When designing linkage mechanisms for motion synthesis, many examples have shown that the optimal kinematic constraint on the task motion contain too large deviation to be approximately viewed as a single rotational or translational pair. In this paper we seek to adopt our previously established motion synthesis framework for the design of cam-linkages for a more accurate realization, while still maintaining a one-DOF mechanism. To determine a feasible cam to lead through the task motion, first a kinematic constraint is identified such that a moving point on the given motion traces a curve that is algebraically closest to a circle or a line. This leads to a cam contour that is simple and smooth to avoid the drawbacks of cam mechanisms. Additional constraints could also be imposed to specify the location and/or size of the cam-linkages. An example of the design of a lower-limb rehabilitation device has been presented in the end of this paper to illustrate the feasibility of our approach. It is shown that our design could lead the user through a normal walking motion.

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