6-Bar Linkage Mechanism For Hopper Tipper Hoisting

Manohar M Hegde
Introduction
Hopper Tippers are used for carrying material and then to transfer to another vehicle.
Small hopper tipper vehicles are very popular in urban areas for garbage clearance work,
and are used extensively to transport collected garbage over short distances and then reload into the bigger compactor trucks. Fig-1

a. Typical Hopper Tipper

b. Tipper dumping into a Garbage Compactor Truck

Fig-1 Hopper Tipper and Its Usage

Unlike the normal truck tipper where the material is dumped on the ground, a Hopper
Tipper is used to dump material into another container and hence the dumping height in
a Hopper Tipper is almost at the same height as the top edge of its load body. Fig-2.

a. Typical Truck Tipper

b. Hopper Tipper
Fig-2 Truck Tipper and Hopper Tipper

.
Hoisting of the tipper body during dumping is accomplished by hydraulic cylinders. Due to
the fact that the edge of the load body during dumping needs to be at much higher level
in a Hopper Tipper, the hinge pin level of the load body also needs to be at a much
higher level.
There are two aspects of this :
1. During dumping, the load body of a Hopper Tipper has to tilt by about 80-85
compared to about 45-50 in case of a normal truck tipper in order to completely empty
the material body,Fig-3, and,
2. The hydraulic cylinder needs to have a long stroke to hoist the material body to the
required height.

a. Typical Truck Tipper Dumping Action

b. Hopper Tipper Dumping Action
Fig-3 Comparison of Dumping Actions

4-Bar linkage mechanism is the most preferred arrangement to hoist a Hopper Tipper
load body, mainly due to its simplicity. Hydraulic cylinder acts as a sliding pair. Most
commonly used arrangement of linkage in todays Hopper Tipper is shown in Fig-4

a. 4-Bar Mechanism in Normal Condition

b. 4-Bar Mechanism During Dumping

Condition
Fig-4 Usage of a 4-Bar Mechanism for Hopper Tipper Hoisting

Engineers while designing the hoisting system for a Hopper Tipper have to meet multiple
objectives. One such objective is to limit the maximum cylinder length within target value.
Another objective is to avoid high concentration of forces and stresses. Although a 4-Bar
linkage can very well meet the basic functionality of hoisting the load body, and is most
commonly used as well, there are situations when design engineers find it inadequate to
meet the above mentioned specific design objectives. The configuration of the 4-Bar
linkage currently used in most of the Hopper Tippers is not optimised, and results in fairly
long cylinder stroke. For example, one popular model of a smallest Hopper Tipper in the
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market has a minimum cylinder length of about 680mm and extended length of about
1030mm.
Hence, alternative configurations of hoisting arrangement are desirable for linkage
optimisation.
In this article, 2 alternative arrangement of 4-Bar linkage are evaluated with respect to
two criteria, namely, 1). maximum length of the hydraulic cylinder, and, 2). maximum
reaction force on the load body hinge pin. The results are compared with the values
obtained on existing 4-Bar arrangement. Further, a 6-Bar mechanism is designed and
evaluated, and the results compared with the values obtained on existing and alternative
proposals of 4-Bar mechanisms.
Existing 4-Bar mechanism and also alternative 4-Bar arrangement are shown in Fig-5

a. Existing

b. Alternative-1
c. Alternative-2
Fig-5 Existing and Alternative 4-Bar Mechanisms

Problem Statement
A very common objective during product design stage is to achieve the most compact
equipment size possible. When hydraulic cylinders are used for tipper hoisting, shorter
cylinder lengths are preferred. This will result in efficient packaging. This will also
improve ease of assembly and ease of maintenance. Tippers are generally used in
outdoor atmosphere, and hence are subjected to a lot of wear and tear. The pin joints
used in a tipper mechanism are prone to rapid wear which leads to quicker failures of
these joints. The maximum load on the pin and the amount of rotation are the major
factors affecting the rate of wear. In a typical tipper hoisting mechanism, several pins are
used (body hinge pin, cylinder anchor pins,etc) but the body hinge pin is the one which
goes through the maximum rotation( 80-85 in case of Hopper Tippers). Hence, design
engineers have to look for ways of keeping the static loads on the rotating pins,
especially the load body hinge pin as low as possible in order to improve the life of the
pins. This article focuses on the ways of reducing the force on the load body hinge pin.
Methodology
The location of the Center of Gravity (C.G.) of the loaded body was estimated based on
the shape of the load body and type of material it carried. (Generally, urban refuse will
have comparatively lesser density, and this needs to be taken into account while
estimating the location of C.G.). The total load during hoisting (payload and weight of the
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load body) was taken as acting through this C.G. Kinematic model of the hoisting linkage
mechanism was set-up, and the design parameters were arrived at by iterations, to
achieve the desired tipper body rotation. A total rotation of 85 was considered for the
load body during hoisting, and the instantaneous values of length of the hydraulic
cylinder(L) and vertical position of C.G.(H) were determined with respect to the angular
orientation () of the load body using kinematic relationships. Once the linkage
dimensions were achieved, force analysis was carried out to determine the pin forces and
the cylinder force.
The methodology was verified by calculating the minimum and maximum cylinder
lengths of an existing popular Hopper Tipper (using measured lengths of its links) and
then comparing these values with the actual cylinder minimum and maximum lengths
measured. Calculation of hinge pin force was then carried out to establish the reference
value.
The main objective of the investigation was to seek an alternative 4- Bar linkage
mechanism resulting in lower levels of load body hinge pin force, while meeting the
kinematic requirement (continuous movement of the load body with respect to the
cylinder stroke). Secondary objective was to have shorter cylinder lengths.
In addition, feasibility of using a 6-Bar mechanism, and the pros and cons of the same
are also investigated.

Analysis of existing 4-Bar linkage

Fig-6 shows Hopper Tipper load body during normal and dumping conditions, and the
corresponding orientations of the 4-Bar hoisting mechanism.

a. Hopper Tipper in Normal

b. Orientation of 4-Bar Mechnaism Used for Hoisting
and Dumping Conditions
Fig-6 4-Bar Mechanism Analysis Scheme
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The following parameters, obtained from the measurement of an existing Hopper Tipper,
were used for the analysis of existing 4-Bar mechanism :
Sl
No
1
2
3
4
5
6

10
11

Parameter
Total weight of body with material

Symbol

Value

Unit

W LB

500

Kgs

0-85

Degrees

H1

(-50)

mm

Dependent variable

H2

(1100)

mm

Dependent variable

1110

mm

Fixed design parameter

xc

85

mm

Primary design parameter

yc

240

mm

Primary design parameter

575

mm

Secondary design
parameter

870

mm

Secondary design
parameter

Angular orientation of load body from

normal position
Initial position of CG from hinge pin
level
Final position of CG from hinge pin level
Distance between CG and body hinge
pin (C.G. moment arm)
Dimension Horizontal distance
between body hinge pin and cylinder
anchor point on chassis
Dimension - Vertical distance between
body hinge pin and cylinder anchor
point on chassis
Dimension - Side of the triangle formed
between C.G., body hinge pin and
cylinder force application point on the
load body.
Dimension - Side of the triangle formed
between C.G., body hinge pin and
cylinder force application point on the
body.
Application Force in the hydraulic
cylinder required to hoist load body
Reaction Force in the hinge pin of the
load body.

Remarks
Fixed design
parameter(Input)
Design parameterIndependent variable

Fc

Calculated (Output)

Fr

Calculated (Output)

Table-1
Mathematically, cylinder stroke, cylinder force and pin reaction force are represented as:
L= (,xc,yc,R,b,c) ;

Fc = (W LB,L,,xc,yc,R,b,c) ;

Fr = (WLB,Fc,L,xc,yc,R,b,c)

The steps involved in calibrating the calculations are as follows :

1. Measure and record the linkage dimensions, dimensions of the load body, minimum
and maximum cylinder lengths during normal and dumping conditions.
2. Using the measured values calculate the theoretical minimum and maximum lengths
of the cylinder (Lmin, Lmax)
3. Check if the calculated values of Lmin and Lmax match with the measured values.
4. Once the calculation has been verified with the actual measured values, then, using
the weight of the loaded body acting at the CG as input, carry out force resolution in the
linkages to calculate the cylinder force and force at the load body hinge pin.
For the example taken, the comparison between the measured and calculated values of
cylinder lengths are given below :
Sl No
1
2
3

Parameter
Minimum length of the cylinder, mm
Maximum length of the cylinder, mm
Maximum Hinge pin force, N
Table-2
5

Measured value
680
1030
Not applicable

Calculated value
684
1028
30518

The comparison shows that the methodology used for kinematic analysis is appropriate
for the given purpose.
Variation of load body hinge pin reaction force with respect to the rotation of the load
body is shown in the graph Fig-7:
35000
30000

Force ,N

25000
20000
15000
10000
5000
0
0

20

40

60

80

100

Load Body Tilt in Degrees

Fig-7 Variation of Resultant Hinge Pin Force With Respect to Load

Body Rotation

Synthesis of new 4-Bar linkages and their analysis :

Keeping the basic arrangement of link elements same, by changing the cylinder
connection points two alternative 4 bar linkage arrangements were arrived at for
evaluation.Fig-8

a. Existing
a. Alternative-1
b. Alternative-2
Fig-8 Existing and Proposed Alternative 4-Bar Linkage Mechanisms

The synthesis and analysis of new mechanisms were carried out as given below :
1. Parameters Xc and Yc were changed to move the anchor point of the cylinder.
Similarly, keeping R and the relative position of C.G. in the load body
same,parameters b and c were changed to alter the connection point of the cylinder
with the load body.
2. For each set of the above parameters, cylinder minimum and maximum lengths
were calculated to achieve 85 rotation of the load body.
3. Kinematic compatibility, like the ratio and/or difference between minimum and
maximum cylinder lengths, minimum and maximum angles between adjacent
links,etc, was considered.
4. By iteration, two feasible sets of parameters satisfying the kinematic compatibility
were arrived at(Alternative-1 and Alternative-2).
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5. Force resolution was carried out for the final configurations to arrive at the cylinder
force and the load body hinge pin force

The results were compiled in the following table :

Sl
No
1
2
3

Parameter

Existing
(calculated)
Minimum length of the cylinder, mm
684
Maximum length of the cylinder, mm
1028
Maximum Hinge pin force, N
30518
Table-3

Alternative-1

Alternative-2

591
1014
10963

271
420
36898

Variation of load body hinge pin reaction force with respect to the rotation of the load
body is shown in the graph.Fig-9 :

30000
20000
10000
0
0

50

100

Fig- 9

40000
30000
20000
10000
0
0

Load Body Tilt in

Degrees

Existing 4-Bar Linkage

12000
10000
8000
6000
4000
2000
0

Force ,N

Force ,N

Force ,N

40000

50

100

Load Body Tilt in

Degrees

Alternative-1,4-Bar Linkage

50

100

Load Body Tilt in

Degrees

Alternative-2, 4-Bar Linkage

Comparison of Variation of Hinge Pin Force with Respect to Load Body Rotation

Synthesis of a new 6-Bar linkage and its analysis :

A 6-Bar linkage was conceived for adaptation, considering functionality, simplicity of
kinematics and space utilisation.

a. Watt II Mechanism

b. Adaptation on Vehicle
Fig -10

c. Kinematic Representation and

Analysis Scheme
6-Bar Mechanism Analysis Scheme

Synthesis of a 6-Bar linkage to suit an application is more challenging since the number of
design variables required for the solution are more. Keeping this in mind, a standard Watt II
type linkage was adapted for this application.
The increased complexity of analysis is reflected in the mathematical expression for cylinder
stroke, cylinder force, and pin reaction force :
L= (,xc,yc,xp,yp,R,b,c,l,m,n,p) ;

Fc = (W LB,L,,xc,yc, xp,yp,R,b,c,l,m,n,p)

Fr = (W LB,L,,xc,yc, xp,yp,R,b,c,l,m,n,p)
A brief description of mechanism synthesis and analysis procedure is given below :
1. A standard Watt II linkage is adapted. The mechanism consists of 2 ternary links,one
binary link and a sliding pair(hydraulic cylinder), and the machine chassis forming the
common fixed link. Fig-10. Parameters Xc ,Yc ,Xp and Yp were decided on the basis
of space available on vehicle chassis for the fixed hinges. Similarly, keeping R and
the relative position of C.G in the load body same,parameters b and c were changed
to alter the connection point of the cylinder with the load body.
2. For each set of the above parameters, cylinder minimum and maximum lengths were
calculated to achieve the required 85 rotation of the load body.
3. Kinematic compatibility, like the ratio and/or difference between minimum and
maximum cylinder lengths, minimum and maximum angles between adjacent
links,etc were ensured.
4. By iteration, two feasible sets of parameters satisfying the kinematic compatibility
were arrived at.
5. Force resolution was carried out for the final configuration to arrive at the cylinder
force and the hinge pin reaction force
Variation of load body hinge pin reaction force with respect to the rotation of the load
body when a 6-Bar linkage is adapted is shown in the graph. Fig-11 :

25000

Force ,N

20000
15000
10000
5000
0
0

20

40

60

80

100

Load Body Tilt in Degrees

Fig-11

6-Bar Linkage. Variation of Resultant Hinge Pin Force with Respect to

Load Body Rotation

Result :
The results of the 4-Bar and 6-Bar linkage were compiled in the following table :
Sl
Parameter
Existing 4-Bar Alternative-1
No
(calculated)
4-Bar
1 Minimum length of
684
591
the cylinder, mm
2 Maximum length of
1028
1014
the cylinder, mm
3 Maximum
hinge
30518
10963
pin force, N
Table-4

Alternative-2
4-Bar
271

Alternative-3
6-Bar
255

420

432

36898

21383

Discussion :
There are several ways in which a 4-Bar linkage can be used to accomplish the task of
hoisting a load body in a Hopper Tipper. The two alternative linkage arrangement proposed
are found to be functionally satisfactory (hoisting to a rotation of 85). However, looking at
the tabulated results and the performance graphs, it is clear that design engineers who want
to meet the twin objectives of compact cylinder size and lower hinge pin reaction force will
have to compromise on at least one of them. Hence, exploring other options, like a 6-Bar
linkage arrangement for hoisting is desirable. In this investigation only one arrangement of a
6-Bar linkage to replace the 4-Bar linkage was studied. Comparing the results of analysis
with those of 4-Bar linkages, it is evident that, both the design goals could be achieved with
a 6-Bar linkage. It may be noted here that, prima-facie, a 6-Bar linkage has more number of
parts, and hence costs more compared to a 4-Bar linkage. However, two aspects of a 6-Bar
linkage still make it worth considering as an option 1). possibility of optimising the link sizes
to achieve shorter cylinder sizes and lower pin forces compared to what has been shown in
this article, and,2). to use variants of the 6-Bar linkage to make the Hopper Tipper versatile.

Conclusion :
1. Most popular Hopper Tippers used today have 4-Bar linkage with hydraulic cylinder for
load body hoisting. Although the linkage arrangement is functionally adequate, it
results in longer cylinder and also higher hinge pin reaction force. .
2. Out of the two alternative 4-Bar linkages considered, one (alternative-1) achieves a
reduced hinge pin reaction force, using almost same cylinder length as the existing
arrangement.
3. The second alternative gives the most compact packaging arrangement due to shorter
cylinder, but results in much higher hinge pin reaction force..
4. A 6-bar linkage arrangement results in shorter cylinder length as well as lower hinge
pin reaction force. But, on the flip side,a 6-Bar arrangement requires more number of
components..
5. Scope for further study - 1). A careful optimisation study can result in even more
efficient design - occupying lesser space, shorter cylinder length and lesser pin
reaction force. 2). Development of variants of 6-Bar mechanisms to use in Hopper
Tippers targeting new applications.