Synthesis of precision serial flexure systems using freedom and constraint topologies (FACT)

In this paper we introduce the principles necessary to synthesize the complete body of serial flexure system concepts, which satisfy desired design requirements using Freedom and Constraint Topologies (FACT). FACT utilizes a comprehensive library of geometric shapes that represent regions were constraints may be placed for synthesizing flexure systems that possess designer-specified degrees of freedom (DOFs). Prior to the theory of this paper, FACT was limited to the synthesis of parallel flexure systems only. The ability to synthesize serial flexure systems is important because serial flexure systems (i) may possess DOFs not accessible to parallel flexure systems, (ii) exhibit larger ranges of motion, and (iii) enable cancellation of parasitic errors. Geometric shapes that represent motions only accessible to serial flexure systems have been derived and added to the existing body of FACT shapes initially intended for parallel flexure synthesis only. Systematic rules and guidelines have been created that help designers use these shapes to generate every parallel and serial flexure concept that satisfies the desired functional requirements. We demonstrate how to use these shapes to utilize or avoid underconstraint in serial flexure synthesis. A serial flexure system is designed that interfaces the lead screw of a lathe to the carriage that it drives as a case study to demonstrate the theory of this paper.