Kinematic Coupling for Precision Fixturing & Assembly
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1 Kinematic Coupling for Precision Fixturing & Assembly Folkers E. Rojas, MS & Nevan C. Hanumara, PhD MIT 1 February 2013 material from Profs. Alexander H. Slocum & Martin Culpepper
2 OUTLINE Kinematic Coupling Overview Hertz Contact Review Types Standard Canoe (High Load) Compliant Three Tooth Case Studies Servo Controlled Ford (Duratec TM ) QKC Elastic Averaging
3 Review of Coupling Methods 0.01 μm 0.1 μm 1 μm 10 μm 100 μm Pinned Joints Flexural Kinematic Couplings Elastic Averaging Quasi-Kinematic Coupling Kinematic Couplings
4 Kinematic Coupling Overview When a component is constrained by a number of points equal to the number of degrees of freedom, it is said to be exactly constrained. # Points of Contact = # Degrees of Freedom Constrained Low-Medium Force Precision Applications Do Not Allow Sealing Contact Moderate Stiffness Moderate Cost Excellent repeatability 1/4 micron common On order of surface Finish
5 Key Hertz Relations Contact Pressure is proportional to: Force to the 1/3 rd power Radius to the 2/3 rd power Modulus to the 2/3 rd power Deflection is proportional to: Force to the 2/3 rd power Radius to the 1/3 rd power Modulus to the 2/3 rd power Contact ellipse diameter is proportional to: Force to the 1/3 rd power Radius to the 1/3 rd power Modulus to the 1/3 rd power CAREFUL TO NOT ALLOW THE CONTACT ELLIPSE TO BE WITHIN ONE DIAMETER OF THE EDGE OF A SURFACE!
6 Standard KC
7 Canoe-Ball Kinematic Interface for High Load Applications The Canoe Ball shape acts like a 1m diam ball 100 times the stiffness & load of normal 1 ball 10 times load capacity of crowned cone Large Shallow Hertzian zone (very repeatable) US Patent 5,711,647
8 Compliant Kinematic Couplings Clamping Load/Friction/Mated Surface Joint Location Compliant Members Kinematic Interface
9 Compliant Kinematic Couplings Characteristics Low Cost Small Medium Stroke Precision 5 10 um Applications/Process Assembly Lines Stamping, Forging, Forming Equipment Die Alignment Semiconductor Manufacturing Equipment Casting Dies Cost $10 200
10 Compliant Kinematic Couplings Characteristics Medium Cost Long Stroke Precision 2.5 um Applications/Process Assembly Lines Casting Fixtures Cost $2000
11 Three Tooth Semi-kinematic 6 point mating 3-5 micron repeatability Layton Hale (LLNL) added crowns to 1 set teeth yielding 1 micron repeatability
12 Wafer Transport
13 Ford 2.3 L V-6 Duratec TM
14 Quasi Kinematic Couplings (QKCs) What is a QKC & why is it important Attain Sub-Micron Repeatability Use Less Restrictive Tolerances Have More Flexibility in Assigning Precision Tolerances Impact Better Precision At Lower Cost Extension of Practical HVM Precision Eliminate Precision Pinned Joints ( microns) Reduce Number of Parts
15 QKCs Physical Components Arc Contact Sub-micron Precision Stiffness Increase Sealing Contact
16 QKC Design
17 QKC Contact Mechanics Assume Hertzian Line Contact Profile Specify Profile in Rotating Coord. System Integrate Profile to get forces
18 Engine Assembly Comparison Manufacturing Pinned Joint Using Quasi-KC Coupling
19 Servo-Controlled KC Michael Chiu s Doctoral Thesis Application: precision location and automatic leveling of precision electronic test equipment Teradyne has shipped over 500 systems
20 Elastic Averaging Multiple compliant contact points Members elastically deform High overall stiffness Application from toys, to office chairs to couplings
21 Anti Backlash Coupling Torsional couplings: spline, oldham, spyder Backlash causes noise, wear & failure Elastically averaged design based on multiple long, compliant fingers Low force, easy assembly, locked radially
22 Anti Backlash Coupling Load carried by multiple teeth Compliance provided by beam bending Radial flex accommodates finger variation Fingers self lock to prevent relative slip Chamfered ends for assembly No axial forces, good damping
23 Contacts: Nevan: Folkers:
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