Compliant Gripper with Flexure and Ball Transfer for TEM Sample Handling
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Solution Overview
Problem
Automation of sample handling for transmission electron microscopy (TEM) and focused ion beam (FIB) systems faces challenges due to robotic holders susceptible to jamming or binding during insertion, especially with tight tolerances, which requires manual handling and increases contamination risk and slows production.
Innovation Solution
A precision handling system incorporating a gripper with compliance in multiple directions, including a flexure and ball transfer, allowing for precise and repeatable movement of sample holders with orthogonal compliance to accommodate misalignments and reduce friction, enabling automated sample placement and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robotic holder is used for automated sample handling, then productivity is improved, but the holder is susceptible to jamming or binding during insertion due to tight tolerances
Solution Approach 1:
The patent applies compliance mechanisms that change the physical parameters of the gripper system by introducing controlled flexibility through flexures and compliant joints. This allows the gripper to adapt its degree of freedom and mechanical compliance to match the tight tolerances of the sample holder insertion interface, preventing jamming while maintaining automated handling capability
Solution Approach 2:
The gripper is designed with dynamic compliance characteristics that allow it to adjust its mechanical behavior during insertion. The compliant mechanism enables real-time adaptation to misalignments and tolerance variations, transforming a static rigid structure into a dynamic system that can accommodate dimensional variations without binding
2Reliability
If manual handling is used to avoid jamming, then reliability is improved, but contamination risk increases and production slows
Solution Approach 1:
The compliant gripper mechanism is designed to self-adjust and self-align during the insertion process. The compliance mechanisms automatically compensate for misalignments and tolerance variations without requiring manual intervention, allowing the system to handle samples autonomously while maintaining reliability and preventing contamination
3Manufacturing precision
If tight tolerances are used for precision handling, then manufacturing precision is improved, but the system becomes more susceptible to binding
Solution Approach 1:
The patent introduces compliance as a variable parameter that changes the effective tolerance stack-up. By incorporating flexures and compliant mechanisms, the system transforms fixed tight tolerances into a dynamic system where the compliance absorbs dimensional variations, maintaining precision while preventing binding
Solution Approach 2:
The compliant mechanism adds an additional degree of freedom to the insertion process. Instead of relying solely on precise linear positioning in one dimension, the compliance introduces rotational and lateral degrees of freedom that allow the gripper to accommodate misalignments, effectively adding dimensional flexibility to the precision handling system
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables repeatable and automated sample placement with high precision, reducing the risk of contamination and increasing production efficiency by minimizing misalignment and binding issues, while maintaining sub-micron positional accuracy.
Implementation Method 1
The ball transfer includes a ball configured to engage the object to transfer the gripping force thereto and configured to spherically rotate to allow the object to move with respect to the first jaw
Implementation Method 2
The flexure is coupled to the gripper and configured to provide compliance in at least one direction
Data Source
AI summary
A precision handling system including a gripper, a flexure, and a ball transfer. The gripper includes a first jaw and a second jaw configured to provide a gripping force therebetween for gripping and moving an object. The flexure is coupled to the gripper and configured to provide compliance in at least one direction. The ball transfer is coupled to the gripper. The ball transfer includes a ball configured to engage the object to transfer the gripping force thereto and configured to spherically rotate to allow the object to move with respect to the first jaw.