Interlocked Monolithic Flexures for Low-Shift Compliant Pivots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing methods for compliant mechanisms, such as pivot bearings, are complex, bulky, and prone to axial centre shift due to asymmetrical blade arrangements, requiring dedicated production apparatuses and limiting scalability and load capacity.
Innovation Solution
The method involves interlocking monolithic flexible elements with openings between their ends to facilitate additive manufacturing, reducing axial centre shift and allowing for easy modification of dimensions and stiffness through 3D CAD models, eliminating the need for dedicated production apparatuses and enabling mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods (milling, wire electro-discharge machining, soldering, gluing) are used to assemble flexible elements and hemi-cylindrical parts, then the device can be manufactured with functional compliance, but the manufacturing process becomes complex, bulky, and requires dedicated production apparatuses
Solution Approach 1:
The patent merges multiple separate components (flexible elements and hemi-cylindrical parts) into a single monolithic structure manufactured via additive manufacturing. This eliminates the need for assembly operations such as soldering or gluing, and removes the requirement for dedicated production apparatuses, thereby simplifying the manufacturing process while maintaining functional compliance.
Solution Approach 2:
The additive manufacturing process enables a single production apparatus to manufacture pivots of various sizes and stiffness characteristics by simply modifying the 3D CAD model parameters. This universal approach replaces the need for dedicated production apparatuses required for each specific pivot configuration, allowing mass production with high adaptability.
2Ease of operation
If flexible elements are arranged in an asymmetrical configuration to achieve pivot functionality, then the mechanism can transfer force and displacement, but axial centre shift occurs during deformation
Solution Approach 1:
The patent intentionally introduces asymmetry in the form of strategically placed openings within the monolithic flexible elements. These openings are positioned to counterbalance the axial centre shift that would otherwise occur during pivot deformation, allowing the mechanism to maintain both functionality and precision simultaneously.
Solution Approach 2:
The openings are locally positioned within specific regions of the flexible elements to achieve precise control over the deformation behavior. This local modification allows the structure to compensate for axial centre shift only in the critical areas where it occurs, without affecting the overall pivot functionality.
3Manufacturing precision
If dedicated production apparatuses are used for each pivot size and stiffness configuration, then manufacturing precision can be maintained, but productivity decreases and cost increases
Solution Approach 1:
The additive manufacturing process enables a single universal production apparatus to manufacture pivots of any size and stiffness by simply changing the digital 3D CAD model parameters. This eliminates the need for multiple dedicated apparatuses, thereby maintaining manufacturing precision through digital control while dramatically increasing productivity and enabling true mass production.
Solution Approach 2:
The invention allows pivot characteristics (size, thickness, stiffness) to be modified by changing parameters in the 3D CAD model rather than reconfiguring physical production apparatuses. This digital parameter control maintains manufacturing precision while enabling rapid production of varied pivot configurations, directly improving productivity.
4Force
If flexible elements are made with larger dimensions to increase load capacity, then the mechanism can handle higher forces, but the device becomes bulky
Solution Approach 1:
The patent introduces openings (voids) within the monolithic flexible elements, creating a porous or lattice-like structure. This allows the material to maintain high load capacity through optimized stress distribution while significantly reducing the overall volume and mass of the device, thereby decreasing bulkiness without sacrificing force handling capability.
Solution Approach 2:
The monolithic structure with strategically placed openings creates a composite-like architecture that combines rigid and flexible regions. This allows the device to achieve high load capacity in critical areas while minimizing material usage overall, resulting in a compact design that does not sacrifice strength.
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 approach results in a compliant mechanism with reduced dimensions, improved mechanical properties, and minimal axial centre shift, enabling efficient mass production of pivots with various sizes and stiffness without the need for complex assembly or dedicated production equipment.
Implementation Method 1
a first monolithic flexible element, having first and second ends defining a first longitudinal direction, arranged such that it is able to be subjected to an elastic deformation involving a relative movement between its first and second ends
Data Source
AI summary
Disclosed is a device including a compliant mechanism including: a first monolithic flexible element, having first and second ends defining a first longitudinal direction, arranged such that it is able to be subjected to an elastic deformation involving a relative movement between its first and second ends; and at least a second monolithic flexible element, having first and second ends defining a second longitudinal direction distinct from the first longitudinal direction, arranged such that it is able to be subjected to an elastic deformation involving a relative movement between its first and second ends. At least one of the first and second monolithic flexible elements includes at least one opening located between its first and second ends and defining a passage for a portion of the other monolithic flexible element such that the first and second monolithic flexible elements are interlocked.