Topology Optimization of a Remote Center Compliance Device for Peg-in-Hole Assembly Operations

Abstract A remote center compliance (RCC) device is a passive compensator that can be installed at the end of a robotic arm to correct positioning and angular errors that may occur during automated assembly. Traditional RCC devices often rely on existing configurations and lack a systematic approach for identifying designs that meet the required boundary conditions. To develop an innovative RCC device with a larger compensation range and lower contact force during assembly, this study presents a topology optimization method that combines the concepts of translational and revolute flexure hinges to design RCC devices for peg-in-hole insertion applications. The compliant part of the prototype was manufactured through three-dimensional (3D) printing. Experiments, including tests for the maximum allowable translational and angular deviations during assembly, as well as contact force during peg-in-hole insertion, were conducted. The experimental results showed that the innovative RCC device developed in this study can minimize contact force and successfully complete peg-in-hole assembly with a misalignment of up to 4 mm and an angular deviation of up to 9 degrees.