Hydroformed Robot Arm Structure With Flanged Thin-Wall Pipe
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Solution Overview
Problem
Existing methods for producing arm-like structures for industrial robots, such as casting metal, face challenges in achieving a lightweight yet strong design with a smooth curved shape and easy assembly features.
Innovation Solution
A method involving bulge forming of metal pipe members to create a thin-walled arm-like structure with ring-shaped flange portions and work openings, allowing for a smooth external shape and easy attachment to driven bodies, using a series of dies and high-pressure liquid expansion to form the desired shape and features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal casting is used to produce arm-like structures, then strength is ensured, but weight reduction and smooth curved shape formation become difficult
Solution Approach 1:
The invention changes the material form from solid cast metal to thin-walled formed pipe, altering the physical parameters of the material configuration. This enables weight reduction while maintaining strength through optimized wall thickness distribution and structural geometry achieved via bulge forming and rolling processes
Solution Approach 2:
The invention employs bulge forming to create smooth curved shapes and rounded contours in the arm-like structure. The bulge forming process inflates the pipe to conform to curved die cavities, producing aesthetically pleasing smooth surfaces and ergonomic shapes that would be difficult to achieve with traditional casting methods
2Weight of moving object
If thin-walled formed pipes are used, then weight is reduced and smooth shape is achieved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is divided into distinct sequential stages: bulge forming to create the basic curved shape, followed by rolling to form flange portions and work openings. This segmentation allows each operation to be optimized independently and simplifies the overall manufacturing complexity by breaking down the complex forming process into manageable steps
Solution Approach 2:
The bulge forming process is performed first to pre-shape the pipe into the desired curved configuration before subsequent rolling operations. This preliminary action prepares the workpiece in advance, making the final forming operations easier and more efficient, thereby reducing overall manufacturing complexity
3Ease of operation
If flange portions and work openings are added for assembly, then ease of assembly improves, but manufacturing precision requirements increase
Solution Approach 1:
The invention combines multiple features (flange portions and work openings) into a single integrated rolling operation. The rolling process simultaneously forms the flange portions at the pipe ends and creates work openings along the pipe length, reducing the number of separate manufacturing steps and minimizing cumulative precision errors that would arise from multiple discrete operations
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
This method enables the production of lightweight, strong, and easily assembled arm-like structures with a smooth curved shape, suitable for cooperative robots, and allows for efficient wiring and assembly, while maintaining uniform thickness and suppressing thickness variations.
Implementation Method 1
pressurizing the pipe member with liquid supplied to an inside thereof to cause an external surface of the thus expanded pipe member to be pressed against an inner surface of the cavity
Data Source
AI summary
A method for producing an arm structure in which the arm structure is produced by: forming an arm precursor member having an external shape of the arm structure by, in a state in which a die is closed with a metal pipe member being disposed in a cavity thereof, pressurizing the pipe member with liquid supplied to an inside thereof to cause an external surface of the thus expanded pipe member to be pressed against an inner surface of the cavity; and forming a flange portion to be attached to a driven body by machining at least an end of the formed arm precursor member.