑚𝑚 − 𝑓𝑓𝑓𝑓

Torque required to lower a load down:

𝑑𝑑𝑚𝑚 𝐹𝐹𝑑𝑑𝑚𝑚 π𝑓𝑓𝑑𝑑𝑚𝑚 − 𝑙𝑙
𝑇𝑇𝐿𝐿 = 𝑃𝑃𝐿𝐿 ⇒ 𝑇𝑇𝐿𝐿 = ( )
2 2 π𝑑𝑑𝑚𝑚 + 𝑓𝑓𝑓𝑓
 Torque Calculations for Acme Thread
The torque necessary to raise a load:
Divide the equations where 𝑇𝑇𝑅𝑅 and 𝑇𝑇𝐿𝐿 are calculated for square thread
by cos 𝛼𝛼 ;

𝐹𝐹𝑑𝑑𝑚𝑚 𝑙𝑙 + π𝑓𝑓𝑑𝑑𝑚𝑚 sec 𝛼𝛼

𝑇𝑇𝑅𝑅 = ( )
2 π𝑑𝑑𝑚𝑚 − 𝑓𝑓𝑓𝑓 sec 𝛼𝛼

𝐹𝐹𝑑𝑑𝑚𝑚 π𝑓𝑓𝑑𝑑𝑚𝑚 − 𝑙𝑙 sec 𝛼𝛼

𝑇𝑇𝐿𝐿 = ( )
2 π𝑑𝑑𝑚𝑚 + 𝑓𝑓𝑓𝑓 sec 𝛼𝛼
Power Screw Efficiency
The torque needed to raise a load with no friction losses (f = 0):

𝐹𝐹𝑑𝑑𝑚𝑚 𝑙𝑙 + π𝑓𝑓𝑑𝑑𝑚𝑚 𝐹𝐹𝐹𝐹

𝑇𝑇𝑅𝑅 = ( ) , f = 0 => 𝑇𝑇0 =
2 π𝑑𝑑𝑚𝑚 − 𝑓𝑓𝑓𝑓 2𝜋𝜋

The efficiency of the power screw

𝑇𝑇0 𝐹𝐹𝐹𝐹
𝑒𝑒 = =
𝑇𝑇𝑅𝑅 2𝜋𝜋 𝑇𝑇𝑅𝑅
Power Required to Drive the Power Screw
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑁𝑁𝑁𝑁 .𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠[𝑟𝑟𝑟𝑟𝑟𝑟]
• 𝑃𝑃[𝑘𝑘𝑘𝑘] =
9550
Example:
Two Acme-threaded power screws are to be used to raise a heavy access hatch, as
sketched in the Figure. The total weight of the hatch is 12000 kg.
Coefficient of friction is 0.15
Screw diameter is 40 mm
Pitch diameter 36.5mm
Lead is 7mm
Thread angle 𝛼𝛼 = 14.5𝑜𝑜

Find lead angle, 𝜆𝜆,

𝑇𝑇𝑅𝑅 𝑎𝑎𝑎𝑎𝑎𝑎 𝑇𝑇𝐿𝐿
Solution of Lead Angle
Lead angle:
𝑙𝑙
tan 𝜆𝜆 =
π𝑑𝑑𝑚𝑚

7
tan 𝜆𝜆 = = 0.06
π(36.5)
𝐭𝐭𝐭𝐭𝐭𝐭−𝟏𝟏 𝟎𝟎. 𝟎𝟎𝟎𝟎 = 𝟑𝟑. 𝟒𝟒𝟒𝟒𝒐𝒐
Torque Required to Raise the Load
𝐹𝐹𝑑𝑑𝑚𝑚 𝑙𝑙 + π𝑓𝑓𝑑𝑑𝑚𝑚 sec 𝛼𝛼
𝑇𝑇𝑅𝑅 =
2 π𝑑𝑑𝑚𝑚 − 𝑓𝑓𝑓𝑓 sec 𝛼𝛼

F = 58839.9 N, 𝑓𝑓 = 0.15, l = 7mm, 𝑑𝑑𝑚𝑚 = 36.5 𝑚𝑚𝑚𝑚,

Thread angle 𝛼𝛼 = 14.5𝑜𝑜 , sec 14.5 = 1.033

58839.9 (0.0365𝑚𝑚) 0.007𝑚𝑚 + π 0.15 0.0365𝑚𝑚(1.033)

𝑇𝑇𝑅𝑅 =
2 π0.0365𝑚𝑚 − 0.15 0.007𝑚𝑚(1.033)
𝑇𝑇𝑅𝑅 = 233.6469 𝑁𝑁𝑁𝑁
𝑇𝑇𝐿𝐿 = 92.8274 𝑁𝑁𝑁𝑁
Example
It is desired to raise the hatch given in the previous Figure a total of 380 mm no more
than 12 seconds. Compute the required rotational speed for screws and the power
required.

The selected screw has 7 mm per revolution

0.38𝑚𝑚 0.0316𝑚𝑚 1 𝑟𝑟𝑟𝑟𝑟𝑟 60

𝑉𝑉 = = , 𝑛𝑛 = 0.0316 . . = 270.85 𝑟𝑟𝑟𝑟𝑟𝑟
12𝑠𝑠 𝑠𝑠 0.007 𝑚𝑚𝑚𝑚𝑚𝑚

233.65 𝑁𝑁 . 270.85 𝑟𝑟𝑟𝑟𝑟𝑟

𝑃𝑃 = = 6.63 𝑘𝑘𝑘𝑘
9550
Ball Screw
Company THK, link: [Link]
[Link]
Example
When moving an object with a mass of 500 kg using a screw with an effective diameter
of 33 mm and a lead length of 10 mm (lead angle: 50 30’), the required torque is
obtained as follows.
Rolling guide (𝜇𝜇= 0.003) Ball screw (from 𝜇𝜇 = 0.003, 𝜂𝜂= 0.96)
𝐹𝐹𝑎𝑎 : Frictional resistance on the guide surface?
T: Driving torque?

𝐹𝐹𝑎𝑎 = 0.003 . 500 . 9,8 = 14.7𝑁𝑁

14.7 . 10
𝑇𝑇 = = 24 𝑁𝑁𝑁𝑁𝑁𝑁
2𝜋𝜋 . 0.96
Gears
Gears are toothed, cylindrical wheels used for transmitting motion and power from
one rotating shaft to another. The driving teeth push on the driven teeth, exerting a
force perpendicular to the radius of the gear. Thus, a torque is transmitted, and
because the gear is rotating power is also transmitted.
Gear Velocity
𝑣𝑣 = 𝑅𝑅 𝑤𝑤
Pitch line speed for pinion and gear same
For pinion: 𝑣𝑣𝑡𝑡 = 𝑅𝑅𝑃𝑃 𝑤𝑤𝑃𝑃
For gear: 𝑣𝑣𝑡𝑡 = 𝑅𝑅𝐺𝐺 𝑤𝑤𝐺𝐺
𝑤𝑤𝑃𝑃 𝑅𝑅𝐺𝐺
Velocity ratio: 𝑉𝑉𝑉𝑉 = =
𝑤𝑤𝐺𝐺 𝑅𝑅𝑃𝑃

𝑤𝑤𝑃𝑃 𝑅𝑅𝐺𝐺 𝑛𝑛𝑃𝑃 𝐷𝐷𝑃𝑃 𝑁𝑁𝑃𝑃 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑃𝑃

Velocity ratio for gear pair: 𝑉𝑉𝑉𝑉 = = = = = =
𝑤𝑤𝐺𝐺 𝑅𝑅𝑃𝑃 𝑛𝑛𝐺𝐺 𝐷𝐷𝐺𝐺 𝑁𝑁𝐺𝐺 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝐺𝐺
where;
𝑤𝑤: Angular velocity, R: radius of pitch circle, n: rotational speed (rpm),
D: Pitch circle diameter, N:number of teeth, Speed: Linear speed
Example
Figure shows a gear pair in which a 20-tooth pinion drives a 40-tooth gear. The pinion
has an angular velocity of 1000 rpm. Determine the velocity ratio and the angular
velocity of the gear.

Solution:
𝑤𝑤𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜
𝑉𝑉𝑉𝑉 = =
𝑤𝑤𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑁𝑁𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖
40
VR = =2
20
𝑤𝑤𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 1000
𝑤𝑤𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = = = 2𝜋𝜋 500 𝑟𝑟𝑟𝑟𝑟𝑟/60
𝑉𝑉𝑉𝑉 2
Example
Let’s take the gear and place it on the input drive shaft and place the pinion on the
output drive shaft as shown in Figure below. The 40-tooth gear is now the input and
drives the 20-tooth pinion which in now the output. Determine the velocity ratio and
the output angular velocity if the input shaft rotates at 1000 rpm.

Answer:

20 1
VR = =
40 2

𝑤𝑤𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 2𝜋𝜋 2000 rpm / 60

 Example
For the gear train shown in Figure, if the input shaft rotates at 1750 rpm clockwise, compute the
speed of the output shaft and its direction of rotation

Train value: TV = 𝑉𝑉𝑉𝑉1 𝑉𝑉𝑉𝑉2

𝑁𝑁 𝑁𝑁 70 54
TV = 𝐵𝐵 𝐷𝐷 = = 10.5
𝑁𝑁𝐴𝐴 𝑁𝑁𝐶𝐶 20 18

𝑛𝑛𝐴𝐴 1750 𝑟𝑟𝑟𝑟𝑟𝑟

𝑛𝑛𝐷𝐷 = = = 166.7 𝑟𝑟𝑟𝑟𝑟𝑟
𝑇𝑇𝑇𝑇 10.5

Gear A rotates clockwise;

gear B rotates counterclockwise.
Gear C rotates counterclockwise;
gear D rotates clockwise.
Rack and Pinion
The function of such a drive is to produce a linear motion of the rack from the
rotational motion of the driving pinion. The opposite is also true: If the rack is the driver
having a linear motion, it produces a rotational motion of the pinion.
Rack and Pinion
Linear velocity of the rack 𝑣𝑣𝑅𝑅 should be equal to pitch line velocity of the pinion 𝑣𝑣𝑡𝑡 ;
𝑣𝑣𝑅𝑅 = 𝑣𝑣𝑡𝑡 = 𝑅𝑅𝑃𝑃 𝑤𝑤𝑃𝑃 = (𝐷𝐷𝑃𝑃 /2)𝑤𝑤𝑃𝑃

𝐷𝐷 𝑚𝑚𝑚𝑚 𝑛𝑛[𝑟𝑟𝑟𝑟𝑟𝑟] 2𝜋𝜋[𝑟𝑟𝑟𝑟𝑟𝑟] 1[𝑚𝑚𝑚𝑚𝑚𝑚] 1𝑚𝑚 𝜋𝜋𝐷𝐷𝑛𝑛

𝑣𝑣𝑡𝑡 = = 𝑚𝑚/𝑠𝑠
2 [𝑚𝑚𝑚𝑚𝑚𝑚] [𝑟𝑟𝑟𝑟𝑟𝑟] 60 [𝑠𝑠] 1000𝑚𝑚𝑚𝑚 60000
𝐷𝐷𝑃𝑃
Linear displacement 𝑆𝑆𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 = 𝜃𝜃
2 𝑃𝑃
𝜃𝜃𝑃𝑃 : Angular displacement of the pinion
Belt and Pulley System
A belt is a loop of flexible material used to mechanically link two or more
rotating shafts. Belts may be used as
-a source of motion,
-to transmit power efficiently,
-or to track relative movement.
 Kinematics of Belt
𝑃𝑃𝐷𝐷𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑃𝑃𝐷𝐷𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑒𝑒𝑒𝑒
Belt linear velocity: 𝑉𝑉𝑏𝑏 = . 𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = . 𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑒𝑒𝑒𝑒
2 2
𝑃𝑃𝐷𝐷1 𝑃𝑃𝐷𝐷2
𝑉𝑉𝑏𝑏 = . 𝑤𝑤1 = . 𝑤𝑤2
2 2
𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑃𝑃𝐷𝐷𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑁𝑁𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
The angular velocity ratio: 𝑉𝑉𝑉𝑉 = = =
𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑃𝑃𝐷𝐷𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑁𝑁𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

Belt configuration
Kinematics of Belt
The angle of wrap on the driving and
driven sprockets can be found from,
𝑃𝑃𝐷𝐷2 −𝑃𝑃𝐷𝐷1
2
sin 𝜙𝜙 =
𝐶𝐶𝐶𝐶
The angle of wrap on sprocket (1)
𝜃𝜃1 = 180𝑜𝑜 − 2𝜙𝜙

The angle of wrap on sprocket (2)

𝜃𝜃2 = 180𝑜𝑜 + 2𝜙𝜙
Kinematics of Belt
The length of the belt wrap on sprocket 1 and sprocket 2 is the arc length 𝑠𝑠1 and 𝑠𝑠2 .
𝑃𝑃𝐷𝐷1 𝑃𝑃𝐷𝐷2
𝑠𝑠1 = , 𝑠𝑠2 =
. 𝜃𝜃1 . 𝜃𝜃2
2 2
𝑑𝑑 = 𝐶𝐶𝐶𝐶. cos 𝜙𝜙

Belt perimeter length:

𝐿𝐿𝑃𝑃 = 2𝑑𝑑 + 𝑠𝑠1 + 𝑠𝑠2
 Example
A synchronous belt drive system shown in Figure is used as a speed reducer. The input
shaft rotates at 1000 rpm and has a 36-tooth sprocket with a pitch diameter of
9.16cm. The output shaft has a 72-tooth sprocket with a pitch diameter of 18.33cm.
The center distance between the two shafts is 38.12cm.

a) Velocity ratio?
b) The angular velocity of the output shaft?
c) The linear belt speed?
d) The belt wrap on the input and output sprockets
e) The belt perimeter length
Solution
Given :
𝑁𝑁𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 36 𝑃𝑃𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 9.16𝑐𝑐𝑐𝑐 𝑛𝑛𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 1000 𝑟𝑟𝑟𝑟𝑟𝑟
𝑁𝑁𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑒𝑒𝑒𝑒 = 72 𝑃𝑃𝐷𝐷𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑒𝑒𝑒𝑒 = 9.16𝑐𝑐𝑐𝑐 CD = 38.12 cm

𝑁𝑁 72
a) 𝑉𝑉𝑉𝑉 = 𝑁𝑁 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 36 = 2
𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 1000
b) 𝑉𝑉𝑉𝑉 = 𝑤𝑤𝑑𝑑𝑑𝑑𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖
⇒ 2=
𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
⇒ 𝑤𝑤𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 2𝜋𝜋 500 𝑟𝑟𝑟𝑟𝑟𝑟/60
𝑃𝑃𝐷𝐷1 𝑃𝑃𝐷𝐷2 0.0916𝑚𝑚 2𝜋𝜋1000𝑟𝑟𝑟𝑟𝑟𝑟
c) Belt velocity: 𝑉𝑉𝑏𝑏 = . 𝑤𝑤1 = . 𝑤𝑤2 = = 4.795 𝑚𝑚/𝑠𝑠
2 2 2 60
Solution
d) The belt wrap on the input and output sprockets:
𝑃𝑃𝐷𝐷2 −𝑃𝑃𝐷𝐷1 0.1833𝑚𝑚−0.0916𝑚𝑚
sin 𝜙𝜙 = 2
= 2
= 0.12 , 𝜙𝜙 = sin−1 12 = 6.905𝑜𝑜
𝐶𝐶𝐶𝐶 0.3812𝑚𝑚
The angle of wrap on sprocket (1)
𝜃𝜃1 = 180𝑜𝑜 − 2𝜙𝜙 = 166.2𝑜𝑜
The angle of wrap on sprocket (2)
𝜃𝜃2 = 180𝑜𝑜 + 2𝜙𝜙 = 193.8𝑜𝑜
Solution
e) The belt perimeter length:
𝐿𝐿𝑃𝑃 = 2𝑑𝑑 + 𝑠𝑠1 + 𝑠𝑠2
We need to calculate d, 𝑠𝑠1 and 𝑠𝑠2 :
𝑃𝑃𝐷𝐷1 0.0916𝑚𝑚 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋
𝑠𝑠1 = . 𝜃𝜃1 => 𝑠𝑠1 = . 166.2𝑜𝑜 = 0.133 m
2 2 360𝑜𝑜
𝑃𝑃𝐷𝐷2 0.1833𝑚𝑚 2𝜋𝜋𝜋𝜋𝜋𝜋𝜋𝜋
𝑠𝑠2 = . 𝜃𝜃2 => 𝑠𝑠2 = . 193.8𝑜𝑜 = 0.31 m
2 2 360𝑜𝑜

𝑑𝑑 = 𝐶𝐶𝐶𝐶. cos 𝜙𝜙 => 0.3812m (cos 6.905𝑜𝑜 ) = 0.378 m

𝐿𝐿𝑃𝑃 = 2. 0.378 + 0.133 + 0.310 = 1.199 𝑚𝑚