Algorithm for the static balancing of serial and parallel mechanisms combining counterweights and springs: Generation, assessment and ranking of effective design variants

Abstract Static balancing through passive devices is a suitable strategy to reduce motor loads for numerous applications in the automation and robotics fields. Many known methods require initially defining which balancing elements to install, thus possibly limiting the compensation effectiveness, since potentially optimal solutions may be neglected. This work presents an approach to statically balance linkages characterized by open and/or closed kinematic chains. The proposed algorithm searches for possible balanced variants of the mechanism that can be arranged by installing combinations of counterweights and springs, without auxiliary linkages. If solutions are found, the corresponding balancing parameters are tuned for optimizing the mechanism energy consumption, by considering the mechanism dynamics when performing its operational tasks. Actual benefits and drawbacks of the variants are assessed through quantitative criteria. The corresponding performance indicators are proposed as a guideline for designers to identify the most convenient balancing solutions. The implemented procedure is general and suitable to study any mechanism admitting closed-form solutions for its forward kinematics. A case study concerning an industrial palletizing robot is reported as an example of application. Overload issues affecting the robot actuators are solved through gravity compensation. The results achieved for the industrial problem prove the procedure effectiveness.

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