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Design of Revolute Joints for In-Mold Assembly Using Insert Molding

机译:使用嵌件成型的模内装配旋转接头设计

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摘要

Creating highly articulated miniature structures requires assembling a large number of small parts. This is a very challenging task and increases cost of mechanical assemblies. Insert molding presents the possibility of creating a highly articulated structure in a single molding step. This can be accomplished by placing multiple metallic bearings in the mold and injecting plastic on top of them. In theory, this idea can generate a multi degree of freedom structures in just one processing step without requiring any post molding assembly operations. However, the polymer material has a tendency to shrink on top of the metal bearings and hence jam the joints. Hence, until now insert molding has not been used to create articulated structures. This paper presents a theoretical model for estimating the extent of joint jamming that occurs due to the shrinkage of the polymer on top of the metal bearings. The level of joint jamming is seen as the effective torque needed to overcome the friction in the revolute joints formed by insert molding. We then use this model to select the optimum design parameters which can be used to fabricate functional, highly articulating assemblies while meeting manufacturing constraints. Our analysis shows that the strength of weld-lines formed during the in-mold assembly process play a significant role in determining the minimum joint dimensions necessary for fabricating functional revolute joints. We have used the models and methods described in this paper to successfully fabricate the structure for a minimally invasive medical robot prototype with potential applications in neurosurgery. To the best of our knowledge, this is the first demonstration of building an articulated structure with multiple degrees of freedom using insert molding.
机译:创建高度铰接的微型结构需要组装大量的小零件。这是一项非常具有挑战性的任务,并增加了机械装配的成本。嵌件成型提供了在单个成型步骤中创建高度铰接结构的可能性。这可以通过在模具中放置多个金属轴承并在其顶部注入塑料来实现。从理论上讲,这种想法可以在一个处理步骤中生成多个自由度结构,而无需任何后成型组装操作。但是,聚合物材料倾向于在金属轴承顶部收缩,从而卡住接头。因此,到目前为止,还没有使用嵌件成型来制造铰接结构。本文提出了一种理论模型,用于估计由于聚合物在金属轴承顶部收缩而产生的接头卡塞的程度。接头卡塞的程度被视为克服通过嵌件成型形成的旋转接头中的摩擦所需的有效扭矩。然后,我们使用该模型选择最佳设计参数,这些参数可用于制造功能性强,铰接性强的组件,同时满足制造限制。我们的分析表明,在模内组装过程中形成的焊缝强度在确定制造功能性旋转接头所需的最小接头尺寸方面起着重要作用。我们已经使用本文中描述的模型和方法成功地制造了具有微创医疗机器人原型结构的结构,该结构在神经外科领域具有潜在的应用。据我们所知,这是首次使用嵌件成型法构建具有多个自由度的铰接结构的演示。

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