Hayashibara, Y.

Paper: Study on a Variable Stiffness Mechanism UsingWire Spring Yasuo Hayashibara Chiba Institute of Technology, 2-17-1 Tsudanuma, Narashino, Chiba, Japan E-mail:yasuo.hayashibara@it-chiba.ac.jp [Received October 2, 2007; accepted December 17, 2007] In this paper, we propose a variable stiffness mechanism using wire springs. We have proposed such kind of mechanism using nonlinear coil springs. We intend to apply it to continuous passive motion (CPM) machine. It can change the spring characteristic continuously. Its disadvantages are need for wide space and powerful motor to change stiffness. And, it is difficult to design such nonlinear spring. To solve these problems, we propose a mechanism with wire springs. It is easy to obtain the wire spring, because it is material of coil spring. We explain how the design and evaluate it in experiments. Keywords: variable stiffness mechanism, wire spring, stretch robot 1. Introduction We have been studying mechanisms to vary stiffness using nonlinear coil springs and have proposed and verified them. We applied a proposed mechanism to a continuous passive motion (CPM) machine used for rehabilitation and conducted experiments with machines for flexing joints of a patient with flexibility suitable for the patient [1 4]. The proposed mechanismvaries an apparent spring modulus by compressing nonlinear springs. It, however, requires a large force to change the modulus and space to accommodate the mechanism. Nonlinear coil springs with quadratic spring characteristics are difficult to design and produce. In this paper, we propose a mechanism to vary stiffness using wire springs and verify its effectiveness. Wire springs are commonly available and used to produce coil springs. A study for varying stiffness by changing the effective length of a spring includes a study for MIA arm using blade springs [5]. The MIA arm not only varies stiffness but also the friction coefficient. Many other studies have been conducted to vary stiffness using springs [6 8]. Our method uses popular wire springs and features easy adjustment of the varying range of spring modulus and the moving zone by using multiple springs. A way to vary apparent stiffness includes compliance control [9], which controls a motor by feedback from a sensor output. Our method generates flexibility using passive spring force and is easy to provide safety. These mechanisms are (a) Low Stiffness. (b) High Stiffness. Fig. 1. Proposed Variable Stiffness Mechanism. used for rehabilitation or stretch where patients are provided with force by machines. The prototyped machine for this study was also intended for stretch. 2. Variable Stiffness Mechanism Figure 1 shows conceptual drawing of the variable stiffness mechanism using wire springs. The proposed mechanism varies stiffness in the rotational directions by

changing the effective length of springs. Wire springs are mounted to a round base (Fig. 1). The base has a shaft fixed at the center and a variable stiffness ring is inserted to the shaft at its center. The ring has holes to pass wire springs. When the ring is turned around the shaft, the wire springs are deflected in the tangent direction, generating a certain degree of stiffness around the shaft. The effective length can be changed by sliding the ring along the shaft, which changes the stiffness in the rotational direction. The major advantages of this mechanism are as follows: 1) Commonly available wire springs are used. 2) Stiffness in a wide range is generated by changing the number and thickness of wire springs. 3) The effective length has a wide adjustable range. 4) The stiffness range is limited by stoppers (explained later). A mechanism is needed for sliding the ring to vary stiffness, which we currently use a ball screw. 296 Journal of Robotics andMechatronicsVol.20 No.2, 2008

Study on a Variable Stiffness Mechanism Using Wire Spring Fig. 2. Deflection of a Wire Spring. Fig. 3. Hole Shape of Moving Ring. When torque is applied to the ring and wire springs are deflected, the ring is hard to be slid. This problem may be solved by reducing friction between the wire springs and the ring. When this machine is used as a stretch machine, the problem can be avoided by sliding the ring before using the machine where no torque is applied. 3. Wire Springs Stiffness and Maximum Deflection The proposed mechanism generates rotational stiffness by deflecting wire springs. Wire springs have individual spring moduli and maximum deflections by their materials and the diameters. In designing a mechanism, understanding of the characteristics of wire springs is required to select them. We formulated the relationship between the stiffness and maximum deflection to set a guideline for spring selection and machine designing. The relationship between the force and deflection of a wire spring is expressed as follows: d .. l3 6EI ..2..3 l..x l l..x l 3 f . . . . (1) where d represents deflection at position x, l effective length, E Young s modulus, I geometric moment of inertia, and f force applied. Fig. 2 shows an example. The spring is fixed at one end and free at the other. Using a configuration of both fixed ends makes the mechanism much simpler, but gives higher stiffness to the effective length, requiring longer wire springs to obtain the equivalent stiffness. For this reason, we designed the machine with wire springs with one end free. To be concrete, the holes on the ring for wire springs were shaped conically for the wires to be free-ended (Fig. 3). With this Fig. 4. Relation between Effective Length of Spring and Characteristics of Spring: Spring Modulus, Maximum Deflection and Maximum Force. configuration, when the ring is turned and the wires are deflected, the contacts between the ring and wire springs will move, causing friction between them. We applied grease to reduce friction, but if fast movement is required, further improvement may be needed. Next, springmodulus k is obtained from force f applied and deflection d . The points of force and deflection are the same, so x .. l. The spring modulus is expressed as follows: k .. f d .. 3EI l3 .. . . . . . . . . . . . . . (2) The spring modulus varies inversely proportional to the cube of the effective length l. Then the maximum deflection is obtained. Wire spring deflection causes strain on the surface. If it exceeds the

elastic limit, plastic strain or rupture will occur. To prevent this, the maximum deflection needs to be obtained and force applied to the wire spring must be controlled within the limit. The moment applied to a wire spring peaks at the bottom at which the wire spring is fixed. Moment tmax is first obtained to give the elastic limit of surface strain at the bottom. Then maximum force fmax is determined at effective lengths l. fmax .. tmax l .. . . . . . . . . . . . . . (3) Maximum deflection dmax is obtained from Equations 2 and 3 as follows: dmax .. l2 3EI tmax.. . . . . . . . . . . . . (4) Maximum deflection increases proportionally to the square of the effective length of the wire spring. When the effective length is reduced, the deflection is also reduced but an increase of spring modulus exceeds the value. As a result, the maximum force fmax applicable to the wire spring is inversely proportional to the effective length (Eq. 3). Fig. 4 shows these relationships. Journal of Robotics andMechatronicsVol.20 No.2, 2008 297