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Kinematic Analysis of Different Shedding Cams Used in Weaving Looms

Article · December 2019

DOI: 10.26488/IEJ.12.12.1201

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Anindya Ghosh
Government College of Engineering & Textile Technology, Berhampore, India
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Industrial Engineering Journal
ISSN:2581-4915

Industrial Engineering Journal

Volume 12 Issue 12 * December 2019

Kinematic Analysis of Different Shedding Cams Used in

Weaving Looms
Anindya Ghosh 1
1
Government College of Engineering & Textile Technology, Berhampore, India-742101

[email protected]

ABSTRACT: In this study, a computational plotting of different types of shedding cam profiles has been
endeavored. Various shedding cams like linear, simple harmonic, parabolic, cycloidal etc. for designing
plain and twill weaves have been considered. A critical analysis on the kinematic characteristics for different
types of cams suggests that the simple harmonic and cycloidal cams outperform parabolic and linear cams
for high speed weaving.

KEYWORDS: Cam profile, Cycloidal, Follower motion, Kinematics, Simple harmonic, Shedding, Weave

1. INTRODUCTION

Cam-follower mechanism converts a rotary motion into a linear reciprocating motion. The input of cam
rotary motion transforms into output as a follower motion consisting of rise, dwell and fall. The transition of
dwell with rise and fall is an important aspect of cam design since the follower must go from a velocity and
acceleration of zero into a motion with specific velocity and acceleration. The rise and fall of the follower
have many possible motions such as linear, simple harmonic, parabolic, cycloidal etc. [1, 2]. The design of
the cam profile ultimately determines the pattern of follower motion with desired displacement, velocity,
acceleration and jerk.

For excellent loom performance, the cams should be properly selected [3, 4]. The appropriate choice of cam
is more enhanced in case of high speed looms which are required to maintain a high level of performance.
Mali et al. [5] used finite element approach to perform the design optimization of cam and follower
mechanism. Patel [6] made a critical review on the design of cam and follower. Desai and Patel [7] made a
computer aided kinematic and dynamic analysis of cam and follower.

This study endeavors the computational plotting of different types of shedding cam profiles. A comparison
of different types of cams with respect to their corresponding kinematics has also been discussed in this
work.

2. DESIGNING OF SHEDDING CAM PROFILE

A cam is a rotating machine element which offers rectilinear reciprocating or oscillating motion to another
element known as follower. Conventionally, in a cam-follower system, the cam is generally operated at a
fixed rpm and the motion characteristics of the follower are estimated once the cam displacement curve is
designed. The cam profile is the shape of the contoured cam surface by means of which motion is
communicated to the follower. In reality the cam profile can be better visualized by imagining the cam to

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remain stationary while the contact points between cam and follower revolves round the cam in the opposite
sense of the actual cam rotation. With such an idea the locus of the successive touching points of tangents
with the follower yields the cam profile [8, 9]. The position of the follower depends on the centre-to-centre
distance between cam and follower (𝜌) and angle of the cam shaft rotation (𝜃) as depicted in Figure 1.
Therefore, if 𝑓(𝑥, 𝑦, 𝜌, 𝜃) = 0 describes the locus of the follower surfaces, the 𝑥, 𝑦 coordinates of cam
profile are obtained by solving the following two equations

𝑓(𝑥, 𝑦, 𝜌, 𝜃) = 0 (1)

𝛿𝑓(𝑥,𝑦,𝜌,𝜃)
=0 (2)
𝛿(𝜌,𝜃)

𝛿𝑓
where is the partial derivative with respect to 𝜌 and 𝜃.For a cylindrical follower with radius 𝑟as shown
𝛿(𝜌,𝜃)
in Figure 1, the locus of its surface is given by:

(𝑥 − 𝜌𝑐𝑜𝑠𝜃)2 + (𝑦 − 𝜌𝑠𝑖𝑛𝜃)2 − 𝑟 2 = 0 (3)

From which the partial derivative gives

2(𝑥 − 𝜌𝑐𝑜𝑠𝜃)(𝜌′ 𝑐𝑜𝑠𝜃 − 𝜌𝑠𝑖𝑛𝜃) + 2(𝑦 − 𝜌𝑠𝑖𝑛𝜃)(𝜌′ 𝑠𝑖𝑛𝜃 + 𝜌𝑐𝑜𝑠𝜃) = 0 (4)

where 𝜌′ is the derivative of 𝜌. By solving Equations (3) and (4), the𝑥, 𝑦 coordinates of cam profile are
obtained which are expressed by:

𝑟(𝜌′ 𝑠𝑖𝑛𝜃+𝜌𝑐𝑜𝑠𝜃)
𝑥 = 𝜌𝑐𝑜𝑠𝜃 ± (5)
√𝜌2 +𝜌′2

𝑟(𝜌′ 𝑐𝑜𝑠𝜃−𝜌𝑠𝑖𝑛𝜃)
𝑦 = 𝜌𝑠𝑖𝑛𝜃 ∓ (6)
√𝜌2 +𝜌′2

The two solutions of 𝑥 and 𝑦 correspond to the inner and outer profiles of cam, respectively. In this study,
only inner profile has been considered which eventually yields the shape of negative cam profile.

Figure 1. The coordinates of cam and follower

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During the rise and fall regions of the follower, 𝜌 is varied according to the shape of the cam profile and it
remains constant during the dwell position. The expression of 𝜌 in Equations (5) and (6) is substituted by:

𝜌=𝑘+𝑆 (7)

where 𝑆 is the follower displacement with respect to the angle of cam shaft rotation. For a complete rotation
of cam, 𝜌 is ranging from 𝑘 to 𝑘 + ℎ, where 𝑘is the distance from the cam centre to the nearest position of
the follower centre and ℎ is the maximum lift of the follower. In this study the values of 𝑘, ℎand the crank
shaft rpm are considered as 4 cm, 5 cm and 240 rpm respectively. There are many possible motions such as
linear, simple harmonic, parabolic, cycloidal etc. for the follower during its rise and fall. The equations of
follower displacement (𝑆) with respect to the angle of cam shaft rotation (𝜃)for various types of motion are
given in the Table 1 where 𝑚, 𝑝 and 𝑐 are the constants.

To accomplish the computational plotting of the cam profile, some basic weaves like plain and twill have
been chosen with one third dwell period. Different types of basic motions such as linear, simple harmonic,
single parabolic, double parabolic and cycloidal for the heald shaft during its lifting and lowering movement
have been considered in this study.

Table 1: Follower displacement equations for different motions

Types of motions Follower displacement equation

Linear 𝑆 = 𝑚𝜃 + 𝑐

Parabolic 𝑆 = 𝑝𝜃 2 + 𝑚𝜃 + 𝑐

Simple harmonic 𝑆 = 𝑚(1 − cos 𝑝𝜃)

Cycloidal 𝑆 = 𝑚(𝑝𝜃 − sin 𝑝𝜃)

Table 2: Lifting and lowering equations of follower displacement for different cams used in plain weave
design

2𝜋 5𝜋
Cam type Lifting of follower (0 ≤ 𝜃 ≤ 3
) Lowering of follower (𝜋 ≤ 𝜃 ≤ 3
)

3ℎ 3ℎ 5ℎ
Linear 𝑆= 𝜃 𝑆=− 𝜃+
2𝜋 2𝜋 2

Simple ℎ 3𝜃 ℎ 3𝜃 𝜋
harmonic 𝑆= (1 − cos ) 𝑆= {1 − cos ( − )}
2 2 2 2 2

Single 9ℎ 2 9ℎ 2 15ℎ 25ℎ

parabolic 𝑆= 𝜃 𝑆= 𝜃 − 𝜃+
4𝜋 2 4𝜋 2 2𝜋 4

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9ℎ 2 𝜋 9ℎ 2 9ℎ 7ℎ 4𝜋
2
𝜃 , 0 ≤ 𝜃 ≤ − 2
𝜃 + 𝜃 − , 𝜋 ≤ 𝜃 ≤
Double
𝑆 = { 2𝜋 3 𝑆 = { 2𝜋 𝜋 2 3
parabolic 9ℎ 2 6ℎ 𝜋 2𝜋 9ℎ 2 15ℎ 25ℎ 4𝜋 5𝜋
− 2𝜃 + 𝜃 − ℎ, ≤ 𝜃 ≤ 𝜃 − 𝜃+ , ≤𝜃≤
2𝜋 𝜋 3 3 2𝜋 2 𝜋 2 3 3
ℎ ℎ
Cycloidal 𝑆= (3𝜃 − sin 3𝜃) 𝑆=− {3(𝜃 − 𝜋) − sin 3(𝜃 − 𝜋)} + ℎ
2𝜋 2𝜋

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Table 3: Lifting and lowering equations of follower displacement for different cams used in 1
twill
weave design

𝜋 𝜋 5𝜋
Cam type Lifting of follower (0 ≤ 𝜃 ≤ 3 ) Lowering of follower ( 2 ≤ 𝜃 ≤ 6
)

3ℎ 3ℎ 5ℎ
Linear 𝑆= 𝜃 𝑆=− 𝜃+
𝜋 𝜋 2

Simple ℎ ℎ 𝜋
harmonic 𝑆= (1 − cos 3𝜃) 𝑆= {1 − cos (3𝜃 − )}
2 2 2

Single 9ℎ 2 9ℎ 2 15ℎ 25ℎ

parabolic 𝑆= 𝜃 𝑆= 𝜃 − 𝜃+
𝜋2 𝜋 2 𝜋 4
18ℎ 2 𝜋 18ℎ 18ℎ 7ℎ 𝜋 4𝜋
2
𝜃 , 0≤𝜃≤ − 2 𝜃2 + 𝜃− , ≤𝜃≤
Double
𝑆={𝜋 6 𝑆={ 𝜋 𝜋 2 2 6
parabolic 18ℎ 2 12ℎ 𝜋 𝜋 18ℎ 2 30ℎ 25ℎ 4𝜋 5𝜋
− 2 𝜃 + 𝜃 − ℎ, ≤ 𝜃 ≤ 𝜃 − 𝜃+ , ≤𝜃≤
𝜋 𝜋 6 3 𝜋2 𝜋 2 6 6
ℎ ℎ 𝜋 𝜋
Cycloidal 𝑆= (6𝜃 − sin 6𝜃) 𝑆=− {6 (𝜃 − ) − sin 6 (𝜃 − )} + ℎ
2𝜋 2𝜋 2 2

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(a) (b)

(c)
(d)

(e)

Figure 2. Profiles of various cams used in plain weave design: (a) linear, (b) simple harmonic, (c) single
parabolic, (d) double parabolic, (e) cycloidal

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(a) (b)

(c) (d)

(e)

3
Figure 3. Profiles of various cams used in twill weave design; (a) linear, (b) simple harmonic, (c) single
1
parabolic, (d) double parabolic, (e) cycloidal

The profile of each cam consists of four parts, namely lifting, dwell at top position, lowering and dwell in
bottom position. Tables 2 and 3 depict the actual lifting and lowering equations of the follower displacement
3
( 𝑆 ) corresponding to different cams used in the shedding operation for plain and 1
twill weaves,

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respectively. The values of 𝑆 during the dwell at top and bottom positions are remaining constants which are
ℎ and 0, respectively. For designing a specific type of cam profile, firstly the corresponding equations of 𝑆
during the periods of lifting, dwell at top position, lowering and dwell at bottom position are replaced in
Equation 7. Then the Equations 5 and 6 are used to find the coordinates of x and y over a range of 𝜃 from 0
to 2𝜋 radians for obtaining the cam profile. MATLAB coding was used for the purpose of plotting.

Figure 2 illustrates the profile of the various types of shedding cams used in plain weave design. The profile
2𝜋
of each cam depicted in Figure 2 consists of four parts, namely the rise from 0 to 3 radian, the dwell from
2𝜋 5𝜋 5𝜋
3
to 𝜋 radian, the fall from 𝜋 to 3
radian and another dwell from 3
to 2𝜋 radian.

3
The profiles of different types of shedding cams used in 1
twill weave design are shown in Figure 3
𝜋 𝜋 𝜋
where profile of each cam is consisting of the rise from 0 to 3
radian, the dwell from 3
to 2
radian, the fall
𝜋 5𝜋 5𝜋
from 2
to 6
radian and another dwell from 6
to 2𝜋 radian.

3. KINEMATICS OF FOLLOWER MOTIONS FOR DIFFERENT CAMS

The velocity, acceleration and jerk equations can be obtained by differentiating the displacement equation
with respect to time (𝑡) by once, twice and thrice respectively. Therefore, the velocity, acceleration and jerk
𝑑𝑆 𝑑 2 𝑆 𝑑3 𝑆
of the follower are given by 𝑑𝑡 , 𝑑 𝑡 2 and 𝑑 𝑡 3 , respectively [10]. Figures 4 and 5 depict the displacement,
velocity, acceleration and jerk plots of follower for different types of cams used for the plain weave
shedding operation.

The linear cam produces constant velocity but the main problem associated with this cam is that at the start
and end of the dwell period, the acceleration and jerk become infinity, since the velocity and acceleration
changes its direction in an infinitely short time. Hence this cam cannot be suitable at high speed.

The single parabolic cam produces linear velocity and constant acceleration during the lifting and lowering.
During the end of the lifting motion and start of the lowering motion, the follower velocity reaches
maximum. Similar to the linear cam it shows infinity jerk at the beginning and the end of the dwell period
because the acceleration changes its direction in an infinitely short time. Thus it creates trouble in high speed
application.

In case of double parabolic cam the velocity of follower during its rise and fall is represented by two straight
lines having opposite slopes. The velocity of follower increases linearly, reaches maximum at the mid
position and then start to fall linearly during the lifting and lowering movements but it becomes zero during
the beginning and end of the dwell periods. As a result of that the acceleration changes abruptly from
positive to negative direction and vice versa during the lifting and lowering motion of follower. This creates
infinite jerk as the acceleration changes its direction in an infinitely short time. Hence this cam is not also
desirable in high speed application.

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(a)

(b)

(c)

Figure 4. Displacement (S), velocity (V), acceleration (A) and jerk (J) plots of follower for
different types of cams; (a): Linear, (b) Parabolic, (c) Double parabolic

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(a)

(b)

Figure 5. Displacement (S), velocity (V), acceleration (A) and jerk (J) plots of follower for different types of
cams; (a): Simple harmonic (b) Cycloidal

For a simple harmonic cam, velocity of the follower during its rise and fall represents by a sine curve while
the acceleration of the same represents a cosine curve. The follower velocity remains zero at the start and
end of the rise and fall which ensures a suitable linking with the dwell by means of smooth transition at the
junction of zero velocity. As a consequence acceleration and jerk remain finite. The nature of the jerk curve
is in a direction opposite to the velocity curve. Thus it is quite suitable cam for high speed application.

A cycloid can be defined as the trajectory followed by a point on the circumference of a circle which is
rolling without slipping on a straight line. For a cycloidal cam, acceleration and jerk of the follower are
represented by sine and cosine curves, respectively. Both the velocity and acceleration of follower are

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remaining zero at the start and end of the rise and fall. Therefore, a cycloidal cam ensures a perfect linking
with the dwell caused by the smooth transition at the junctions of zero velocity as well as acceleration.
Consequently, the jerk produces a non-infinite pulse. This cam is also suitable for high speed application.

4. COMPARISON OF VARIOUS TYPES OF SHEDDING CAMS

The lifting motion of the follower corresponding to different types of shedding cams has been considered for
the purpose of comparison. Figures 6 and 7 depict the displacement, velocity, acceleration and jerk plots of
the follower during its lifting motion.

It is quite obvious from the Figure 6 (a) that the follower displacement diagram of the linear cam is a straight
line whereas in case of single parabolic cam it is parabolic and concave towards the displacement axis. In
case of all but the single parabolic cam, the follower reaches the half of the displacement at the same time.
The follower displacement of the simple harmonic, double parabolic and cycloidal cams shows a sigmoidal
type of curve and the second half of the displacement curve during the lifting is a mirror image of that first
half. Among these three types, the follower of the cycloidal cam devotes maximum time during its initial
and completion parts of the lifting movement, but it spends minimum time at the middle position of the
lifting movement. On the contrary, the follower of the simple harmonic cam spends minimum time during
the commencement and end of the lifting movement but at the middle position of the lifting it allows
maximum time.

(a)

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(b)

Figure 6. Displacement and velocity plots of follower for different cams during the lifting motion; (a)
Displacement plots (b) Velocity plots

(a)

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(b)

Figure 7. Acceleration and jerk plots of follower for different cams during the lifting motion; (a)
Acceleration plots, (b) Jerk plots

The velocity plot of follower during lifting for various types of cams is shown in Figure 6(b). The follower
of linear cam has constant velocity. In case of single parabolic cam, the velocity of follower increases
linearly from zero to maximum during the entire lifting motion. The velocity of the follower during the
course of lifting motion for simple harmonic, double parabolic and cycloidal cams commences from zero,
reaches to peak at the centre position of the lift and again becomes zero at the end. In case of double
parabolic cam this change of velocity occurs in a linear fashion. As compared to simple harmonic cam, the
follower velocity of the cycloidal cam during its lifting motion starts in a slower and smoother manner, at
the middle of the lift it becomes faster and at the end position it reduces more gradually. The peak velocities
of double parabolic and cycloidal cams are higher than the simple harmonic cam.

Figure 7(a) depicts the acceleration plot of follower generated by different cam profiles during the lifting
motion. The follower acceleration of the linear cam reaches infinity just at the beginning and end of the lift,
but rest of the time during the lift it remains zero. The follower acceleration remains at a constant value for
single parabolic cam. The follower acceleration of double parabolic cam is also constant but changes its
direction from positive to negative at the mid position of lifting. In case of simple harmonic cam, the
follower acceleration shows an equal and opposite finite value at the start and end of the rise; and it becomes
zero at the mid of the rise. On the other hand, the follower acceleration of cycloidal cam is zero at the start,
middle and end of the rise. A common feature of the follower acceleration for double parabolic, simple
harmonic and cycloidal cams is that first and second half of the rise are symmetric but opposite in direction.

The jerk plot of the follower during its lifting for various cam profiles is illustrated in Figure 7(b). The jerk
of follower touches to infinity at the start and end of its rise for linear, single as well as double parabolic
cams. However, for simple harmonic and cycloidal cams the jerk of the follower remains finite throughout
its lifting motion. As a consequence, a minimum amount of shock, wear and noise are expected for the
simple harmonic and cycloidal cams. The follower jerk of simple harmonic motion is zero at the start and
end of the rise, whereas the same for the cycliodal cam shows a finite value. Overall, simple harmonic cam
generates less jerkiness than that of cycloidal cam.

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Figure 8. Overlaying of profiles for various cams used in plain weave design

Figure 8 represents the overlaying of the profiles of various cams used in plain weave design. It is clear from
Figure 8 that each cam profile has distinct shape in comparison with the others. The single parabolic cam
profile comprises of minimum surface area. As far as the shape of the rise and fall parts of the cam profile
connecting the two dwell positions is concerned, the distance from the cam centre to its surface changes
more gradually for the cycloidal cam followed by the simple harmonic and double parabolic cams. Hence,
the cycloidal cam profile provides a smooth transition of dwell with the rise and fall parts. Nevertheless, the
profiles of linear and single parabolic cams provide bumpy connection between the dwell and changeover
parts.

5. CONCLUSIONS

A comparison of different types of cam profile and their kinematics of the follower motion reveals that
linear and parabolic cams generate infinity jerk at the start, whereas simple harmonic cam causes minimum
jerk. A cycloidal cam ensures zero acceleration at the start as well as a perfect linking with the dwell and the
changeover positions. The simple harmonic and cycloidal cams are suitable for high speed weaving.

REFERENCES

[1] Bevan, T., (2010). The Theory of Machines, 3rd edition, Pearson India, New Delhi.
[2] Martin, G. H., (2002). Kinematics and Dynamics of Machines, 2nd edition, Waveland Press Inc.,
Long Grove, Illinois
[3] Marks, R., Robinson, A. T. C., (1976). Principles of Weaving, The Textile Institute, Manchester.

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[4] Banerjee, P. K., (2014). Principles of Fabric Formation, CRC Press.

[5] Mali, M. R., Maskar, P. D., Gawande, S. H. and Bagi, J. S. (2012). Design Optimization of Cam
and Follower Mechanism of an Internal Combustion Engine for Improving the Engine Efficiency,
Modern Mechanical Engineering, 2, 114-119.
[6] Patel, N. S. (2015). Modelling, Design and Analysis of Cam and Follower-A Review,
International Journal of Engineering Studies and Technical Approach, 1, 1-7.
[7] Desai, H. D. and Patel, V. K. (2010). Computer Aided Kinematic and Dynamic Analysis of Cam
and Follower, Proceedings of the World Congress on Engineering, London, Vol. 2, pp.117-127.
[8] Grosberg, P., (1968).An Introduction to Textile Mechanism, Ernest Benn Ltd., London.
[9] Booth, J. E., (1975). Textile Mathematics, Vol. 2, The Textile Institute, Manchester.
[10] Lord, P. R., Mohamed, M. H., (1982). Weaving: Conversion of Yarn to Fabric, 2nd edition,
Merrow Publishing Co. Ltd., Durham.

AUTHORS

Anindya Ghosh, Government College of Engineering & Textile Technology, Berhampore, India-742101

Email: [email protected]

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