This paper presents a novel six degrees of freedom mechanism to integrate conical article with the cylindrical article which are large and heavy. The six desired motions include six linear motions and six rational motions. The linear motions are vertical, longitudinal and lateral. The vertical motion is achieved by toggle jack, longitudinal by wheel and rail assembly and the lateral motion is achieved by cross slides. The three rotational motions namely pitch, yaw and roll are achieved by simultaneous movement of toggle jacks, simultaneous movement of cross slides and rollers respectively. It is designed in such a way that it sustains the weight of the heavy articles and also prevents slipping and toppling of the conical article. This approach helps to satisfy and fulfil the goal of aligning the main article flange to the conical article flange for further bolting. The mechanism is designed keeping in mind factors like ergonomics and aesthetics.

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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 7, Issue 3, May–June 2016, pp.193–199, Article ID: IJMET_07_03_018
Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=7&IType=3
Journal Impact Factor (2016): 9.2286 (Calculated by GISI) www.jifactor.com
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
SIX DEGREES OF FREEDOM
INTEGRATION DEVICE
Pranav Suryawanshi, Soham Wadnap, Ruchita Pedram, Nikhil Wakode,
Prof. Ajaj Attar
Mechanical Engineering Department,
Smt. Kashibai Navale College of Engineering, Pune–MS
ABSTRCT
This paper presents a novel six degrees of freedom mechanism to integrate
conical article with the cylindrical article which are large and heavy. The six
desired motions include six linear motions and six rational motions. The linear
motions are vertical, longitudinal and lateral. The vertical motion is achieved
by toggle jack, longitudinal by wheel and rail assembly and the lateral motion
is achieved by cross slides. The three rotational motions namely pitch, yaw
and roll are achieved by simultaneous movement of toggle jacks, simultaneous
movement of cross slides and rollers respectively. It is designed in such a way
that it sustains the weight of the heavy articles and also prevents slipping and
toppling of the conical article. This approach helps to satisfy and fulfil the
goal of aligning the main article flange to the conical article flange for further
bolting. The mechanism is designed keeping in mind factors like ergonomics
and aesthetics.
Key words: Six Degrees of Freedom Mechanism, Linear Motion, Rotational
Motion, Toggle Jack, Cross Slide, Ergonomics, Aesthetics
Cite this Article: Pranav Suryawanshi, Soham Wadnap, Ruchita Pedram,
Nikhil Wakode, Prof. Ajaj Attar, Six Degrees of Freedom Integration Device.
International Journal of Mechanical Engineering and Technology, 7(3), 2016,
pp. 193–199.
http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType=3
1. INTRODUCTION
Since early ages mankind has been struggling with large and long structures or objects
where the question of how it would be manufactured aroused. Then the thought of
integrating parts came into action where the body would be made in parts and then
assembled. Heavy structures became the integral part of this plan. Manufacturing took
turns under all types of economic systems. In a free market economy manufacturing
was usually directed towards the mass production of parts .Modern manufacturing
includes all intermediate processes required for the production and integration of a
product's components.

2. Pranav Suryawanshi, Soham Wadnap, Ruchita Pedram, Nikhil Wakode, Prof. Ajaj Attar
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The conical article is a very heavy device (say weighing up to 500kgs). It has to
be precisely aligned with the main article (cylindrical) which is placed on a stationary
support on the ground. Due to the large weight of the payload it becomes very
difficult for the operators to integrate it with the main articles. Various problems arise
and a proper mechanism satisfying the purpose satisfactorily is required. A number of
problems had to be tackled arising from this process of integration. An alternative
process was required to overcome these problems, also it was effective to compare old
and the new process. It seems to be very challenging and new and innovative methods
have been thought about. It will be a great help if a more effective and efficient
alternative is being made.
2. PROBLEM STATEMENT
Any launch vehicle (rocket/missile) is usually a cylindrical body having number of
segments like propulsion, navigation & control, payload etc.
These sections are to be precisely located, oriented and assembled at the site of
launch. The payload will be stored separately at other location and is required to be
integrated with the launch vehicle on the launcher. This device must take care of six
degrees of freedom (three rotational and three translational).
The project will comprise of conceptualization of various alternatives, finalization
of suitable concept, detailed design including mechanism design, prototype realisation
and testing and final recommendations for actual system
3. LITERATURE REVIEW
3.1. Eureka: A New 5-Degree-of-Freedom Redundant Parallel Mechanism
with High Tilting Capabilities [1]
It is a new parallel mechanism which provides 5 motions .The five desired motions
include three translational and two rotational motions. High tilting angles (about first
axis and whole revolution about the following axis)is achieved by this device . This is
achieved with the help of actuation redundancy and specific travelling . . Kinematic
models are derived. Due to its particular shape the geometrical model is also derived
with ease. The paper explains plot of well conditioned workspace and practical
designs, free of self-collisions.
3.2. Kinematic Analysis Of a Translational 3-Dof Tensegrity
Mechanism[2]
It presents a novel three-degree-of-freedom mechanism based tensegrity architecture.
A cable driven mechanism is there and it exhibits three-dimensional translational
motion. Analytical solutions to the direct and inverse kinematic problems are
generated based on the geometry as well as statics of the mechanism. The boundaries
of the reachable Cartesian workspace are produced based on maintaining valid
tensegrity configurations and requiring the actuated cables to be in tension. Low
inertia, relatively large workspace volume and the movement produced by the
mechanism assure for high speed applications such as pick and place operations.

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4. METHODOLOGY
4.1. Working
For the precise alignment of the two articles, they must be given all the degrees of
freedom mentioned. Various alternatives have been considered and the finalised
concept is as follows. The rolling motion is given by two drivers and two follower
rollers. The concerned article will be mounted on these rollers with a metal strip
fitting on the rollers. These have tested for load bearing capacity such that they are
sufficient enough to bear the load of the conical object and successfully rotate it to
certain degree sufficient enough for bolting. The rollers, one driver and one follower,
are mounted inside two C-sector curved beams each. The C-sectors being placed at
calculated distances providing stability as well as support. Each curved beam is
supported on an I-beam with the means of the same I-columns. Vertical motion is
given to this I-beam (the top frame) with the help of a toggle jack with a capacity
2452.5 N. The toggle jack is mounted on the middle frame made of two C-sectors.
Two such toggle jacks have been provided on two middle frames .C-sector thus
doubling the chances of safety and increasing capacity. Varying the motions of the
toggle jacks simultaneously results in achieving pitching, a desired motion.
To overcome horizontal misalignment of the axes of the two articles, there needs
to be freedom of lateral movement. This movement is provided by cross slides. The
bottom rail is attached to the bottom frame, a composite of two C-beams, and the top
rail is attached to the middle frame. The top rail of cross slide slides over the bottom
rail cross slide. The part in contact is fit with Teflon strips to minimize friction and
give lateral movement. The cross slides are moved by means of a power screw. The
nut of power screw is fixed to the bottom frame and the screw itself fits in a collar fit
with the middle frame. This gives a relative motion when the screw is rotated. A total
of four cross slides provides this motion with ease such that there are two on each side
and a total of two power screws. Thus varying their motion will also result in
achieving yawing motion. To move the cylindrical part closer to the conical part in
longitudinal motion, rail system will be used. The device is rested on these rails on
wheels by rotating the axle of the common shaft wheel, longitudinal movement can be
achieved. So all the six degrees of freedom have been covered by the device.
4.2. Diagram
Figure 1 Front View of The Integration Device

4. Pranav Suryawanshi, Soham Wadnap, Ruchita Pedram, Nikhil Wakode, Prof. Ajaj Attar
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5. SAMPLE CALCULATIONS [3]
5.1. Calculations for roller pin
By flexure formula, we have
i.e.
For circular cross-section,
Therefore
Stress induced,
N/mm2
Zinduced =
=
Zinduced = 548.3636 mm3
Thus,
Where,
σ = bending stress
I = moment of inertia
M = bending moment (here, 17547.6375)
y = location of centroid

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Z = section modulus
d = diameter of roller pin
σall = allowable bending stress (0.66*Syt)
Syt = tensile yield strength of M.S. (240 N/mm2
)
f.s = factor of safety (5)
5.2. Design of Toggle Jack
and link length equal to 127mm
(mild steel)
(co-efficient of friction)
We know that W= 250 kg
= 250*9.81
= 2452.5 N
F = W/2tan
W1 = 2F
effort required to rotate the screw
P =
=
Torque required to rotate the screw
shear stress in the screw due to torque
direct tensile stress in the screw
Maximum principal (tensile) stress,
According to Rankine’s formula, buckling load (Wcr)

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5.3. Bottom Channel Frame
σ = Bending Stress
Y = Moment of Inertia
M = Bending Moment
Y = Section Modulus
Diag.1 Line Diagram For The C-Channel
5.4 Shaft Bearing Selection
Deep groove ball bearing, which is easily available in the market and has a high
stability has been selected. The shaft diameter is 50 mm, from this diameter, using
design data book selecting series 6010 bearing
5.5 Design of Shaft
Diag.2 Line Diagram For Shaft
I =
Z =
Z =

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5.6 Final Results
Table 1
Sr. no Component Dimensions
1. Roller pin d= 20mm
2. Toggle jack l= 127mm, b1=24mm, t1=12mm
3. Bottom channel frame ISJC 150, b=50mm, h=150mm
4. Shaft d= 50mm
Here:
d: diameter
l: link length, b1: link breadth, t1: link thickness
Other values hold their usual meanings.
6. CONCLUSION
Thus the six degrees of freedom have been achieved amongst which three being
translational and three being rotational. Vertical motion has been successfully
achieved by means of the toggle jack. The rotational motion has been achieved by
means of rollers, lateral motion by the cross slides and the horizontal traverse by rails
and wheels. The other motions like yawing and pitching are achieved by varying the
inputs of these parameters needed to provide these motions precisely and safely. Thus
all motions are achieved under safe and precise considerations so as to assemble the
required parts.
ACKNOWLEDGEMENT
We would like to acknowledge our sincere gratitude to project supervisor Mr. Anil
Chavan for his valuable suggestions and encouragement. Also our sincere thanks to
administrative and technical staff members of the Department who have been kind
enough to advice during our work at SKNCOE Pune.
REFERENCES
[1] Sébastien Krut, Olivier Company, Sani Rangsri, François Pierrot, Eureka: A New
5-Degree-of-Freedom Redundant Parallel Mechanism, Intl. Conference on
Intelligent Robots and Systems, IEEE, pp.3575-3580, 2003.
[2] Chris A. Mohr, Marc Arsenault, Kinematic Analysis of A Translational 3-Dof
Tensegrity Mechanism, Transactions of the Canadian Society for Mechanical
Engineering, 35(4), 2011
[3] R. S. Khurmi, J. K. Gupta, A textbook of machine design, Eurasia publishing
house Pvt. ltd.
[4] Akash Sood and Padam Singh, Prof. Ajaj Attar Analysis of Space Frame of
Formula Sae at High Speed with Ergonomic and Vibrational Factors.
International Journal of Mechanical Engineering and Technology, 6(11), 2016,
pp. 202–212.
[5] Jan-Cristian Grigore and Nicolae Pandrea, Calculation of The Undetermined
Static Reactions For The Articulated Plan Quadrilateral Mechanism.
International Journal of Mechanical Engineering and Technology, 4(3), 2013,
pp. 400–408.