On the numerical synthesis of a contact-aided branch hinge (CABH) with variable stiffness

• Published in: Mechanism and machine theory 2023-02, Vol.180, p.105167, Article 105167
• Main Authors: Dai, Shenyuan, Qiu, Lifang, Yu, Yue, Li, Chongxiang
• Format: Article
• Language: English
• Subjects: Compliant mechanism; Contact-aided; Flexure hinge; Numerical synthesis; Variable stiffness
• ISSN: 0094-114X; 1873-3999
• DOI: 10.1016/j.mechmachtheory.2022.105167

•A contact-aided branch hinge (CABH) with variable stiffness is proposed.•A compliant-element-based dimensional synthesis (CEBDS) method is proposed.•Several derivative mechanisms are proposed to illustrate the potential applications of the CABH.•The theoretical models for calculating the hinge's motion are established.•The numerical analysis, FEA and experimental test are carried out for verification. Based on the mortise-and-tenon structure, this paper proposes a Contact-Aided Branch Hinge (CABH) with variable stiffness. The equivalent spring model (ESM) and the chain pseudo-rigid body model (CPRBM) of the hinge are derived respectively, and the applicability of these two models is analyzed by the finite element method and experimental tests. Therefore, a compliant-element-based dimensional synthesis (CEBDS) method is proposed. Taking the CABH as an example, three derivative mechanisms are synthesized to meet the complex working requirements. The finite element analysis (FEA) results are consistent with the kinematic requirements, which verifies the correctness and feasibility of the synthesis method. In addition, the prototypes are fabricated. The potential applications of the CABH in robotics and medical devices can be increased by combining multiple derivative mechanisms.