Design optimization and robustness analysis of rigid-link flapping mechanisms

Rigid link flapping mechanisms remain the most practical choice for flapping wing micro-aerial vehicles (MAVs) to carry useful payloads and onboard batteries for free flight due to their long-term durability and reliability. However, MAVs with these mechanisms require significant weight reduction to achieve high agility and maneuverability. One approach involves using single-DOF planar rigid linkages, which are rarely optimized dimensionally for high lift and low power, considering their sweeping kinematics and the unsteady aerodynamic effects. We integrated a mechanism simulator based on a quasistatic nonlinear finite element method with an unsteady vortex lattice method-based aerodynamic analysis tool within an optimization routine. We optimized three different mechanism topologies from the literature. Significant power savings were observed up to 34% in some cases, due to increased amplitude and higher lift coefficients resulting from optimized asymmetric sweeping velocity profiles. We also conducted a robustness analysis to quantify performance sensitivity to manufacturing tolerances. It provided a trade-off between performance and reliability and revealed the need for tight manufacturing tolerances and careful material selection. Finally, the analysis helped select the best mechanism topology, as we observed significant variation in sensitivity to manufacturing tolerances and peak input torque values across different topologies for a given design lift value. The presented unified computational tool can find application in flapping mechanism topology optimization, as it can simulate any generic single-DOF planar rigid linkage without supplying kinematics manually.