This thesis presents the foundation of a computer program for the unified design of spatial mechanisms. The program will be capable of synthesizing any mechanism that can be described using an equivalent chain containing only revolute and prismatic joints. The supporting analysis routine will be general and will be able to analyze any lower pair mechanism using the iterative approach developed by Sheth and Uicker [1972]. Unlike precision point synthesis methods that allow only a limited number of positions to be specified, optimization will be employed to synthesize a wide variety of mechanisms. This approach will allow the user to interactively monitor and control objectives and constraints, which will yield practical solutions to realistic mechanism design problems. The creation of this program will provide practicing engineers with the capacity to design many previously intractable spatial mechanisms. / Master of Science

Over the last decade there has been a worldwide increase in the use of retractable roofs for stadia. This increase has been based on the flexibility and better economic performance offered by venues featuring retractable roofs compared to those with traditional fixed roofs. With this increased interest an evolution in retractable roof systems has followed. This dissertation is concerned with the development of concepts for retractable roof systems. A review is carried out to establish the current state-of-the-art of retractable roof design. A second review of deployable structures is used to identify a suitable retractable structure for further development. The structure chosen is formed by a two-dimensional ring of pantographic bar elements interconnected through simple revolute hinges. A concept for retractable roofs is then proposed by covering the bar elements with rigid cover plates. To prevent the cover plates from inhibiting the motion of the structure a theorem governing the shape of these plate elements is developed through a geometrical study of the retractable mechanism. Applying the theorem it is found that retractable structures of any plan shape can be formed from plate elements only. To prove the concept a 1.3 meter diameter model is designed and built. To increase the structural efficiency of the proposed retractable roof concept it is investigated if the original plan shape can be adapted to a spherical surface. The investigation reveals that it is not possible to adapt the mechanism but the shape of the rigid cover plates can be adapted to a spherical surface. Three novel retractable mechanisms are then developed to allow opening and closing of a structure formed by such spherical plate elements. Two mechanisms are based on a spherical motion for the plate elements. It is shown that the spherical structure can be opened and closed by simply rotating the individual plates about fixed points. Hence a simple structure is proposed where each plate is rotated individually in a synchronous motion. To eliminate the need for mechanical synchronisation of the motion, a mechanism based on a reciprocal arrangement of the plates is developed. The plate elements are interconnected through sliding connections allowing them mutually to support each other, hence forming a self-supporting structure in which the motion of all plates is synchronised. To simplify the structure further, an investigation into whether the plate elements can be interconnected solely through simple revolute joints is carried out. This is not found to be possible for a spherical motion. However, a spatial mechanism is developed in which the plate elements are interconnected through bars and spherical joints. Geometrical optimisation of the motion path and connection points is used to eliminate the internal strains that occur in the initial design of this structure so a single degree-of-freedom mechanism is obtained. The research presented in this dissertation has hence led to the development of a series of novel concepts for retractable roof systems.

This thesis has developed an efficient methodology for automatic kinematic analysis of planar linkages using the concept of modular kinematics. Unlike conventional general purpose kinematic analysis packages where each joint in the mechanism is represented using a set of non-linear constraint equations which need to be solved by some iterative numerical procedure, modular kinematics is based on the original observation by Assur that kinematic state of a mechanism involving large number of links can be constructed out of the kinematic states of patterns of sub chains called modules taken in a given sequence called module sequence which in turn emulates the step by step construction procedure of traditional graphical methods. The position, velocity and acceleration analysis of modules are available in closed form. Kinematic analysis of modules later in the sequence is enabled by those of the ones earlier in the sequence, hence, the kinematic analysis of a mechanism is accomplished without any iterative endeavor by doing the kinematics of the modules as given in the module sequence. [102] classified all modules into three fundamental types namely input, dyad and transformation and also introduced the concept of constraint module for analyzing graphically non-constructible mechanisms within the paradigm of modular kinematics where a small step of numerical search was needed in an over all closed form kinematic formulation. Module sequence for a mechanism using the modules is not unique. Choice of a later module in the sequence depends upon the selection of modules earlier in the sequence. This thesis has presented a systematic approach of identifying all such methods for all the inversions of the mechanism and represented in the form of a module hierarchy or a module tree where each path from root to the leaf node represents a valid module sequence for the kinematic chain in hand. The work also extended the set of modules by adding eight new modules to what has already been used in literature to make it complete in the sense that all planar mechanisms involving revolute, prismatic and pin-in-slot (including circular slots) can be handled. The computational effort involved for analyzing these mechanisms thus depend on the number of constraint modules occurring in succession in the module sequence. However, maximum possible number of constraint modules in any mechanism with up to twelve links is only two. The derivative analysis also uses the same module sequence, but they are always devoid of any iterative steps. During the process of generation of a module sequence, at every stage multitude of modules could be identified for their potential placement in the sequence. But for every module sequence the difference between the number of input modules and that of constraint modules is constant and is equal to the kinematic degrees-of-freedom (d.o.f) of the mechanism. The algorithm presented in this thesis minimizes the number of generalized inputs (and hence extraneous constraints) and thus attempting to identify the simplest of the module sequences. In that sense the module sequences represented in the module tree are all optimal module sequences. The present work introduced the concept of multi phase modular kinematics which enables a large variety of mechanisms, conventionally identified as complex mechanisms, to be solved in closed form. This is achieved through the use of novel virtual link and virtual joints. Virtual link is slightly different from a normal rigid link in the sense that the joint locations on this are functions of some independent parameters. Since, the locations of joints are not fixed even in the local coordinate frame of the virtual link, the relative velocities between joints are not zero, they need to be appropriately accounted in kinematic analysis. The theory presented in the thesis is implemented in a computer program written in C++ on Windows platform and Graphics library (OpenGL) is used to display linkage configurations and simulations. The program takes the data of joints, input pairs, ground link in certain format through a file. Geometric models developed in any of the existing modeling softwares like ProE, Ideas, AutoCad etc. can be imported in VRML format to the links and in case of no geometric models a simple convex 2D geometry is created for each link for the purpose of visualization. Geometric import of links helps not only in understanding the simulations better but also in useful for dynamic analysis, dynamic motion analysis and interference analysis. A complete kinematic analysis (position, velocity and acceleration) is given for a four bar mechanism and illustrated the positional ( configuration) analysis using modular kinematics for several other examples like old-ham, quick-return mechanisms etc. in the current work. Multi-phase modular approach is illustrated using a five bar with floating input pairs, a back actor and a drafter mechanism and the Back actor configuration is shown with the imported link geometries. It is observed in practice that there are many apparently spatial Mechanisms, which are constructed out of symmetric dispositions of planar mechanisms in space. A pseudo spatial mechanism concept is proposed to solve this class of spatial mechanisms, which can actually be analyzed with the effort of solving only one such component. This concept is illustrated with Shaker and Umbrella mechanisms. Possible extensions of the concept for modeling and analysis of more general class of pseudo-spatial mechanisms are also indicated.

In this thesis, the inertial parameters of a spatial mechanism are used in order to optimize various aspects of the dynamic behaviour of the mechanism (such as minimizing actuator torque/ force fluctuations, shaking force/moment balancing, etc.) while the effects of loads are considered as well. Here, inertial parameters refer to the mass, 6 elements of the inertia tensor and coordinates of the center of mass of the links. The concept of Force Fluctuation Number (FFN) is utilized to optimize the dynamic behaviour of the mechanism. By using the FFN concept, one obtains a number of linear equations to be satisfied by the optimal inertial parameters. In general, the number of such equations is less than the number of the inertial parameters. Therefore, some of the inertial parameters may be selected freely in order to satisfy other design constraints. Using MATHEMATICA, a program has been developed to obtain the linear equations to be satisfied by the optimal inertial parameters. The developed program includes a kinematic and force analysis module, which can be used independently for a complete kinematic and dynamic analysis of any one degree of freedom, single loop, spatial mechanism. The different closures of the mechanism may be identified by using the developed package and these analyses can be performed on any selected closure of the mechanism.

Designing mechanical products in a competitive environment can present unique challenges, and designers constantly search for innovative ways to increase efficiency. One way to save space and reduce cost is to use ortho-planar compliant mechanisms which can be made from sheets of material, or lamina emergent mechanisms (LEMs). This thesis presents principles which can be used for designing LEMs. Pop-up paper mechanisms use topologies similar to LEMs, so it is advantageous to study their kinematics. This thesis outlines the use of planar and spherical kinematics to model commonly used pop-up paper mechanisms. A survey of common joint types is given, as well as an overview of common monolithic and layered mechanisms. In addition, it is shown that more complex mechanisms may be created by combining simple mechanisms in various ways. The principles presented are applied to the creation of new pop-up joints and mechanisms, which also may be used for lamina emergent mechanisms. Models of the paper mechanisms presented in Chapter 2 of the thesis are found in the appendix, and the reader is encouraged to print, cut out and assemble them. One challenge associated with spherical and spatial LEM design is creating joints with the desired motion characteristics, especially where complex spatial mechanism topologies are required. Hence, in addition to a study of paper mechanisms, some important considerations for designing joints for LEMs are presented. A technique commonly used in robotics, using serial chains of revolute and prismatic joints to approximate the motion of complex joints, is presented for use in LEMs. Important considerations such as linkage configuration and mechanism prototyping are also discussed. Another challenge in designing LEMs is creating multi-stable mechanisms with the ability to have coplanar links. A method is presented for offsetting the joint axes of a spatial compliant mechanism to introduce multi-stability. A new bistable spatial compliant linkage that uses that technique is introduced. In the interest of facilitating LEM design, the final chapter of this thesis presents a preliminary design method. While similar to traditional methods, this method includes considerations for translating the mechanism topology into a suitable configuration for use with planar layers of material.