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Light-weight origami-inspired mechanisms can provide advantages in deployable space systems and other applications. However, a significant challenge in their design is ensuring that they are sufficiently stiff. Compliant, deployable stiffeners utilizing a profile that approximates the Euler Spiral are proposed as one possible solution. It is shown that a structure with this specific profile, called a lenticular stiffener, permits stiffeners to be flattened using a force applied at their edge. Formulas for calculating the increase in stiffness are developed. Relations needed to design the deployment behavior of the stiffeners are also derived. Finally, advantages of different configurations of stiffeners are evaluated. These results are verified through simulation and experiments. [ABSTRACT FROM AUTHOR]

Reducing the motion-direction stiffness of compliant mechanisms reduces their actuation effort and simplifies associated static balancing mechanisms. This work introduces a flexure type called lattice flexures and evaluates some of their fundamental properties. Lattice flexures have a reduced bending stiffness when compared to traditional rectangular-section blade flexures of similar size. The motion-direction bending stiffness of two lattice flexure types, called X-type and V-type, are analytically derived, corroborated with finite element analysis, and validated with measurements of physical prototypes. The lattice flexure has the potential to reduce the bending stiffness of some compliant mechanisms by 60–80%, as demonstrated in devices manufactured using 3D printing technologies. It is shown that some lattice flexures exhibit a torsional/bending stiffness ratio as much as 1.7 times higher than an equal aspect-ratio blade flexure, and a transverse bending/motion-direction bending stiffness ratio up to 6.5 times higher than an equal aspect-ratio blade flexure. [ABSTRACT FROM AUTHOR]

Although the use of compliance or elastic flexibility in microelectromechanical systems (MEMS) helps eliminate friction, wear, and backlash, compliant MEMS are known to be sensitive to variations in material properties and feature geometry, resulting in large uncertainties in performance. This paper proposes an approach for design stage uncertainty analysis, model validation, and robust optimization of nonlinear MEMS to account for critical process uncertainties including residual stress, layer thicknesses, edge bias, and material stiffness. A fully compliant bistable micromechanism (FCBM) is used as an example, demonstrating that the approach can be used to handle complex devices involving nonlinear finite element models. The general shape of the force-displacement curve is validated by comparing the uncertainty pre- dictions to measurements obtained from in situ force gauges. A robust design is presented, where simulations show that the estimated force variation at the point of interest may be reduced from ±47 µN to ±3 µN. The reduced sensitivity to process variations is experimentally validated by measuring the second stable position at multiple locations on a wafer. [ABSTRACT FROM AUTHOR]

A new class of bistable mechanisms, the fully compliant tensural bistable micromechanism (FTBM) class, is introduced. The class consists of linear bistable micromechanisms that undergo tension loads, in addition to the bending loads present, through their range of motion. Proof-of-concept designs fabricated in two different microelectromechanical systems (MEMS) surface micromachining processes were demonstrated. Three sets of refined designs within the FTBM class were designed using optimization methods linked with nonlinear finite element analysis (FEA), then fabricated and tested. Measured force and displacement performance are compared to values obtained by FEA. On-chip actuation of the bistable mechanisms was achieved using thermomechanical in-plane microactuators (TIMs). The FTBM class of bistable mechanisms explores a relatively new design space for fully compliant micromechanisms, and mechanisms from this class have promise in such applications as micro shutter positioning, microvalves, and electrical microrelays. [ABSTRACT FROM AUTHOR]

Abstract: This paper presents the compliant contact-aided revolute (CCAR) joint, a planar mechanism capable of performing the functions of a bearing and a spring. The pseudo-rigid-body model is used to predict the behavior of the CCAR joint, and this model is validated through the use of finite element analysis and prototype testing. The CCAR joint is shown to have high maximum rotation and lateral stiffness. A case study is presented, and manufacturing considerations are discussed for the macro, meso, and micro scales. [Copyright &y& Elsevier]

Cross-axis flexural pivots, formed by crossing two flexible beams at their midpoints, have been used in compliant mechanisms for many years. However, their load–deflection behavior has yet to be appropriately modeled to allow easy analysis and synthesis of mechanisms containing them. This paper uses results of non-linear finite element analysis to investigate this behavior. Based on the analysis, two models for the pivots are presented – one simple and one more complex. The accuracy of the models is demonstrated by comparing results to those measured for pivots made from polypropylene and steel. [Copyright &y& Elsevier]

A fully compliant constant-force mechanism that uses an initially angled parallel-guiding mechanism is proposed. A pseudo-rigid-body model (PRBM) of the mechanism is developed and validated using both finite element models and experimental prototype testing. The PRBM is used as a preliminary design tool to identify parameters that result in a constant-force mechanism. An adjustable version of the mechanism is also proposed and is used to assess the range of validity of the PRBM and highlights how the system response can be varied by changing the flexible beams inclination. A finite element based optimization is used to create a modified version of the mechanism that incorporates beam-end rotation effects and offers greater performance. Potential applications for the mechanism are discussed and it is demonstrated as a component of a statically balanced system. [ABSTRACT FROM AUTHOR]

Because compliant mechanisms achieve their motion through deflection of flexible members, they have a limited range of motion and finite stiffness. Many common flexure geometries also suffer from a non-stationary center of rotation. These properties can be obstacles to their adoption in applications that require large displacements, low stiffness, or stationary centers of rotation. This work presents the concept of compound flexures: by assembling arrays of flexures, we can increase range of motion, decrease stiffness, and reduce center shift. We first develop the theory behind some of the basic behavior of compound joints. Then finite element analysis is used to explore other aspects of compound joint behavior such as off-axis stiffness and quantifying the center shift for two flexure types when used in compound joints of various configurations. It is shown in an example that range of motion can be doubled with no appreciable loss in off-axis stiffness, while the desired stiffness κ θz remains unchanged. A method is presented to achieve zero center shift for a specified rotational displacement. Compound joints are shown to exhibit greater ranges of motion, higher off-axis stiffness, and reduced center shift compared to traditional joints. [ABSTRACT FROM AUTHOR]

The concept of a statically balanced mechanism with a single rotational degree-of-freedom is presented. The proposed device achieves static balancing by combining positive stiffness elements and negative stiffness elements within an annular domain. Two designs are discussed. The first is composed of an Archimedean spiral and two pinned-pinned pre-buckled beams. The overall mechanism is modeled via an analytical approach and the element dimensions are optimized. The optimal configuration is then tested through finite element analysis (FEA). A second approach replaces the spiral beam with elastic custom-shaped spline beams. A FEA optimization is performed to determine the shape and size of such spline beams. The behavior of the negators is used as reference for the optimization so as to achieve a complete balancing. A physical prototype of each configuration is machined and tested. The comparison between predicted and acquired data confirmed the efficacy of the design methods. [ABSTRACT FROM AUTHOR]

The cylindrical cross-axis flexural pivot (CCAFP) is proposed as an ultra-compact flexure capable of being integrated into hollow cylindrical shafts, enabling shaft motion without inhibiting cables or other components inside the shaft. Mechanism geometry, materials, and manufacturing are proposed and the results analyzed and tested. A parametric finite element model of the CCAFP was created to analyze the force-deflection and strain-deflection relationships and the predicted behavior was verified by experiment. Analytic models of stress-limiting cam-surfaces suggest even larger motions may be possible when not limited by current practical constraints. The CCAFP is demonstrated and tested at multiple size scales and in multiple materials, ranging from 28.6 mm diameter 4130 steel (achieving 9 degrees of angular deflection) to 3 mm diameter NiTi (achieving an angular deflection of 85 degrees). The results are generalized to apply to a range of applications, and the CCAFP particularly shows promise for implementation in minimally invasive surgical instruments to decrease instrument size while maintaining instrument performance. [ABSTRACT FROM AUTHOR]

This paper introduces a large-displacement monolithic compliant rotational hinge, called the Flex-16. The Flex-16 achieves 90° of rotation and is aimed for application as a compliant deployment hinge. A nonlinear parametric finite element model was created to rapidly analyze a variety of designs identified during a configuration study. Prototypes were tested to verify the model and to validate that the Flex-16 was capable of 90° of rotation without failure or self collision. Five prototypes were fabricated from three different materials (polypropylene, titanium, and a carbon nanotube framework) on two different size scales (macro and micro). Rotational stiffness, stress, center shift, and mode shapes and frequencies were analyzed. [ABSTRACT FROM AUTHOR]

• An analysis method is proposed for contact-aided compliant mechanisms (CCMs). • An approximation is proposed to determine the moving boundary of contact. • The chained pseudo-rigid-body model is used to evaluate deformation and stress. • The proposed method is straightforward. Contact-aided compliant mechanisms (CCMs) utilize contact to achieve enhanced functionality. The contact phenomenon of CCMs increases the difficulties of their analysis and design, especially when they exhibit beam-to-beam contact. Considering the particularity of CCMs analysis, which is more about the mechanisms' deformation, this paper presents a numerical method to analyze the large deflection and stress of the CCMs considering beam-to-beam contacts. Based on our previous work on beam-to-rigid contact, the large deformation of general beams in CCMs is modeled by using the chained pseudo-rigid-body model (CPRBM). An approximation based on the geometric information of CPRBM is proposed in this paper to rapidly determine the moving boundary curve for beam-to-beam contact constraints. The static equilibrium configuration of CCMs is solved by minimizing its potential energy function under the geometric constraints from the boundary curves of contacts. A formulation is also provided to evaluate the normal stress along the deformed beam based on the deformation of CPRBM's torsional springs. Numerical examples and finite element analysis are used to verify the feasibility and accuracy of the proposed method. [ABSTRACT FROM AUTHOR]

An underactuated or underconstrained compliant mechanism may have a determined equilibrium position because its energy storage elements cause a position of local minimum potential energy. The minimization of potential energy (MinPE) method is a numerical approach to finding the equilibrium position of compliant mechanisms with more degrees of freedom (DOF) than inputs. Given the pseudorigid-body model of a compliant mechanism, the MinPE method finds the equilibrium position by solving a constrained optimization problem: minimize the potential energy stored in the mechanism, subject to the mechanism’s vector loop equation(s) being equal to zero. The MinPE method agrees with the method of virtual work for position and force determination for underactuated 1-DOF and 2-DOF pseudorigid-body models. Experimental force-deflection data are presented for a fully compliant constant-force mechanism. Because the mechanism’s behavior is not adequately modeled using a 1-DOF pseudorigid-body model, a 13-DOF pseudorigid-body model is developed and solved using the MinPE method. The MinPE solution is shown to agree well with nonlinear finite element analysis and experimental force-displacement data. [ABSTRACT FROM AUTHOR]