Designing Multi-axis Compliant Mechanisms With Lockable Decoupled Inputs: A Tip–Tilt Case Study

Abstract

This research is about designing multi-degree-of-freedom (multi-DOF) compliant mechanisms with decoupled inputs that can be independently locked/unlocked using bistable switches to achieve different combinations of DOFs. A case study mechanism achieving two decoupled rotational DOFs (tip and tilt) is designed, fabricated, and characterized. It can be triggered using two pairs of bistable switches, achieving drastically different states of torsional stiffness for each DOF in four sets of DOF combinations—no DOFs, a tip DOF, a tilt DOF, and both tip and tilt DOFs. Bistability and stiffness cancelation principles are exploited to achieve the desired changes in stiffness. Two flexure elements can be identified—the switch providing a negative stiffness and the cross-axis-flexural-pivot (CAFP) producing a positive stiffness. The mechanism is tuned to achieve static balancing, reaching a near-zero stiffness over much of its range. The pseudo-rigid body model and two-dimensional (2D) finite element model (FEM) are combined defining a fast method to dimension the system. The 3D FEM is simulated to validate the obtained results. For each DOF, the system is tested in two configurations (stiff and compliant) for three cycles over a ±10 deg rotation, achieving a stiffness reduction of around 99%. Comparable stiffness values were measured after triggering the switches more than once, repetitively reaching the required two states of stiffness, confirming the system's usability in practical applications. The positive stiffness provided by the CAFP is measured and compared to the device's overall stiffness, highlighting the stiffness cancelation concept.