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Procedia Engineering 96 (2014) 302 309

Modeling of Mechanical and Mechatronic Systems MMaMS 2014

Functional Analysis and Mechatronic Design of a Cam Controlled

Mechanism
Lajos Nagya* Tams Szaba, Endre Jakaba
a
University of Miskolc, Robert Bosch Department of Mechatronics, Miskolc-Egyetemvros 3515, Hungary

Abstract

The paper discusses a part of an industrial project which can be solved by mechatronic design method. In general, it follows VDI
Guidelines 2206 and 2143, applying a model-based design tool. The objective of the project was to design and construct of a new state of
the art pinion-engaging mechanism for starter motors. The pinion-engaging mechanism is a cam follower mechanism which contains the
following parts: dc servo motor, rotational to translational transducer and the drive pinion. The rotational to translational transducer can be
realized by designing a cylindrical roller follower mechanism. The goal of this paper is to present a mechanism design process and a test
bench of the achieved construction. Some aspects of the kinematic relationships of the motion control, including electromechanical
modeling are considered.

2014
2014TheTheAuthors. Published
Authors. by Elsevier
Published Ltd. Ltd.
by Elsevier This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Peer-review under responsibility of organizing committee of the Modelling of Mechanical and Mechatronic Systems MMaMS 2014.
Peer-review under responsibility of organizing committee of the Modelling of Mechanical and Mechatronic Systems MMaMS 2014

Keywords: mechatronic design, pinion-engaging mechanism, cam mechanism, starter motor

1. Introduction

Many theories and methods were and have been developed during the last fifty years such as systematic design
methodology [2], decision-based design theory, Theory of Inventive Problem-Solving (TRIZ), computational design theory,
Axiomatic Design [12], General Design Theory, Dynamic Product Developement, etc. Several papers [14], [15], [21]
discusses the difference between of these theories. Nowadays, these theories are taught in many engineering schools and
reported being applied industrially.
The objective of this paper is to present the solution of a particular industrial task by VDI Guidelines 2206 and 2143. The
project is started in 2006 from an industrial commission, with the objective of developing and constructing a new, state-of-
the-art pinion engaging mechanism (PEM) for starter motors for passenger cars. The contents of the paper are related to this
objective.

2. Pinion-engaging mechanism

The PEM is a part of a component of the starter motor. The purpose of the PEM is to be able to switch a high current
(about 600-1200 Amperes) by means of relatively low control current [5]. It performs the following two functions: it moves
the drive pinion outwards so that engages in the engines ring gear and it closes the switch which completes the starter

* Corresponding author. Tel.: +0-036-704-327- 433.

E-mail address: [email protected].

1877-7058 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Peer-review under responsibility of organizing committee of the Modelling of Mechanical and Mechatronic Systems MMaMS 2014
doi:10.1016/j.proeng.2014.12.138
 Lajos Nagy et al. / Procedia Engineering 96 (2014) 302 309 303

motors primary electric circuit. The two part functions are in close connection with each other. There are two basic types of
starter motor pinion-engaging mechanisms: direct operation switch, where the starter motor and the pinion-engaging
mechanism are uni-axial, and the indirect operation switch, where the central line of the switch and the axis of the starter
motor do not coincide and the forward movement of the pinion gear is supported by a lever or a release gear.
The functional drawing of the analyzed PEM is shown in Figure 1., where Item 1 is the solenoid switch (electromagnet),
item 2 is a pinion engaging lever (translational to translational transducer), item 3 is the drive pinion. The drive pinion can
do translational and also rotational movement.
1 2 3

Fig 1. Functional drawing of the PEM

3. Mechatronic design

Mechatronic system design is modern interdisciplinary design procedure. Mechatronic systems emerge from a suitable
combination of mechanics, electronics and information processing. The very popular German VDI guidelines 2206 describe
an integrated model of product development (see in Figure 2.). There are based on the traditional design methods [15-17]
and respective design theories developed mainly by P AHL, BEITZ, HUBKA, KOLLER, FRANKE, and ROTH. The V-
model envisages a macrocycle, which based on the requirements of the product development provides for the system design
which is subsequently transferred to the now parallelised domain design [8]. The guidelines mainly aim at supplying
generally accepted methodical and branch independent bases for developing and designing technical systems and products
for a wide range of applications [3]. They provide a systematic and planned procedure for solving technical problems. The
VDI product development model is based on a system-oriented flexible procedural model.
Based on the V model the requirements can be divided into four large groups on the basis of [13]: Functional or basic
requirements (determining the actual objective of the task, always assigned to the particular task). General requirements
(general main requirements set for starters). Priority requirements (requirements with the greatest impact on development
strategies). Typical requirements of all types of machine (Table 1.). In [6], [7] the electromechanical model of the PEM is
described. The results are used in the functional and general requirements.

Fig. 2.VDI 2206 V model [16]

Traditional methods [17-19], for mechatronics design are often based on a sequential approach, where the mechanical
structure is designed first. Mechanical systems generate certain motions or transfer forces or torques. For an oriented
command of, e.g., displacements, velocities or forces [3]. The task is how to develop a new PEM construction. First of all it
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should be analyze the different motion transducers. Figure 3. shows a design procedure which is applying machine tool
design [8].

Table 1. Requirements list

Functional requirements Engaged and disengaged the pinion-flywheel connection,
Positioning, the maximum axial displacement, h2=13,5 mm,
New technical solution
General Requirements A great number of connection (over then 250 000),
Short connection time (less than 0,03 sec),
Modular design,
Low level of noise
Priority requirements Rapid repair, service or replacement in case of faults
Easy fit in many different engines
Operability also in extreme weather conditions
Reliability
Typical Requirements of all types of machine Long service life
Compactness and small weight
Manufacturing requirements
Industrial law requirements
Other (e.g. servicing) requirements

Fig. 3.Model-based design tool [8]

Recognizing that the two most common types of available power inputs are: (1) rotational (electric motor, fluid motor,
crank, etc.), and (2) translational (hydraulic or pneumatic cylinder, linear motor and ball screw, etc.), The first step in the
conceptual mechatronic design is: the types of motion that are transmitted between the input and output members, i.e.
translation-to-translation or translation-to-rotation, without any regard to specific axes, and the type of spatial relationship
between the input and the output axes, i.e. parallel, perpendicular, or skew [1].
The aim of the new mechanism is built in coaxial with the electric motor shaft. The point of this construction is the
following: the pinions axial movement ensured with a DC servo motor combined with cam mechanism. The DC servo
 Lajos Nagy et al. / Procedia Engineering 96 (2014) 302 309 305

motor is energized only to perform pinion-engagement and not during the whole starting process. The control of the PEM
can be done independently from the switching on/off of the starter motor. At the first stage we neglect the whole starting
process. The functional drawing of the new PEM is shown in Figure 4. It contains the following parts: DC motor with
rotating potentiometer (servo motor) (1), rotational to translational transducer (2) and drive pinion (3). The rotation to
translation transducer can be realized with a cam follower system.

1 2 3

Fig. 4.Functional drawing of the new PEM

A cam is a versatile, specially shaped part of a machine that is always in contact with a member called the follower. The
most significant advancement of cam systems has resulted from the application of the digital computer. New techniques and
information are available for cam synthesis, analysis and dynamics. Several authors have proposed applications for
improving the kinematic and dynamic behavior of cam-follower mechanisms [9], [11], [20].
The cam mechanism design includes two stages. The selection of transfer functions which fulfill prescribed kinematical
specifications, and the optimization of the mechanism geometry, regarding constructive restrictions [9]. The cam shape may
be determined the transfer function of the mechanism. Dependent upon the values of the follower velocity and acceleration
at the start and at the end of each transient region. The displacement diagram is a rectangular layout of the follower motion
in one cycle of cam operation. The rise of the follower (output motion) is shown as the ordinate. The abscissa is divided into
equal cam angles or equal time divisions. The displacement diagram is generally sketched as the first step in the
development of the cam profile [1], [9], [11], [20]. In all cams, the displacement of the follower is given by the
mathematical relationship. For a cam follower system, the follower displacement, s(t), is a function of cam rotation angle
4(t). Mathematically it can be expressed as:

s t  f  4 t  (1)

The follower acceleration can be obtained from (1):

a t  f cc  442  t   f c  4 4  t  (2)

These equations present the kinematic relationship between the cam input angular velocity 4  t  and the follower output
motion s(t), v(t), a(t) and jerk j(t). Figure 5. shows different basic acceleration curves. The selection of the suitable
acceleration is based on the jerk function. That curve suits to the less jerk-like behaviour (delicate motion), which provide
the smallest maximum value for the jerk. This is one of the explanations why we cannot choose the suitable acceleration and
velocity parameters. Usually the selection is done on the price of compromises due to operation's parameters since the most
adverse jerk value construction may suit to the given task.
306 Lajos Nagy et al. / Procedia Engineering 96 (2014) 302 309

Basic curves
2.5
const acceleration
simple harmonic motion
2
sinusoidal acceleration
modified trapezoidal acc.
1.5 modified sinusoidal acceleration

cam follower acceleration [mm/rad ]

3-4-5 polynomial

2
1

0.5

-0.5

-1

-1.5

-2

-2.5
0 pi/2 pi 3pi/2 2pi
T [rad]

Fig. 5.Basic acceleration curves

In our cam design the acceleration functions selected as sinusoidal, and 3-4-5 degree polynomial functions, since these
functions meet the most machine design requirements. In addition to these we may obtain better performance for wear,
stress, shock, noise, cam surface fatigue and the lowest amplitudes for vibrations, etc.
The selected mechanism, which fulfils the requirements, is a cylindrical roller follower mechanism. There are 4 possible
concept variants shown in Table 2.

Table 2. Concept variants

Cam angle Form of the cam
Motion program Function (E)
rotation shape
DRD Polynomial 180 +180 -180 opened
DRD Trigonometric 180 +180 -180 opened
DRRD Polynomial 360 +180 +180 closed
DRRD Trigonometric 360 +180 +180 closed

In Table 2. the total rise angle J defines the cam angle 4 of the DC motor driving the mechanism.. If the total rise angle
is 180 degrees then DC motor also rotate 180 degrees and the drive pinion-flywheel gear connection will be engaged. After
the adverse rotation with 180 degrees the connection will be disengaged. Only the first variant of the above solutions in
Table 2. has been manufactured, since the rest variants can be easily developed from it. The chosen displacement function is
a 5th polynomial:

4 5 4
4
4
3

s 10  15  6 (3)
J J J

4. Mechanical modeling of the cam mechanism

The equations of the mechanical model (see in Figure 5.) are derived form Euler-Lagrange Equations [4], [10]:

d wL wL
 Q, i 1, 2
dt wqi wqi (4)
q1 s1 ; q2 x2

where L is the Lagrange function, s1 is the position of cam follower, x2 is the position of the pinion. The Lagrange function
is constructed using kinetic co-energy T* and potential energy V.
 Lajos Nagy et al. / Procedia Engineering 96 (2014) 302 309 307

L T * V (5)

h2
h2

k kb
M(d4/dt)

M2 4
b
m2, J2 b2
m 1, J 1
x2
s1

Fig. 5.Mechanical model of the new PEM

The kinetic co-energy can be written as follows:

1 d s1 2 1 2
2
J2
 J1 4  m2 
*
T m1 x2 (6)
2 d 4 2 r0 tan  90q  E 

where m1 is the mass of the cam, J1 is the inertia moment of the cam mechanism, m2 is the mass of the pinion, J2 is inertia
moment of the pinion, r0 is the radius of the pinion, E is the helix angle of the pinion-shaft.
The potential energy:

1
kb  x2  s1  4  
2
V (7)
2
where kb is the spring stiffness. Fig. shows the theoretical and measured spring characteristics. The applied spring force can
be calculated the following equations:

Fb kb x2  F1 if 0  x2  h2
Fb  x2  (8)
Fb kf  x2  h2  if x2 t h2

N
where F1 = 42 N is denote the extent pre-stressing of the spring, kf 2 106 is spring stiffness of butting-on of the
m
pinion
The virtual work of the non-conservative elements is:

ds ds
G Wnc M  4  G4  b2 x2  1 4 G x2  G4 (9)
d 4 d4

 
Where M 4 is the applied servo motor torque-speed characteristic, and b2 x2 is the damping force.
308 Lajos Nagy et al. / Procedia Engineering 96 (2014) 302 309

M 0 if 4  40
M 4
M 0  a 40  4  if 4 t 40 (10)
M0
where a
4 max  40 

Substituting (6), (7) into (5), then using (4) and taking expression (9) into consideration, the following system of differential
equations are obtained:

m1 s1c2  J1 4  m1 s1c s1cc42  b2   x2  s1c4 sc  kb   x2  s1 s1c M 4 (11)

J2
m2  x2  b2  x2  s1c4   kb  x2  s1  0 (12)
r0 tan  90q  E 
2

5. Experimental and simulation results

In the first phase we adjusted the parameters of the servo motor and the servo controller to produce the required motions.
In the second phase the test bench worked at least 300 000 cycles continuously without real life load. We tested the axial
movement of the pinion, the heat of the motor and the time of 1cycle. The test was successfully, and the mechanism had
been not significant abrasion and not sign fatigue.

6. Conclusion

The paper presented of a mechatronic design process at the conceptual design stage. The method is based on traditional
design method. The paper described a new pinion-enganging mechanism for starter motors which is fulfill the requirements
of the modern starting system. We built up the mechanical model of the new PEM. The model is described by a nonlinear
system of differential equations. The simulation of the PEM was performed by Matlab. Figure 6. shows the simulation
results of the drive-pinion displacement versus time. The dash line denote the results of the new PEM. The red line denote
the analyzed PEM.
 Lajos Nagy et al. / Procedia Engineering 96 (2014) 302 309 309

0.016

0.014

0.012

drive pinion desplacement [m]

0.01

0.008

0.006

0.004

0.002

0
0 0.005 0.01 0.015 0.02 0.025 0.03
t [s]

Fig. 6.Simulations results

Acknowledgements

This research was (partially) carried out in the framework of the Center of Excellence of Mechatronics and Logistics at
the University of Miskolc

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