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Breadth cam profile design with oscillating roller follower

Article · August 2010

DOI: 10.1109/ICMA.2010.5589191

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J. Cent. South Univ. Technol. (2011) 18: 451−457
DOI: 10.1007/s11771−011−0717−3

Kinematical system of breadth cam profile design

SHIN Joong-ho, LI Lin(李琳), YANG Hyun-dai, KWON Soon-man

Department of Mechanical Design & Manufacturing, Changwon National University, Changwon 641−773, Korea
© Central South University Press and Springer-Verlag Berlin Heidelberg 2011

Abstract: The design solutions for breadth cam mechanism were presented. The main topics of the shape design for breadth cam was
to calculate the coordinate at each contact point to determine the cam profile. The proposed method according to velocity and
geometric relationships of instant velocity centers can easily determine each contact point at any instant moment. The cam profile
was defined by contouring of the contact points. And also a program was developed by using Microsoft Visual C++ program, which
can quickly and easily draw a 2D cam profile through the displacement diagram. Finally, the program was used to confirm the
accuracy on the breadth cam profile design by computer animation graphically.

Key words: cam profile; breadth cam; reciprocating follower; oscillating follower; instant velocity center

1 Introduction

With the rapidly development and popularization of

mechanical products in modern society, it has been such
an important question on designing and producing
mechanisms precisely. Cam mechanisms can transfer the
evolvement of cam to the motion of follower, so it was
widely applied to various machineries. With numerical
controlled manufacture systems being widely applied in
this time, it is necessary for the designers to design a new
type of cam profile. But, the conventional type of cam
profile is usually defined in approximation by lines or
curves which have bigger error and require more nodal
points, resulting in chattering of principle axis. In fact, Fig.1 Breadth cam mechanism with reciprocating motion
the design process of cam must make the accurate
solutions for precise cam profile.
The common cam mechanisms have only one
follower contacted with one cam. If the designers want to
use two followers, the only way is to design a conjugate
cam system, which means two-cams mechanism. So, it
not only occupies larger space, but also has higher cost.
Breadth cam system can be subjected as a new type of
cam system with a pair of followers for one cam.
A breadth cam gets its name because the centers of
the rollers are a constant distance apart. By the motion of
follower, a breadth cam mechanism can be classified as Fig.2 Breadth cam mechanism with oscillating motion
two types: one with a pair of reciprocating motion
followers in Fig.1, and the other with a pair of oscillating velocity between cam and followers. Thus, it can be used
motion followers in Fig.2. widely for the film projector, the gear grinding machine,
The advantage of the breadth cam is elimination of the piston pump and other types of machines.
the redundant preloading constraints to avoid jumping QIAN [1] presented a constant-diameter cam

Foundation item: Work supported by the Second Stage of Brain Korea 21 Projects
Received date: 2010−04−28; Accepted date: 2010−06−24
Corresponding author: KWON Soon-man, PhD, Associate Professor; Tel: +82−55−213−3629; E-mail: smkwon@changwon.ac.kr
452 J. Cent. South Univ. Technol. (2011) 18: 451−457
mechanism with a planar motion follower. The cam had
two followers on the coupler link of the slider
mechanism. By the motion of followers, the relations
between the geometric parameters and the cam rotational
angles were established. YE and MICHAEL [2] gave the
synthesis and analysis of constant-breadth cam
mechanisms with oscillating or translating flat-faced
followers. They defined the cam profile design of cam
with different lengths of flat-faced followers. And
ZAYAS et al [3] gave the displacement function of
follower generated by constant breadth cam mechanisms.
They built the displacement by combining segments for
the complete cycle of displacement functions. QIU et al
[4] proposed a universal optional method to cam curve
design using uniform B-splines. ZHOU and QIAN [5]
presented the analysis and design method for yoke typed
cam mechanism activated in dobby shedding machines.
The main topic of the shape design for breadth cam
is to calculate the coordinates to determine the profile
through each contact point. The design solutions for
breadth cam profiles were presented. The proposed
method according to velocity and geometric relationships
at instant velocity centers can determine the coordinates
at contact points easily and correctly. And an automatic
program using Microsoft Visual C++ program, which
can quickly and easily confirm a 2-dimensional cam
profile through a displacement diagram, was developed.
Fig.3 Instant velocity centers of cam mechanisms: (a) For
2 Kinematic relationships of general cam reciprocating motion; (b) For oscillating motion
mechanism
the follower must be equal based on kinematic
Fig.3 shows two types of the conventional cam constraints. Thus, l is given by
mechanisms, which consist of frame (link 1), cam (link
vC = vf (3)
2), and follower (link 3). According to Kennedy’s
dy
theorem, 3-bar linkage has three instant velocity centers, l= (4)
and they lie on the same straight line [6]. Fig.3(a) shows dθ C
three instant velocity centers for a cam mechanism in In Fig.3(b), oscillating follower cam rotate around a
reciprocating motion and Fig.3(b) shows three instant pivot, and it has angular displacement and velocity as
velocity centers for a mechanism in oscillating motion, dφ
vf = Z L (5)
where Rr, R and C represent the roller follower radius, dt
the center of the roller follower and the contact point, Also, two velocities in Eq.(1) and Eq.(5) for the
respectively. cam and the follower have the following relationship:
The velocity at I23 by cam rotation can be presented
vf ZL
as = (6)
dθ
vC Z xy − l
v23 = vC = l C (1)
dt where Zxy is the distance to I13 from cam center I12 [7].
where vC represents the velocity of cam; l represents the dφ
Z xy ⋅
distance from cam center to I23 and θC represents the cam l= dt
(7)
rotating angle. dφ
1+
As shown in Fig.3(a), reciprocating follower has dt
linear displacement (y) and velocity, which is defined as After determining the location of I23 in Fig.3, it is a
dy keypoint that the contact point between the cam and
vf = (2)
dt roller follower is positioned on the radial line from
Here, two velocities in Eqs.(1)−(2) for the cam and follower center to I23.
J. Cent. South Univ. Technol. (2011) 18: 451−457 453
The coordinate of contact points for the upper and
3 Shape design for breadth cam with lower followers as C1 and C2 under Sm coordinate system
reciprocating followers can be expressed in terms of the displacement S1 and S2
of the followers:
3.1 Design solution for contact points ⎡ m C1x ⎤ ⎡ cosθ C sin θ C ⎤ ⎡ E + Rr sinψ 1 ⎤
As shown in Fig.4, a breadth cam mechanism has a ⎢ ⎥=⎢ ⎥⎢ ⎥ (10)
⎢ m C ⎥ ⎢− sin θ C cosθ C ⎥ ⎢ s1 − Rr cosψ 1 ⎥
pair of rollers as followers. The cam rotates in counter ⎣ 1y ⎦ ⎣ ⎦⎣ ⎦
clockwise (CCW) with a constant angular velocity and ⎡ m C 2 x ⎤ ⎡ cosθ C sin θ C ⎤ ⎡ − E − Rr sinψ 2 ⎤
drives the pair of the followers to translate up and down ⎢ ⎥=⎢ ⎥⎢ ⎥ (11)
in reciprocating motion. ⎢ m C ⎥ ⎢− sin θ C cosθ C ⎥⎦ ⎢⎣− s 2 + Rr cosψ 2 ⎥⎦
⎣ 2y ⎦ ⎣
Thus, breadth cam mechanism must satisfy the
kinematic conditions: roller followers on upper and 3.2 Application for reciprocating cam mechanism
lower sides have the same displacement, velocity and The profile design of a breadth cam is built by the
acceleration. In order to design the breadth cam profile to proposed solution method. A breadth cam rotates in
satisfy the kinematic conditions, instant velocity centers constant speed, and the followers move to reciprocating
for I23 by two followers must be the same point. This displacement with 3-4-5-6 polynomial function in
means that the normal lines at the contact points by the Eq.(12). The design parameters for the cam shape are
upper roller and the lower roller must pass through the gave in Tables 1 and 2, and the corresponding cam
same point (i.e. instant velocity center I23). displacement curves are presented in Fig.5:
For deriving the profile equation of the breadth cam, ⎛ ⎛ θ ⎞3 ⎛θ ⎞ ⎞
4 5 6
⎛θ ⎞ ⎛θ ⎞
two coordinate systems are defined, as shown in Fig.4, s = h 64 ⎜ ⎟ − 192 ⎜ ⎟ + 192 ⎜ ⎟ − 64 ⎜ ⎟ ⎟ (12)
⎜
⎜ ⎝β ⎠ ⎝β ⎠ ⎝β ⎠ ⎝ β ⎠ ⎟⎠
where ψ1 and ψ2 represent contact angle, E represents the ⎝
eccentricity, Q represents the pitch distance l. Sf(Xf, Yf) where h represents the maximum lift.
represents a stationary reference system and Sm(Xm, Ym)
represents a mobile reference system. The reference Table 1 Displacement conditions for cam 1
system Sm is defined by the input shaft rotation angle θC Segment Cam angle/(°) Motion type Function
of Link 2. 1 0−60 20 mm rise 3-4-5-6 polynomial
2 60−180−180 0 mm Dwell
3 180−240 −20 mm return 3-4-5-6 polynomial
4 240−360 0 mm Dwell

Table 2 Design parameters for cam 1

Parameter Value
Base circle radius (Rb)/mm 50
Roller follower radius (Rr)/mm 10
Eccentricity (E)/mm 0−20

Fig.6 shows a general model for breadth cam

mechanism in reciprocating motion. Generally, industrial
applications use the geometry of cam mechanisms with
Fig.4 Geometry of breadth cam with reciprocating follower an eccentricity, which is defined as a position of the
follower axis to the cam axis. The design solutions based
The contact angles for the upper and lower on the displacement conditions and design parameters
followers can be given in the following equations: are given in Fig.7(a) for cam profile with no eccentricity
⎛ l −f R ⎞ (E=0 mm) and Fig.7(b) for profile with eccentricity
ψ 1 = tan −1 ⎜ f 1x ⎟ (8) (E=20 mm).
⎜ R1 y ⎟
⎝ ⎠
⎛ l −f R ⎞ 4 Shape design for breadth cam with
ψ 2 = tan −1 ⎜ f 2 x ⎟ (9) oscillating followers
⎜ R2 y ⎟
⎝ ⎠
where left upper-script “f” represents the Sf-coordinate 4.1 Design solution for contact points
system. As can be seen in Fig.8, a breadth cam mechanism
454 J. Cent. South Univ. Technol. (2011) 18: 451−457

Fig.5 Displacement diagram for cam 1

Fig.8 Geometry of breadth cam with oscillating follower

has a pair of rollers as followers which can rotate around

a pivot. The kinematical constraints must be satisfied that
two followers have the same properties (displacement,
velocity and acceleration) in the angular motion by the
cam rotation. This means that instant velocity centers
with the upper follower and lower follower must be the
same position, as shown in Fig.8.
The contact angles for the upper and lower
followers are
⎛ l − pR ⎞
Fig.6 Breadth cam with reciprocating follower ψ 1 = tan −1 ⎜ p 1x ⎟ (13)
⎜ R1 y ⎟
⎝ ⎠
⎛ l − pR ⎞
ψ 2 = tan −1 ⎜ p 2 x ⎟ (14)
⎜ R2 y ⎟
⎝ ⎠
where left upper-script “p” represents the Sp-coordinate
system.
The coordinates of contact points for the upper and
lower followers as C1 and C2 under Sm coordinate system
are expressed as
⎡ m C1x ⎤ ⎡ cosθ C sin θ C ⎤ ⎡ Z xy − Z L cos φ1 + Rr sinψ 1 ⎤
⎢ ⎥=⎢ ⎥⎢ ⎥
⎢ m C ⎥ ⎢− sin θ C cos θ C ⎥ ⎢ Z L sin φ1 − Rr cosψ 1 ⎥
⎣ 1y ⎦ ⎣ ⎦ ⎣ ⎦
(15)
⎡ m C 2 x ⎤ ⎡ cos θ C sin θ C ⎤ ⎡ Z xy − Z L cos φ 2 + Rr sinψ 2 ⎤
⎢ ⎥=⎢ ⎥⎢ ⎥
⎢ m C ⎥ ⎢ − sin θ C cos θ C ⎥⎦ ⎢⎣ Z L sin φ 2 − Rr cosψ 2 ⎥⎦
⎣ 2y ⎦ ⎣
(16)
where θC represents the rotating angles of cam.
Fig.9 shows a general model for breadth cam
mechanism in oscillating motion with a pair of followers.

4.2 Design constraints

For a general case of breadth cam shape design, it is
necessary to define the geometric relationships among
Fig.7 Breadth cam shape with E=0 mm (a) and E=20 mm (b)
the follower length ZL, the radius of cam base circle Rb,
for cam 1
J. Cent. South Univ. Technol. (2011) 18: 451−457 455
in Tables 3 and 4. The corresponding displacement
diagram is depicted in Fig.10.
Table 3 Displacement conditions for cam 2
Segment Cam angle/(°) Motion type Function
1 0−90 5 mm rise 3-4-5-6 polynomial
2 90−180 −5 mm return 3-4-5-6 polynomial
3 180−270 5 mm rise 3-4-5-6 polynomial
4 270−360 −5 mm return 3-4-5-6 polynomial

Table 4 Design parameters for cam 2

Parameter Value
Fig.9 Breadth cam with oscillating follower Base circle radius (Rb)/mm 74.852 8
Roller follower radius (Rr)/mm 10
and the displacement angular period, based on a specific Pivot of follower (Zxy)/mm 120
follower angle θz between two followers. Breadth cam Follower lengths (ZL)/mm 84.852 8
mechanism has five design parameters: Rb, Rr, ZL, Zxy,
and θz. On the view of design process, Rr, Zxy, θz are
commonly given by the users. Thus, the design
parameters ZL and Rb can be derived by the geometric
relationships as follows.
The follower length ZL can be defined by the
triangular relationships between three lengths (ZL, Zxy,
Rb+Rr) and the angle θz, when Rb is given as the known
parameter:

ZL = (Rb + Rr )2 + Z xy2 − 2( Rb + Rr ) Z xy cos⎛⎜ θ z ⎞⎟ (17)

⎝ 2 ⎠
And for the design case of the known parameter ZL,
the radius of base circle of cam is given as
Fig.10 Displacement diagram for cam 2: 1—Displacement; 2—
⎛θ ⎞
Rb = Zxy 2 + Z L2 − 2 Z xy Z L cos⎜ z ⎟ (18) Velocity; 3—Acceleration
⎝ 2 ⎠

In addition to the design parameters, a displacement
curve must be satisfied with the geometric constraints.
As shown in Fig.8, two followers must be positioned in
the conjugated motions: If the upper follower (R1)
locates at the lowest displacement, then the lower
follower (R2) is at the highest displacement during the
cam rotation.
This means that the period of displacement must be
twice of the follower angle θZ. For example, if θZ is 90°,
displacement period will become 180°. Thus, the
displacement has two periods, and the follower has two
times of the oscillating motions during one revolution of
the cam. If θz is 60°, the displacement has three periods
and each period has 120°.
4.3 Example of breadth cam with no dwell motion
Here, we use the 3-4-5-6 polynomial function in
Eq.(12) to design the breadth cam shape. The
displacement conditions of the follower motion and the
design parameters of the cam mechanism are presented
In this example, there is no dwell motion. This
means that the cam will rotate with no rest. The
application of breadth cam profile is given in Fig.11.
Also, it is easy to use 3D CAD program to draw a
3-dimensional model of the breadth cam system in order
to check the movement of the designed cam mechanism,
as shown in Fig.12.
4.4 Example of breadth cam with 20° dwell motion
Here, the 3-4-5-6 polynomial function is also used
to design the breadth cam shape with the dwell motion.
This part gives the dwell motion in the displacement
conditions for designing the cam profile.
The displacement conditions of the follower motion
and the design parameters of the cam mechanism are
presented in Tables 5 and 6. The corresponding
displacement diagram is depicted in Fig.13.
In this example, it uses dwell motion. This means
that the cam will rotate with a rest of 20° for each period.
456 J. Cent. South Univ. Technol. (2011) 18: 451−457
The application of breadth cam profile is given in Fig.14.
Also, it is easy to use CATIA program to draw a
3-dimensional model of the breadth cam system in order
to check the movement of the designed cam mechanism,
as shown in Fig.15.

5 Development of program

A breadth cam designing program was developed by

Fig.11 2D model of breadth cam profile for cam 2

Fig.13 Displacement diagram for cam 3: 1—Displacement; 2—

Velocity; 3—Acceleration

Fig.12 3D model of breadth cam mechanism for cam 2

Table 5 Displacement conditions for cam 3

Cam
Segment Motion type Function
angle/(°)
1 0−10 0 Dwell
2 10−80 5 mm rise 3-4-5-6 polynomial
3 80−100 0 Dwell
4 100−170 −5 mm return 3-4-5-6 polynomial
5 170−190 0 Dwell Fig.14 2D model of breadth cam profile for cam 3
6 190−260 5 mm rise 3-4-5-6 polynomial
7 260−280 0 Dwell
8 280−350 −5 mm return 3-4-5-6 polynomial
9 350−360 0 Dwell

Table 6 Design parameters for cam 3

Parameter Value
Base circle radius (Rb)/mm 80
Roller follower radius (Rr)/mm 20
Pivot of follower (Zxy)/mm 150
Follower lengths (ZL)/mm 106.239 3 Fig.15 3D model of breadth cam mechanism for cam 3
 J. Cent. South Univ. Technol. (2011) 18: 451−457
using Microsoft Visual C++ program and MFC
languages. The program has the user-friendly connection
with the design and dynamic simulation programs for
verifying breadth cam. It can plot the track of the design
results and simulate the cam motion dynamically.
For using developed program for the breadth cam,
first, the users should define the polynomial functions to
form a displacement cycle including rise and return
motion by using the program of CamDis R7 to form the
displacement diagram. Then by clicking the button
browser in Fig.16, it will read the displacement source
file successfully.
Fig.16 Automatic design of breadth cam V1 program: (a)
Reciprocating motion; (b) Oscillating motion
By inserting the autolisp file into the AutoCAD
software, the cam profile can be plotted interactively.
The system can be used to design the breadth cam
mechanism in the field of engineering simulation, design,
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457
and computer aided instruction, which means that it has a
great practical and theoretical values.
6 Conclusions
1) The design solutions for breadth cam with a pair
of roller followers are presented. The method based on
the geometric and velocity relationship at instant velocity
center is proposed, and then the coordinates for each
contact point are easily found at any instant moment.
2) The general model for reciprocating follower
with eccentricity of the follower moving axis and
oscillating follower is proposed. The program developed
using Microsoft Visual C++ confirms that the cam
profiles for the reciprocating and oscillating motion are
accurately designed by the computer animation
graphically.
References
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[2] YE Z H, MICHAEL R S. Synthesis of constant-breadth cam
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[3] ZAYAS E E, CARDONA S, JORDI L. Analysis and synthesis of the
displacement function of the follower in constant-breadth cam
mechanisms [J]. Mechanism and Machine Theory, 2009, 44(10):
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[4] QIU H, LIN C J, LI Z Y, OZAKI H, WANG J, YUE Y. A universal
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[5] ZHOU Nai-yue, QIAN Chun-yan. The analysis and design of
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(Edited by LIU Hua-sen)