Design of Thermally Actuated Flexure
This project was undertaken during the course of Precision Machine Design in my Masters studies at UNC Charlotte. Flexures are structures which provide smooth and continuous motion without friction losses. In this project, the objective was to modify an existing thermally actuated, single degree of freedom flexure and to evaluate its operation and precision under an applied load in-line with the actuator and opposite the direction of travel. Several changes were made to improve the heating and cooling systems, which along with tuning of control systems reduction in noise and faster response times. Also for achieving the goal of 1000 N load capacity, the overall design of the flexure was changed, which includes an additional reinforcing outer steel frame, discarding the split clamp in original design and replacing it with a spring guided on a rod on the actuation side. Addition of threaded knob and compression plate assembly to apply tension to the spring. It operates through the controlled expansion of a steel tube. The temperature and thermal expansion of the actuator was controlled using Ni-Cr wire coiled around the tube and cooling water flowing through the tube. The controlled thermal expansion of the tube generates the force that was converted into linear motion of the flexure stage. The tube actuator is thermally isolated on both ends using cooling water. A feedback loop was implemented using an IR based optical knife-edge sensor to measure the linear displacement of the flexure stage. The flexure was successfully able to displace the projected 1000 N over a range of 100µm in 60 seconds and was able to retain a constant position with ±0.33µm variation. All the while, the cooling system effectively retained the frame and the flexure stage at 0.5°C above room temperature.
SOLIDWORKS | Mechanical Design | Thermal Design | Electromechanical Design | Kinematics |