Cross flexure suspension system
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Solution Overview
Problem
Existing suspension systems for supporting objects like mirrors fail to provide two degrees of rotational freedom while minimizing translational movement, which is crucial for high scanning frequency applications like optical scanning systems.
Innovation Solution
A compact, two-axis degree of freedom suspension system using a monolithic flexure structure with EDM-manufactured thin flexure blades, eliminating the need for welded or brazed joints, allowing large angular tip-tilt motions while constraining all other degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional suspension systems with multiple joints are used to provide two degrees of rotational freedom, then rotational flexibility is improved, but friction increases and scanning frequency decreases
Solution Approach 1:
The patent combines multiple flexure blades into a monolithic integrated structure that provides two degrees of rotational freedom simultaneously. This merging eliminates the need for separate joints and connections, thereby eliminating friction at joint interfaces while maintaining full rotational capability about two orthogonal axes.
Solution Approach 2:
The patent replaces traditional mechanical joints and connections with a flexure-based compliant mechanism. Instead of using rigid connections with friction, the system uses elastic deformation of the monolithic flexure structure to achieve rotational movement, substituting friction-based mechanical joints with frictionless elastic compliance.
2Adaptability or versatility
If multiple separate flexure components are assembled to achieve two-axis rotation, then rotational capability is improved, but device complexity and potential failure points increase
Solution Approach 1:
The patent integrates multiple flexure blades into a single monolithic component manufactured by EDM. This combining of what would traditionally be separate assembled parts into one integral structure reduces device complexity, eliminates assembly steps, and removes potential failure points at joints and connections.
Solution Approach 2:
Within the monolithic structure, the patent incorporates multiple discrete flexure blades that are segmented in function but integrated in manufacturing. Each blade provides specific compliance in different directions, and their combined action enables two-axis rotation while maintaining a simple single-piece construction.
3Productivity
If thin flexure blades are used to reduce friction and enable high-frequency scanning, then scanning frequency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical machining methods with Electrical Discharge Machining (EDM) for manufacturing the thin flexure blades. EDM enables precise control of blade thickness and geometry through electrical erosion rather than mechanical cutting, achieving the required thin dimensions and tolerances without the limitations and tool wear issues of conventional mechanical machining.
4Strength
If welded or brazed joints are used to connect suspension components, then structural strength is improved, but friction and potential failure points increase
Solution Approach 1:
The patent combines all suspension components into a single monolithic structure manufactured by EDM, eliminating the need for welded or brazed joints entirely. This integration maintains structural strength through the continuous material grain and eliminates the reliability issues associated with thermal processing joints, such as heat-affected zones, residual stresses, and potential cracking.
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 high-frequency operation with minimal decenter and increased load capacity, providing robust motion control with reduced pivot point translation and eliminating potential failure points from individual joints.
Implementation Method 1
a first flexure structure including a first set of flexure blades... allows the connecting structure to rotate relative to the base mounting structure about the first axis of rotation
Data Source
AI summary
Suspension system structures and methods are provided. A system as disclosed allows for rotation of a supported object in two axes, with very little translational movement of the supported object. The system can include a base mounting structure that is joined to an intermediate or connecting structure by a first set of flexure blades. The connecting structure is in turn joined to a supported element structure by a second set of flexure blades. The first set of flexure blades can include four blades that intersect along a line that is coincident with an X axis of rotation, and the second set of flexure blades can include four blades that intersect along a line that is coincident with the Y axis of rotation. The components of the suspension system can comprise a monolithic structure that is formed from a single piece of material.