Six-DOF Compliant Flexure for Tolerance-Tolerant Autonomous Assembly
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Solution Overview
Problem
Existing fastening technologies face challenges in aligning elements with manufacturing tolerances and require flexible fasteners that provide six degrees of freedom with tunable constraint and compliance, especially in automated or autonomous assembly processes where rigid constraints can lead to over-constraint issues.
Innovation Solution
A flexure system with six degrees of freedom, comprising opposing mounting blocks connected by beams with varying geometries, materials, and potting material, allowing for independent or coupled tuning of constraint and compliance, along with a coupling mechanism featuring a grip and coupler for autonomous assembly, utilizing motor-controlled or spring-based mechanisms and electrical/optical connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fasteners are used to join elements, then strength and stability are improved, but alignment difficulty and over-constraint issues worsen due to manufacturing tolerances
Solution Approach 1:
The patent changes the rigidity parameter of the fastening system by introducing flexures with controlled compliance. The flexures have specific geometric parameters (beam dimensions, material properties) that allow them to deform elastically, accommodating manufacturing tolerances while maintaining joint strength. This resolves the contradiction by making the fastening system adaptable rather than rigid.
Solution Approach 2:
The patent introduces dynamic compliance into the fastening system through flexures that can deform elastically. The flexures provide a degree of freedom for movement and adjustment, allowing the system to adapt to misalignment dynamically rather than requiring perfect static alignment. This enables rigid strength with flexible alignment tolerance.
2Ease of operation
If flexible fasteners are used to accommodate misalignment, then alignment ease is improved, but constraint control and compliance tuning become more difficult
Solution Approach 1:
The patent segments the compliance function into separate flexure components, each designed with specific geometric parameters to provide controlled flexibility in particular directions. By dividing the fastening system into multiple flexure elements with distinct compliance characteristics, the overall system achieves tunable compliance without excessive complexity. Each segment can be independently optimized.
Solution Approach 2:
The patent uses parameter changes in the flexure geometry (beam thickness, length, material modulus) to tune compliance characteristics. By systematically varying these parameters, the design achieves controlled flexibility without requiring complex mechanisms. The compliance is tuned through straightforward geometric modifications rather than complex mechanical arrangements.
3Productivity
If automated assembly is implemented, then productivity is improved, but tolerance accumulation and over-constraint issues worsen
Solution Approach 1:
The patent incorporates compliance and flexibility into the fastening design beforehand, which cushions against tolerance accumulation during automated assembly. The flexures are pre-designed to accommodate expected variations in positioning accuracy, preventing over-constraint issues before they occur. This allows high-speed automated assembly without sacrificing precision.
4Adaptability or versatility
If six degrees of freedom compliance is provided, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent designs flexure components that provide multiple functions simultaneously: structural support, compliance in multiple degrees of freedom, and vibration isolation. By making the flexure elements multi-functional, the system achieves six degrees of freedom compliance without proportionally increasing complexity. The same structural elements that provide support also provide the necessary compliance.
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 precise control of constraint and compliance in six degrees of freedom, facilitating efficient and accurate assembly of panels without over-constraint, suitable for applications like automotive, aerospace, and solar panel assembly, while allowing for energy absorption and vibration isolation.
Implementation Method 1
Each of the beams includes a combination of two or more sections, for example, one curvilinear section and one straight arm section
Implementation Method 2
potting material is placed between the beams as an added tuning mechanism and to reduce the transmission of vibrations from one mounting block to the other
Data Source
AI summary
A flexure having six degrees of freedom is disclosed. The constraint and compliance of the flexure in all six degrees of freedom may be independently tuned for an application. The flexure may include various combinations of sections including, for example, straight arm and curvilinear sections. The constraint and compliance of the flexure is determined by the geometry, cross-sectional area, cross-sectional shape, and material used to form the various sections. A coupling mechanism and a corresponding method for using the coupling mechanism for automated or autonomous assembly of elements using tuned flexures is disclosed. The automated or autonomous assembly of elements employs a coupling mechanism having a motor driven grip and a coupler, in which the coupler includes a six degrees of freedom flexure. The motor driven grip and coupler may optionally include electrical or optical interconnections and self-aligning features.