Integrated Intelligent CAD System for Interactive Design, Analysis and Prototyping of Compression and Torsion Springs

This paper presents the development and implementation of integrated intelligent CAD (computer aided design) system for design, analysis and prototyping of the compression and torsion springs. The article shows a structure of the developed system named Springs IICAD (integrated intelligent computer aided design). The system bounds synthesis and analysis design phases by means of the utilization of parametric 3D (three-dimensional) modeling, FEM (finite element method) analysis and prototyping. The development of the module for spring calculation and system integration was performed in the C# (C Sharp) programming language. Three-dimensional geometric modeling and structural analysis were performed in the CATIA (computer aided three-dimensional interactive application) software, while prototyping is performed with the Ultimaker 3.0 3D printer with support of Cura software. The developed Springs IICAD system interlinks computation module with the basic parametric models in such a way that spring calculation, shaping, FEM analysis and prototype preparation are performed instantly.

Stiffness compensation through matching buckling loads in a compliant four-bar mechanism

In this paper a novel alternative method of stiffness compensation in buckled mechanisms is investigated. This method involves the use of critical load matching, i.e. matching the first two buckling loads of a mechanism. An analytical simply supported four-bar linkage model consisting of three rigid links and four torsion springs in the joints is proposed for the analysis of this method. It is found that the first two buckling loads are exactly equal when the two outer springs are three times stiffer than the two inner springs. The force-deflection characteristic of this linkage architecture showed statically balanced behavior in both symmetric and asymmetric actuation. Using modal analysis, it was shown that the sum of the decomposed strain energy per buckling mode is constant throughout the motion range for this architecture. An equivalent lumped-compliant four-bar mechanism is designed; finite element and experimental analysis showed near zero actuation forces, verifying that critical load matching may be used to achieve significant stiffness compensation in buckled mechanisms.

Static Balancing of Four-Bar Compliant Mechanisms With Torsion Springs by Exerting Negative Stiffness Using Linear Spring At the Instant Center of Rotation

A design approach for the quasi-static balancing of four-bar linkages with torsion springs is proposed. Such an approach is useful in the design of quasi-statically balanced fully compliant mechanisms by tuning the stiffness of the pseudo-rigid-body-model. Here, the positive stiffness exhibited by torsion springs at the R-joints is compensated by a negative stiffness function. The negative stiffness is created by a non-zero-free-length linear spring connected between the coupler link and the ground, and where both connecting points trace a line directed to the coupler link’s instant center of rotation. A full example of the static balancing of two compliant linkages for approximate straight path generation is developed, where actuation energy of the compliant designs is reduced in 66% and 54%, respectively.

Deployable Convex Generalized Cylindrical Surfaces Using Torsional Joints

The ability to deploy a planar surface to a desired convex profile with a simple actuation can enhance foldable or morphing airfoils, deployable antennae and reflectors, and other applications where a specific profile geometry is desired from a planar sheet. A model using a system of rigid links joined by torsional springs of tailorable stiffness is employed to create an approximate curved surface when two opposing tip loads are applied. A system of equations describing the shape of the surface during deployment is developed. The physical implementation of the model uses compliant torsion bars as the torsion springs. A multidimensional optimization algorithm is presented to place joints to minimize the error from the rigid-link approximation and account for additional manufacturing and stress considerations in the torsion bars. A proof is presented to show that equal torsion spring spacing along the horizontal axis of deployed parabolic profiles will result in minimizing the area between the model's rigid-link approximation and smooth curve. The model is demonstrated through the physical construction of a deployable airfoil surface and a metallic deployable parabolic reflector.

Shear Behavior of a Reinforced Concrete Frame Retrofitted with a Hinged Steel Damping System

The purpose of this study was to experimentally evaluate the effect of a hinged steel damping system on the shear behavior of a nonductile reinforced concrete frame with an opening. For the experimental test, a total of three full-scale reinforced concrete frame specimens were planned, based on the “no retrofitting” (NR) specimens with non-seismic details. The main research questions were whether the hinged steel damping system is reinforced and whether torsion springs are installed in the hinged steel damping system. From the results of the experiment, the hinged steel damping system (DR specimen) was found to be effective in seismic retrofitting, while isolating the opening of the reinforced concrete (RC) frame, and the torsion spring installed at the hinged connection (DSR specimen) was evaluated to be effective in controlling the amount of deformation of the upper and lower dampers. The strength, stiffness, and energy dissipation capacity of the DSR specimen were slightly improved compared to the DR specimen, and it was confirmed that stress redistribution was induced by the rotational stiffness of the torsion spring installed in the hinge connection between the upper and lower frames.

A new design approach for customised medical devices realized by additive manufacturing

The aim of this work is the design of a new customised elbow orthosis completely realized by Additive Manufacturing and the development of generative algorithms for parametric modelling and creation of 3D patterns to be adapted to the CAD model. This work describes a method to perfect the design of a custom elbow orthosis. A reverse engineering approach has been used to digitalize the patient’s arm and the subsequent CAD modelling of the structure of the custom elbow orthosis has been performed. In particular, two algorithms have been implemented for the creation of 3D patterns and Voronoi tessellations. Subsequently, FEM analyses have been carried out to validate the design. Finally, a prototype of the elbow orthosis with Voronoi tessellation has been realized by means of the SLS technology. The results obtained have demonstrated that the implemented algorithm solved the problems found during CAD modelling with conventional software. Furthermore, the results of FEM analyses have validated the design choices. All this allowed realizing the prototype by AM technologies without problems. Moreover, the new proposed modelling approaches allows creating, in an interactive way, patterns on complex surfaces. The results of this research activity present innovative elements of originality in the CAD modelling sector, which can contribute to solving problems related to the modelling for Additive Manufacturing. Furthermore, another innovative characteristic of the device is the use of torsion springs that simulate the action of physiotherapists during exercises for patient rehabilitation.