Hydroformed Robot Arm Structure With Thin-Wall Flange Assembly
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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 smooth surfaces and easy assembly features.
Innovation Solution
A method involving bulge forming of metal pipe members using high-pressure liquid to shape and form arm precursor members with flange portions, allowing for a thin-walled, smooth, and easily assembled arm-like structure with integrated wire pathways and work openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal casting is used to form arm structures, then strength is ensured, but weight reduction and surface smoothness are compromised
Solution Approach 1:
The invention changes the manufacturing method from traditional metal casting to hydraulic bulge forming of thin-walled metal pipes. This parameter change enables the production of arms with uniform wall thickness (2-4mm) that achieve both weight reduction and structural strength, while the forming process itself creates smooth surfaces without the roughness typical of castings
Solution Approach 2:
The invention employs hydraulic bulge forming where high-pressure liquid is supplied inside the metal pipe to expand and shape the arm structure. This hydraulic forming method enables precise control of the forming process, achieves complex curved shapes with smooth surfaces, and maintains uniform wall thickness while reducing overall weight compared to traditional casting
2Strength
If traditional casting methods are used, then structural strength is achieved, but surface smoothness and assembly ease deteriorate
Solution Approach 1:
Hydraulic bulge forming uses high-pressure liquid to expand the metal pipe into the desired arm shape. The liquid pressure distributes evenly across the pipe wall, ensuring uniform thin-walled formation (2-4mm) and creating inherently smooth surfaces that eliminate the roughness and dimensional variations typical of casting processes
Solution Approach 2:
The invention transitions from casting to hydraulic forming, changing the manufacturing parameter from molten metal solidification to plastic deformation of solid metal. This enables precise control of wall thickness and surface quality while maintaining structural strength through optimized forming parameters and tooling
3Adaptability or versatility
If separate components are used for flange portions, then assembly flexibility is improved, but manufacturing complexity and time increase
Solution Approach 1:
The invention integrates flange portions directly into the arm structure during the hydraulic bulge forming process. The flanges are formed as integral parts of the arm precursor member, eliminating the need for separate manufacturing and assembly steps. This merging reduces manufacturing complexity and time while maintaining assembly flexibility through the designed flange geometry
4Strength
If thick-walled arms are used, then strength is improved, but weight and surface quality worsen
Solution Approach 1:
The invention optimizes the wall thickness parameter to a thin-walled configuration (2-4mm) that is uniform throughout the arm structure. This parameter optimization achieves the right balance between strength and weight, and the hydraulic forming process ensures consistent thickness without the wall irregularities that can occur in thin-walled casting
Solution Approach 2:
Hydraulic bulge forming enables the creation of thin-walled structures by using liquid pressure to evenly distribute material during forming. The process maintains uniform wall thickness (2-4mm) throughout the arm, achieving lightweight construction while preserving strength through optimized geometry and material distribution
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
Enables the production of lightweight, strong, and easily assembled arm-like structures with smooth surfaces, suitable for cooperative robots, and allows for efficient wiring and assembly, while maintaining uniform thickness and reducing bend radius 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.