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Design charts based methods for the kinematic synthesis of four-bar function
generators

Chapter · January 2009

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 Design charts based methods for the kinematic
synthesis of four-bar function generators
Ettore Pennestrı̀
Pier Paolo Valentini
Dipartimento di Ingegneria Meccanica
Università di Roma Tor Vergata
00133 Roma - Italy
May 12, 2009

1 Introduction
This paper describes kinematic synthesis procedures by means of design charts.
The use of such tools are traditionally well accepted by industrial designers.
In fact, they usually are reported in manuals and catalogs for the selection of
mechanical components on the basis of input requirements.
The main advantages of design charts are
- visualisation of the entire design space;
- immediate computation of link dimensions and of their variations as a
function of design parameters;
- avoidance of software and/or computing devices;
- possibility to use them through different design paths.
For many design problems, charts are ideally suited to optimum design
whereby the designer can visually survey the range and relationships of di-
mensional parameters.
The methods herein presented are limited to crank-rocker and drag-link four-
bar linkages. For each method the required design charts are included and a
simple numerical example on how to use the charts is provided.
For the first time the classical method of Freudenstein and Primrose [3, 2] is
available in form of design charts and this should increase its use and popularity.
Moreover it is shown the equivalency of results provided by the semi-analytical
method of Volmer, also embodied in the VDI norms [6, 8], and the method of
Freudenstein and Primrose for the optimal design of crank-rocker mechanisms

1
2 Design of crank-rocker linkage with optimum
transmission angle
Purpose: Design a crank-rocker four-bar linkage with a given rocker swing
angle Ψ and corresponding crank rotation 180◦ + θ, such that the maximum
deviation of the transmission angle from 90◦ is minimized.
The charts reported in the following pages have been computed on the basis
of the algorithm originally proposed by Freudenstein and Primrose [3, 2].
The computational steps of this algorithm have been already reported in a
companion paper1 published in this Bulletin . The nomenclature adopted for

B1
B2
b
θ
c
ψ
A1 ψ0
θ0
A0 d=A0 B0 B0
a
A2

Figure 1: Nomenclature. θ is positive when c.c.w.

this problem is shown in Figure 1. One can compute the link length ratios using
the charts shown in
• Figures 2, 4, 6, when θ < 0;
• Figures 3, 5, 7, when θ > 0.
The extreme values µmin and µmax of the transmission angle can be obtained
from the charts shown in:
• Figure 8, when θ < 0;
• Figure 9, when θ > 0.
Example
Determine the crank-rocker optimal proportions of a four-bar linkage with a
1 E. Pennestrı̀, P.P. Valentini, A review of simple analytical methods for the kinematic

synthesis of four-bar and slider-crank function generators for two and three prescribed finite
positions.

2
swing angle of ψ = 40◦ and a crank rotation of 180◦ + θ = 160◦ .
Solution
In this case θ = −20◦ . From the charts reported in Figures 2, 4 and 6 one
readily obtains
a
≈ 0.25 , (1a)
d
b
≈ 0.52 , (1b)
d
c
≈ 0.78 . (1c)
d
The minimum value of the transmission angle (see Figure 8 ) is

µmin ≈ 66◦ .

3
 0.9

−20° θ=−10°
0.8
−30°

0.7
−40°

0.6
−50°

0.5
a
d
0.4
−60°

0.3
−70°
0.2

0.1

0
20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 2: Design of a crank rocker four-bar linkage. Case:θ < 0

4
 1

0.9
+70°

0.8
+60°
+50°
0.7
+40°
0.6
+30°
a
d 0.5
+20°

0.4
θ=+10°
0.3

0.2

0.1

0
20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 3: Design of a crank rocker four-bar linkage. Case:θ > 0

5
 1
θ=−10°

0.9 −20°

−30°
0.8

0.7
−40°

0.6
−50°
b
d 0.5

0.4
−60°

0.3
−70°
0.2

0.1

0
20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 4: Design of a crank rocker four-bar linkage. Case:θ < 0

6
 1.2

1.1

0.9
+20°
θ=+10°
0.8
+50° +40° +30°
0.7
+60°
b
d 0.6
+70°
0.5

0.4

0.3

0.2

0.1

0
20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 5: Design of a crank rocker four-bar linkage. Case:θ > 0

7
 1
−70°
−60°
−50°
−40°
−30°

0.9 −20°

θ=−10°

0.8

c
d

0.7

0.6

0.5
20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 6: Design of a crank rocker four-bar linkage. Case:θ < 0

8
 1.3

1.2

1.1
+70°

1
+60°
c +50°
d 0.9
+40°

+30°
0.8
+20°

0.7
θ=+10°

0.6

0.5
20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 7: Design of a crank rocker four-bar linkage. Case:θ > 0

9
 180
−70°
170 −60°
−50°
160
µmax (deg)

−40°
150 −30°

140 −20°

130
θ=−10°
120
110
100
90
80
70
µmin (deg)

60
50
40
30
−70° −60°
20
−50° −40°
10 −30°
−20°
θ=−10°
0
0 20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 8: Design of a crank rocker four-bar linkage. Case:θ < 0

10
 180
170
160
+70°
150
µmax (deg)

+60°
+50°
140
+40°
130
+30°
+20°
120
θ=+10°
110
100
90
80
70
θ=+10°
60
+20° +30°
50
+40°
µmin (deg)

40
+50° +60°
30
+70°
20
10
0
0 20 40 60 80 100 120 140 160 180
ψ (deg)

Figure 9: Design of a crank rocker four-bar linkage. Case:θ > 0

11
 It is interesting to compare the above results with an alternative approach
based on design charts often presented in German textbooks2 and design man-
uals 3 .
These charts, commonly known as Alt charts in memory of the first person
who suggested a solution to the problem, were published by VDI4 in the version
prepared in 1958 by J.G. Volmer.

c
b ψ0
φ0
a
φ1 d

Figure 10: Nomenclature

The method, with reference to the nomenclature of Figure 10, is based on

the use of the following equations
 
a sin ψ20 cos φ20 + φ1
=−   , (2a)
d sin φ20 − ψ20
 
ψ0 φ0
b sin 2 sin 2 + φ 1
=   , (2b)
d φ0
cos 2 − 2 ψ0

s  2  
c a b a b
= 1+ + −2 + cos φ1 . (2c)
d d d d d

where the value of φ1 is obtained from the first of the Alt charts together with
max µmin (see Figure 11).
2 See [6] p.195, [8] p.477, [9], [4], p.22
3 See [5]p.397
4 Verein Deutscher Ingenieure, Society of German Engineers.

12
 max m = 0°
min
80° 70° 60° 50° 40° 30° 20° 10°

270°

90°

10°

240°
100° 20°

30°

210°
40°

φ0 50°

60°

70°

180°
60°

50° 10°
40°

20°
30°
150°
20° 30°

40°
10°

50°

120°
f1 =80° 70° 60°

0 30° 60° 90° 120° 150°

ψ0

Figure 11: VDI chart for the design of four-bar linkage with optimal transmission
angle (adapted from [8])

Such a chart, for the case ψ0 = 40◦ and φ0 = 160◦ , returns the values of
φ1 ≈ 50◦ and µmin ≈ 32◦ . It must be observed that if one substitute in (2) this
value of φ1 the same link length ratios (1) are obtained. However, the minimum
and maximum value of the transmission angle estimated by the Alt chart is
different from

µmin ≈ 66◦ ,
µmax =≈ 148◦ .

returned by the chart reported in Figure 8.

The apparent discrepancy is solved considering that, when θ < 0, i.e. φ0 >
180◦, the minimum and maximum transmission angles can also be defined as
shown in Figure 12.

13
 µmax

µmin

Figure 12: Definition of extreme values of transmission angle according to

Volmer’s method when φ0 > 0.

In conclusion, the optimality criterion adopted by F. Freudenstein and E.J.F.

Primrose [3] is the same originally proposed by J.G. Volmer for the compilation
of the Alt charts and the numerical results of the two methods are thus coinci-
dent. To improve the accuracy, in the charts herein presented the link length
ratios and minimum values of transmission angles can be read directly on the
ordinate axes.

3 Design of drag-link four-bar linkage

Purpose: Design a drag-link mechanism with design positions corresponding
at input angles φ1 =0◦ and φ2 =180◦ and a prescribed value µmin of the minimum
transmission angle. The nomenclature is shown in Figure 13. The numerical

B1
180 - µ max= µ min
b
c
A1 d A2
a B0
A0
∆ψ µ min
0

B2

Figure 13: Design of a drag-ling:Nomenclature

procedure for this problem has been already presented in a previous paper con-

14
tained in this Bulletin 5 .
Example
Design a drag-link four-bar linkage such that whan the input crank rotates of
180◦ degrees the opposite crank rotates of ∆ψ0 = 110◦ . The prescribed value
of the minimum transmission angle is µmin = 45◦ .
Solution
One enter the charts shown in Figures 14, 15, 16, for ∆ψ0 = 110◦, on the
horizontal scale, and draw a vertical line to read from the curves of µmin = 45◦
on the vertical the link length ratios ad , db , dc , respectively.
For the prescribed numerical data one approximately reads
a
≈ 2.85 ,
d
b
≈ 2.75 ,
d
c
≈ 1.55 .
d
C. Bagci [1] suggests to investigate the degree of nonuniformity of the output
velocity ratio as a function of ∆ψ0 for a given value of µmin .
5 see E. Pennestrı̀, P.P. Valentini, A review of simple analytical methods for the kinematic

synthesis of four-bar and slider-crank function generators for two and three prescribed finite
positions

15
 6

5.5

4.5
55° 60°

45° 50°
a
d 3.5

40°
35°
3
30°
25°
2.5
20°

2 15°

1.5
µmin=10°

1
20 40 60 80 100 120 140 160 180
∆ψ0 (deg)

Figure 14: Design of a drag-link for prescribed rotation ∆ψ0 of output link and
minimum value of the transmission angle

16
 6

5.5

4.5
60°
4
55°

b 50°
d 3.5
45°

40°
3
35°
30°
2.5
25°

20°
2
15°

1.5
µmin=10°

1
20 40 60 80 100 120 140 160 180
∆ψ0 (deg)

Figure 15: Design of a drag-link for prescribed rotation ∆ψ0 of output link and
minimum value of the transmission angle

17
 6

5.5

4.5

c
d 3.5

3
60°

55°
2.5
50°
40° 45°
2
35°
15° 20°
25° 30°
1.5
µmin=10°
1
20 40 60 80 100 120 140 160 180
∆ψ0 (deg)

Figure 16: Design of a drag-link for prescribed rotation ∆ψ0 of output link and
minimum value of the transmission angle

18
4 Design a drag-link four-bar linkage with min-
max transmission angle deviation
Purpose: Design a drag-link mechanism in its two unity velocity ratio positions
for prescribed crank rotations, ∆φ and ∆ψ, and minimized maximum deviation
∆µmax of the transmission angle from 90◦ (see Figure 17). For best performances

A1 b B1

a φ1 ∆ψ

d=A0 B0
A0 B0
∆φ

A2
B2

Figure 17: Drag-link mechanism at design positions

it is necessary that at initial and final design positions (see Figure 17) the lag is
minimum and maximum, respectively. Hence, at design positions, the angular
velocity ratio of the output link to the input link equals to one [7].
The design charts presented in this section have been prepared making use
of an analytical procedure already described and originally due to L.W. Tsai.
These charts allow a quick kinematic synthesis of a drag-link four-bar linkage.
The input data are the angular displacement ∆ψ of the output link and the
corresponding displacement ∆φ of the input link.
The resulting four-bar linkage is optimal in the sense that the maximum
deviation ∆µmax of the transmission angle from 90◦ is minimized.
The link length ratios are computed using the charts shown in Figures 18,
19, 18. The corresponding value of ∆µmax is readily obtained by means of the
chart shown in Figure 21.
Example
Design a drag-link four-bar linkage with optimal transmission angle variation

19
such that the rotations of input and output cranks between design positions are

∆φ = 170◦ ,
∆ψ130◦ .

At design positions the input-output velocity ratio is unity.

Solution
The value ∆L needs to be computed first

∆L = ∆φ − ∆Ψ = 40◦ .

Then, entering the charts reported in the Figures 18, 19 and 20, from the abscissa
value ∆φ = 170◦ , and reading the ordinate of the intersection point of a vertical
line with the curve ∆L = 40◦ , one obtains
a
≈ 4.3 ,
d
b
≈ 2.7 ,
d
c
≈ 3.0 .
d
The maximum deviation of transmission angle from 90◦ is

∆µmax ≈ 45◦ .

20
 10
9.5
9
8.5
∆L=20° ∆ L=20°
8
7.5
7
6.5 30°
a
d 6 30°
40°
5.5
40° 50°
5 50°
60°
70°
4.5
60°
4
80° 70° 80°
3.5
3
2.5
2
160 165 170 175 180 185 190 195 200
∆φ (deg)

Figure 18: Design of a drag-link four-bar linkage with minimax transmission

angle deviation from 90◦

21
 8

7.5

6.5
∆ L=20°
6
∆ L=20°
5.5 30° 30°
5 40°
40°
b
d 4.5
50° 50°
4 60°
60°
70°
3.5
70° 80°
3
80°
2.5

1.5

1
160 165 170 175 180 185 190 195 200
∆φ (deg)

Figure 19: Design of a drag-link four-bar linkage with minimax transmission

angle deviation from 90◦

22
 6.5

∆L=20°
6

5.5

4.5

c 30° 30°
d 4

3.5

40° 40°
3

2.5 50° 50°

60° 60°
2
70° 70°
80° 80°
1.5
160 165 170 175 180 185 190 195 200
∆φ (deg)

Figure 20: Design of a drag-link four-bar linkage with minimax transmission

angle deviation from 90◦

23
 80

∆L=80° ∆L=80°
70
70° 70°
60°
60°
60 50°
50°
40°
40°
∆µmax (deg)

30° 30°
50
20° 20°

40

30

20

10
160 165 170 175 180 185 190 195 200
∆φ (deg)

Figure 21: Design of a drag-link four-bar linkage with minimax transmission

angle deviation from 90◦

24
 REFERENCES 25

References
[1] C. Bagci. Synthesis of the Double-Crank Four-Bar Plane Mechanism with
Most Favorable Transmission Via Pole Technique. In A.H. Soni, editor,
Linkage Design Monograph. National Science Foundation, 1976.
[2] N.P. Chironis and Sclater N. eds. Mechanisms and mechanical devices
sourcebook. McGraw-Hill Book Company, 2nd edition, 1996.
[3] F. Freudenstein and Primrose E.J.F. The classical transmission angle prob-
lem. In Proceedings of the Conference on Mechanisms, pages 105–110, Lon-
don, 1972. The Institution of Mechanical Engineers.
[4] P.W Jensen. Classical and Modern Mechanisms for Engineers and Inventors.
Marcel Dekker, Inc., New York, 1991.
[5] H. Krzenciessa, K. Luck, K.H. Modler, and G. Nerge. Mechanismen
(getriebetechnik). In K. Luck, S. Fronius, and J. Klose, editors, Taschenbuch
Maschinenbau, volume Band 3, pages 331–440. VEB Verlag Technik, Berlin.
[6] K. Luck and K.H. Modler. Getriebetechnik - Analyse, Synthese, Opti-
mierung. Springer Verlag, 1995.
[7] L.W. Tsai. Design of Drag-Link mechanisms With Minimax Transmission
Angle Deviation. ASME Journal of Mechanisms, Transmissions, and Au-
tomation in Design, 105:686–691, 1983. See discussion by F. Freudenstein.
[8] J. Volmer. Getriebetechnik - Leherbuch. VEB Verlag Technik, Berlin, second
edition, 1976.
[9] J.G. Volmer. Four-bar linkages. Product Engineering, pages 71–76, Novem-
ber 12 1962.

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