The optimization of a long-stroke constant-force actuator (CFA) and its respective force-displacement characteristics are discussed in this paper. In applications requiring constant force the applicability of commercially available low force passive devices could be further enhanced by an increased force level. In this paper such a long stroke constant-force versus displacement actuator topology is optimized by means of output polynomial mapping, which uses a combination of a single analytical equation and comprehensive three dimensional (3D) finite element analyses. Specifically, this optimization is applied to a passive and active force level of 200 N and 250 N, respectively, where the force-displacement response shows a constant force for 70-90% of the total stroke.
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