This paper uses linear quadratic optimal control theory to design high-speed Dwell-Rise-Dwell (D-R-D) cams. Three approaches to D-R-D cam design are compared. In the first approach the cam is designed to be optimal at a fixed operating speed, i.e., a tuned cam design is obtained. In the second approach the cam profile is determined by minimizing a sum of quadratic cost functions over a range of discrete speeds, thus producing a cam-follower system which is optimal over a range of speeds. The third technique uses trajectory sensitivity minimization to design a cam which is insensitive to speed variations. All design methods are formulated as linear quadratic optimal control problems and solved using an efficient numerical procedure. It is shown that the design techniques developed can lead to cams that have significantly lower peak contact stress, contact force and energy loss when compared to a polydyne cam design. Furthermore, the trajectory sensitivity minimization approach is shown to yield cams that have lower residual vibration, over a range of speeds, when compared to a polydyne cam design.

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