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This paper presents a novel design of a flexure-based constant force mechanism with a long travel stroke. Unlike the conventional force control method using a force sensor and feedback controller to obtain constant force output, the proposed compliant mechanism provides a constant force utilizing the unique mechanical property of the mechanical structure. The constant force is generated by using the combination of a negative-stiffness and a positive-stiffness mechanism. In order to achieve a low driving force, the negative stiffness is realized by a special bistable beam, which is a step beam with structural holes. Meanwhile, the positive stiffness is generated by the leaf flexure hinges with structural holes. The regular structural holes can reduce the mass and stiffness of the whole mechanism. Furthermore, the elliptic integral method and the pseudo-rigid-body approach are utilized to establish the model of the constant force mechanism. Based on the established model, the performance of the constant force mechanism is evaluated computationally. Additionally, the parametric model of the proposed mechanism is investigated using the nonlinear finite element analysis. Finally, a prototype is fabricated using 3D printing technique. The open-loop and the closed-loop experimental tests are implemented to investigate the performance of the developed constant force mechanism. It is noted that the constant force mechanism can be robustly controlled by a proportional-integral-derivative control method. Experimental results demonstrate that the developed constant force mechanism has a constant force with slight fluctuation with a range of 500 μm.

Design of a flexure-based mechanism possessing low stiffness and constant force