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Introduction
SVAJ Diagrams
Double Dwell CAM Design
Sizing CAM
Sizing Follower Spring
Practical Design Considerations
1
Introduction
• Many applications, automotive, automated
manufacturing processes
• Easier to design than a linkage for the same
task but more expensive to make
– Cams are a form of four-bar mechanism
• Design can be very compact
• Requires lubrication for long life
2
Two Types of Followers Force and Form Closure
A forced closed joint can only push With form closure external force is not required
Spring must be sized to supply return force But more complex to make
5
Cam Design Process
• Design profile
• Size cam and follower
• Size spring
6
Cam Development
Displacement diagram
Design profile
Wrap it around cam
7
Types of CAM Profiles
• Rise-fall
• Rise-fall-dwell
• Rise-dwell-fall-dwell (double dwell)
• Critical path motion
– Follow exact path
– Constant velocity
8
S V A J Diagrams
S-Displacement
V-Velocity
A-Acceleration
J-Jerk
9
Example: Double Dwell
• 0-90 degrees – dwell at 0 mm
• 90-180 degrees – rise to 25 mm
• 180-270 degrees- dwell at 25 mm
• 270-0 degrees – return to 0 mm
25
Velocity
Acceleration
Jerk
12
Design 2: Simple Harmonic Motion
(still a bad choice)
h
s 1 cos
2
h
v sin
2 High
dwell
2 h section
a 2 cos
2
∞
3 h
j 3 sin
2 90
∞
Rise section of cam
1
s h sin 2
2
h
v 1 cos 2 High
dwell
section
h
a=2 sin 2
2
h
j=4 2 cos 2 90
3
16
Example
h 25mm, 90 , 45
1
s h sin 2
2
h
v 1 cos 2
h
a=2 sin 2
2
h
j=4 2 cos 2
3
17
18
Converting from Angular to Linear Motion
Motion profiles expressed in terms of cam rotation
s s , v v , a a , j j
d
if =
dt
t
s t s t
Therefore
ds ds d
v t v t
dt d dt
Similarly
a t 2 a t
j t 3 j t
19
Motion Profiles in Terms of Cam Angle Motion Profiles in Terms of Time ω2=10 rad/sec
s t s t
v t v t
a t 2 a t
j t 3 j t
20
Beyond Cyclodal Displacement Functions
• Cyclodal displacement functions meet the continuity
requirements for cam design but still have discontinuous
jerk functions and may produce higher accelerations and
velocity than necessary
• Cam designers have come up with many different
displacement functions that trade-off between peak
velocity, acceleration and jerk
• It is important to optimize these quantities in your design
by examining your SVAJ diagram in the context of your
design requirements
• Polynomial spline functions offer greatest design flexibility
• Not required for this course
21
Comparison
Max Max Max
Function Comments
Vel. Accel. Jerk
Constant Infinite jerk not
2.0h/β 4.0h/β2 infinite
accel. acceptable
Harmonic Infinite jerk not
1.6h/β 4.9h/β2 infinite
disp. acceptable
Cycloidal Smooth accel. cont.
2.0h/β 6.3h/β2 40h/β3
disp. jerk
Trap.
2.0h/β 5.3h/β2 44h/β3 Low accel, rough jerk
accel.
Mod.
Low vel
Trap. 2.0h/β 4.9h/β2 61h/β3
Good accel, rough jerk
accel.
3-4-5
poly. 1.9h/β 5.8h/β2 60h/β3 Good compromise
disp.
4-5-6-7
poly. 2.2h/β 7.5h/β2 52h/β3 Smooth jerk high accel
disp.
23
Some Definitions
Rule of thumb
35 roller follower
Offset is sometimes used to reduce pressure angle
3/2
R s 2 v 2
p Rule of thumb
pitch
Rp s 2v 2 a Rp s min at least 2-3 times roller radius
2
d R 2p 2
RAO2 iˆ d s ˆj
28
Cusp or Undercut Due to Oversized Roller
Pitch curve
29
Example
• Cyclodal rise of 25 mm in 90 degrees
• Calculate position, velocity, acceleration at θ=45 degrees
• Find prime circle and offset such that pressure angle at
θ=45 degrees is less than 30 degrees
• Calculate curvature at θ=45 degrees
v 3/2
R s 2 v 2
tan 1
pitch
p
s R p2 2
Rp s 2v 2 a Rp s
2
30
v
tan 1
s R p2 2
3/2
R s 2 v 2
pitch p
Rp s 2v 2 a Rp s
2
31
CAM Example
• Low dwell
– beta1 = 60.0 deg
– h1 = 0.0 mm
• Rise
– beta2 = 180.0 deg
– h2 = 9 mm
• High dwell
– beta3 = 20.0 deg
– h3 = 9mm
• Fall
– beta4 = 90.0 deg
– h4 = - 9 mm
SVAJ Diagram
SVAJ Plots SVAJ Plots in Time Domain
10 0.01
8 0.008
6 0.006
S (mm)
S (m)
4 0.004
2 0.002
0 0
0 1 2 3 4 5 6 0 1 2 3 4 5 6
(rad) (rad)
10 0.1
5
0.05
V (mm/rad)
V (m/s)
0
-5
-0.05
-10
-15 -0.1
0 1 2 3 4 5 6 0 1 2 3 4 5 6
(rad) (rad)
40 1
20 0.5
A (mm/rad2)
A (m/s 2)
0 0
-20 -0.5
-40 -1
0 1 2 3 4 5 6 0 1 2 3 4 5 6
(rad) (rad)
100 40
50 20
J (mm/rad3)
J (m/s3)
0 0
-50 -20
-100 -40
0 1 2 3 4 5 6 0 1 2 3 4 5 6
(rad) (rad)
20
10
Pressure Angle (deg)
Pitch Curve
0
-10
15
-20
10
-30
-40 5
0 1 2 3 4 5 6
(rad)
mm
Radius of Curvature 0
100
80
-5
60
40
Radius of Curvature (mm)
-10
20
0
-15
-20
-40
-15 -10 -5 0 5 10 15
-60 mm
-80
-100
0 1 2 3 4 5 6
(rad)
Rp = 15 mm, e = 0 mm;
Pressure Angle
20
10
0 Pitch Curve
Pressure Angle (deg)
-10 20
-20 15
-30
10
5
-40
0 1 2 3 4 5 6
(rad)
mm
Radius of Curvature 0
150
-5
100
-10
Radius of Curvature (mm)
50
-15
0
-20
-50
-20 -15 -10 -5 0 5 10 15 20
mm
-100
-150
0 1 2 3 4 5 6
(rad)
Rp = 20 mm, e = 0 mm;
Pressure Angle
15
10
5
Pitch Curve
0
Pressure Angle (deg)
-5
25
-10 20
-15 15
-20
10
-25
5
-30
mm
0 1 2 3 4 5 6 0
(rad)
-5
Radius of Curvature
200 -10
150 -15
100 -20
Radius of Curvature (mm)
50 -25
0 -20 -10 0 10 20
mm
-50
-100
-150
-200
0 1 2 3 4 5 6
(rad)
Sizing Follower Spring
37
Modeling Follower as a 1DOF Spring Mass System
• Mass, m, includes all mass attached to the follower including a portion of the spring
• Stiffness, k, is the stiffness of the spring. The cam shaft and frame are assumed to be
infinitely stiff.
• Damping, C, is generally not deliberately added and is typically small.
mx cx kx Fc t
k
Natural Frequency (rad/sec) n
m
Spring stiffness (N/m) k Damping (N/m/s) c 2mn
Mass (kg) m Steady state response x X f sin f
Damping ratio (0.05-0.1)
Forcing frequency (rad/sec) f Xf 1
Amplitude ratio
F0 2 2
k f f
2
1 2
n n
2 f
n
Most important! Phase angle tan 1 2
1 f
n
40
Amplitude Ratio and Phase Angle
f
Ideally 0.1
n
41
Kineostatic Approach for Selecting
Spring Constant
Pre-load
mx cx k x x0 Fc t
m determined via follower selection
c estimated based on damping coeficent
x, x, x from motion profile
k , x0 selected so that Fc t positive
f
check 0.1
n
42
Example
• Cyclodal rise of 25 mm over 90 degrees
• Cam speed = 100 rad/sec
• Damping ratio = 0.06
• Mass = 0.5 kg
• Find spring stiffness and preload
43
Solution
1 s t s t
s h sin 2
2 Find
h v t v t Fc t ma cv k s s0
v 1 cos 2
a=2
h a t 2 a t Constraints
sin 2
2
Fc t 0.0
f
0.1
j=4 2
h
cos
2 j t 3 j t n
3
44
Too small!
Iteration 1
45
Marginal
Iteration 2
46
Practical Considerations
Translating vs Pivoting Follower
• Provides true straight line motion
• More difficult and expensive to design slider
• More friction
Force vs Form-Closed
• Force closed less expensive since there is one not
two cam surfaces to design and manufacture
• Form-closed suffer from crossover shock when
follower moves from one side of groove to the
other
• Force closed must have properly designed spring
47
Practical Considerations
Roller vs Flat-faced Follower
• Rollers are readily available, inexpensive and require
less lubrication
• Rollers can accommodate concave profiles
• Flat faced followers must be custom made and require
copious lubrication but are more compact.
To Grind or Not to Grind
• Cams are first milled and then often ground
• Milling produces inferior surface finish and can only be
used on steels with low to medium hardness
• Grinding produces a smoother surface and can be used
on steels that have been harden
48
Learning Outcomes for Cam Design
• Design cyclodal cam profile in angular and
time domain
• Awareness of other cam profiles
• Size cam and follower
• Size spring and preload
49