12th IFToMM World Congress, Besançon (France), June18-21, 2007
The Ratchet and Pawl Ring (RaPR) Mechanism
J. A. Kennedy*
Dynamic Structures and Materials
Franklin, TN
Abstract—The paper presents a ratchet and pawl ring
(RaPR) mechanism that has advantages for mechanical safety
mechanisms, particularly when the design envelop is too small to
allow for traditional mechanical components. The mechanism
constraints are outlined and the RaPR mechanism and its
modeling are defined. A series of three scaled prototypes and
their testing are described.
Keywords: safety mechanisms, compliant mechanisms
I. Introduction
Technological advances are allowing designers to use
new manufacturing and analysis approaches for devices at
ever smaller dimensions [1–2]. Smaller mechanisms are
also needed in roles where the cost of failure can be
catastrophic [3–6], including mechanical security devices.
This paper describes the ratchet and pawl ring (RaPR)
mechanism as a compact mechanical security device that
shows promise for decreased mechanism size.
A mechanical security device prevents unauthorized or
unintentional access to a critical or proprietary system. An
example of a mechanical security device is a safety and
arming (S&A) device for weapons [7–10].
At the heart of many mechanical security devices is a
ratcheting actuator with pawls connected to solenoids. The
pawl positions are typically biased with conventional
springs, but helical extension springs are a source of
reliability concern, particularly as device size decreases.
The trend for mechanical security devices is to
decrease size and increase functionality [11]. As safety
devices have become smaller, they have reached a point
where physical constraints limit the device design. These
constraints include the availability of precision
mechanical components such as springs, bearings,
spacers, and fasteners. Other constraints include those
imposed by friction [12], limitations of micro fabrication
processes, including assembly and packaging [9–17].
II. RaPR Mechanism Description
The RaPR mechanism described in this work was
designed with the following design criteria as constraints:
the ratchet wheel should advance one and only one tooth
per actuation pulse; the ratchet wheel driver and restraint
mechanism will be in a planar arrangement; the ratchet
mechanism should operate on as little space of the ratchet
* jkennedy@dynamic-structures.com
† lhowell@byu.edu
L. L. Howell†
Brigham Young University
Provo, UT
wheel as possible; stand-alone spring elements and
complicated assemblies should be minimized or
eliminated; moving parts should be balanced about their
pivot points; the aspect ratio of parts will be 10:1 or less;
the device must be able to be actuated by a stator
electromagnet; the driver mechanism will act as the rotor
to the electromagnet stator by completing a magnetic
circuit; the ratchet wheel will have 36 teeth; no lubricants
will be considered for friction reduction; the ratchet
mechanism will be designed such that it can be fabricated
using micro wire EDM.
The RaPR mechanism was designed to meet the above
criteria. The mechanism wraps around a ratchet wheel,
minimizing its footprint. The RaPR is based on recent
developments in compliant mechanisms [18–19].
Figure 1 shows a sketch of a possible RaPR
mechanism with rotary solenoid actuation. The RaPR
mechanism is based on a design that is similar to a u-ring
used in many mechanical assemblies. Four total parts
make up the assembly: the ratchet wheel, RaPR
mechanism (including the flexible u-ring, the hold pawl,
and the drive pawl), solenoid rotor, and solenoid stator.
Drive Pawl
Pinch Point
Hold Pawl
Ratchet Wheel
4 Pin
Joints
Solenoid Rotor
Solenoid Stator
Figure 1: Initial sketch of the RaPR mechanism
12th IFToMM World Congress, Besançon (France), June18-21, 2007

The ratchet wheel and solenoid parts are rigid-body

mechanisms and the RaPR mechanism is a compliant
mechanism.
The rigid-body parts are designed for minimum space
and maximum balance. The ratchet wheel and solenoid
rotor are balanced about their respective pin joints.
Correct balance ensures minimum friction and binding
effects.
The RaPR mechanism is a combination of several
segments. It has two fixed-pinned compliant segments that
are labeled “Hold Pawl” and “Drive Pawl” in Figure 1.
The analytical model for these compliant segments is Figure 3: PRBM of the functionally binary pinned-pinned segment
fairly straightforward [20]. The RaPR mechanism also has [19]
a long circular segment called a functionally-binary
pinned-pinned (FBPP) compliant segment. It is this long
FBPP segment that gives the RaPR its distinctive u-ring
shape.
Finally, the RaPR mechanism also has two pin joints
where it connects to the base plate and the solenoid rotor.
The size of these pin joints can vary depending on the
manufacturing process. As the pin joint increase in
diameter the relative compliance of the FBPP segment
decreases.

III. The Functionally-Binary, Pinned-Pinned Model

A brief overview of the functionally-binary, pinned-
pinned (FBPP) model will help explain the compliant
segment that the RaPR mechanism is based on. Figure 2
shows the basic geometry and initial conditions and Figure 4: Half of the PRBM and the associated variables [19]
variables associated with the FBPP.
l
Figure 3 and Figure 4 show the variables and relative bi = (1 − cos κ o ) (2)
geometry of the pseudo-rigid-body model that can be used κo
to model the FBPP. The variables of the FBPP are quite where κ O = l / RO is the arc angle, RO is the initial radius
different than most other compliant beam segments. From of curvature, and l is the arc length of the half-segment.
geometry the initial end location ( a i , b i ) of the pin joint The radius of the deflection path ( ρ l), shown in
can be calculated as follows: Figure 4, is determined by the characteristic arc length
l ( ρ ). It is calculated using curve fit data from FEA as
ai = sin κ o (1)
κo described in [19] and given to be
2 2
 a i x c   bi y c 
ρ=  −  +  −  (3)
 l l   l l 
where x c and y c are the curve fit parameters for the
location of the pseudo-rigid-body pin joint [18].
Once the initial geometry and curve fit variables are
established, the force-deflection relationship for the
mechanism can be derived. First the new end position (a,
b) is calculated as
a = l ρ cos Θ + x c (4)
b = l ρ cos Θ + y c (5)
where Θ is the pseudo-rigid-body link angle as shown in
Figure 4.
Figure 2: The initial position of the pinned-pinned segment ([19]) The remainder of the derivation depends on the focal
moment method, which finds a location where the
12th IFToMM World Congress, Besançon (France), June18-21, 2007

IV. RaPR Design

The RaPR design begins with the FBPP beam
segment. The simple linear equations expressed in the
previous section can be used to calculate the theoretical
force-deflection relationships for the FBPP. The desired
force-deflection relationships are used to fix the geometry
of the RaPR mechanism. The hold and drive pawls are
then drawn with the FBPP geometry in a CAD model. The
relative space constraints around the ratchet wheel and the
stresses are checked to ensure that yielding does not
occur.
The RaPR design emphasizes three positions: the
manufactured position, the resting position and the cocked
position. Figure 5 shows a CAD model of the RaPR in the
resting position and the cocked position. The
manufactured position would have a tighter FBPP radius
than either of the positions shown.
The three position design has advantages and
disadvantages. An advantage is that the resting position
Figure 5: RaPR mechanism in the resting and cocked positions will always be in a pre-stressed state that will help prevent
external vibrations or shock from inadvertently actuating
the mechanism. However, the disadvantage is that the
relationship between the maximum moment and the focal
ends of the FBPP segment rotates “open” as the
angle is linear for all κ ο between 0.5 and 3.0 radians [19].
mechanism is assembled from its manufactured position
The location point (0, y f ) and the focal angle ( φ ) have
and as it ratchets from its resting position to its cocked
been calculated to be
position. This rotation requires careful modeling of all
y f = 0.15l (6)
three positions to ensure that the hold and drive pawls
and maintain sufficient contact with the ratchet wheel during
b− yf  operation.
φ = atan  
 (7)
 a 
V. Design Assumptions
respectively (see Figure 4).
Next, the non-dimensional moment ( τ ) can be found The working material is assumed to be homogeneous
to be with linear material properties. It is also assumed that the
Ml Fbl actuation forces and ratcheting flexures do not introduce
τ = = = K φ (φ − φ i ) (8) consequential moments or additional forces not modeled
EI EI
where E is the Young’s modulus, I is the area moment of with the FBPP, and that the RaPR mechanism will be
inertia, the initial focal angle ( φ i ) can be found from (7) pinned such that it will not have out-of-plane motion.
Furthermore, the frictional consideration of the RaPR’s
by replacing the point (b, a) with the point (b i , a i ), and
motion is sufficiently small to neglect.
the focal stiffness coefficient ( K φ ) can be found using the The FBPP pseudo-rigid-body model was used to
FEA data fit of design the dimensions of the primary ring. Computer-
aided-design (CAD) was used to draw the ring design to
K φ = 0.0023204κ O3 + 0.0037601κ O2 + 0.094226κ O − 2.4333 fit the desired ratchet wheel size and a reasonable size for
the pin joints and pawl flexures was determined. This
(9)
information was used as input to the FBPP PRBM to
From (8) the force (F) deflection relationship can
generate the RaPR flexure dimensions. Scaled proof-of-
derived as
concept hardware of the design was prototyped in
EI
F = τφ (10) polypropylene with a CNC mill.
bl
12th IFToMM World Congress, Besançon (France), June18-21, 2007
Figure 6: First generation RaPR mechanism
There are several design issues to consider when
designing the RaPR mechanism. First, the design requires
modeling the manufactured position, the assembled
position and the cocked or “fully flexed” position. The
CAD model has all three positions drawn to ensure that
the geometry developed by the analysis can be correctly
modeled. Second, the end angle of the FBPP model
rotates outward as the FBPP segment flexes open. This
means that the drive and hold pawl flexures rotate relative
to their manufactured or assembled positions as the
mechanism actuates. Using the CAD model, the rotation
angle can be viewed relative to the ratchet wheel and
checked to ensure that it will operate despite the end angle
changes. This is the easiest way to ensure functionality of
the mechanism. Third, the theoretical actuation force for
the FBPP model acts along a straight line through the
RaPR mechanism’s pin joints. However, a rotary solenoid
has an actuation force that acts in an arc. The difference is
not a problem as long as the arc radius of the solenoid is at
least as large as the RaPR mechanism’s radius.
VI. RaPR Prototypes
The first polypropylene prototype was fabricated as
shown in Figure 6. Some design decisions that were made
are as follows: the RaPR mechanism would encompass
the ratchet wheel so as to minimize space requirements,
and the drive pawl was designed as a hook to eliminate
the possibility of the drive pawl buckling during actuation.
The plastic, 45 cm diameter, ratchet wheel and the
associated RaPR mechanism shown in Figure 6 is a direct
scale model of the designed micromechanism. The pin
joint heads of the FBPP segment are scaled relative to the
Figure 7: Second generation of the RaPR mechanism
rest of the mechanism to simulate its appearance when
manufactured with a micromanufacturing method.
Testing the first prototype revealed that the drive pawl
had a tendency to slip over the ratchet teeth during
actuation. The design led to design changes and additional
prototypes. The second scaled prototype (Figure 7) was
designed to accommodate a smaller, 120 mm diameter
ratchet wheel which was also designed to have a sharper
tooth angle. The sharper angle reduces the chance of the
drive pawl slipping during actuation. The actuation stop
mechanism was redesigned to help keep the drive pawl
from losing contact with the ratchet teeth during actuation.
Finally, the FBPP segment was designed to have an
increased spring force by increasing its bending thickness.
Several things were learned from this second
prototype. First, the change in tooth angle effectively
prevented the drive pawl from slipping off the teeth.
Second, the reduction in scale resulted in excessive spring
force for the FBPP segment. Third, the friction between
the drive pawl and the ratchet teeth was not negligible, as
had been assumed. The result was that the frictional force
caused the drive pawl to occasionally twist back on itself,
preventing its return to catch the next tooth. This was not
discovered in the previous prototype because the drive
pawl flexure did not have sufficient spring force to cause
significant friction.
The third prototype of the RaPR mechanism is shown
in Figure 8. The drive pawl flexure stiffness was increased
to help overcome the friction between the drive pawl and
the ratchet teeth and prevent the drive pawl from rotating
during actuation. The final prototype ratcheted
consistently and met the desired design objectives.
12th IFToMM World Congress, Besançon (France), June18-21, 2007
Figure 8: Final polypropylene prototype for RaPR mechanism
VII. Results and Conclusions
The RaPR mechanism design was able to adequately
fulfil the design specifications. The uncomplicated, planar
design of the RaPR mechanism minimizes stand-alone
parts and simplifies assembly. The ring design is space
efficient and has a large range of thicknesses that would
allow for a varying actuation force, but would not incur to
yielding or over-burden the rotary solenoid. The RaPR
mechanism ratchets in an acceptable time frame and it
makes use of hard stops on the activation and deactivation
cycles to ensure that one and only one tooth ratchets at a
time.
The RaPR mechanism has some design drawbacks. It
is difficult to design due to the rotation of its pin joints
during operation. Furthermore, the final prototype design
shown in Figure 8 utilizes a hook on the drive pawl to
ratchet the wheel, which may need additional constraints
to ensure it cannot slip off the ratchet wheel under
extreme conditions.
The RaPR mechanism offers a new, compact approach
for miniaturizing mechanical safety devices and its planar
nature it makes it possible to fabricate using
microfabrication approaches.
Acknowledgements
The assistance of Michael Cherry, Jonathan Wittwer,
Daniel Wilcox, and Neal Hubbard is greatly appreciated.
The assistance of Dr. William Greenwood and the
financial support of Sandia National Laboratories are also
gratefully acknowledged.
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