This study presents the design of an underactuated, two-finger, motor-driven compliant gripper for grasping size-varied unknown objects. The gripper module consists of one main frame structure and two identical compliant fingers. The compliant finger is a monolithic compliant mechanism synthesized using a topology optimization method, and then prototyped by 3D printing using flexible filament. The input port for each finger is mounted on a moving platform driven by a gear motor, whereas the fixed port of the finger is mounted on a fixed platform. Each compliant finger can be actuated through the linear motion of the moving platform, and can deform elastically to generate the grasping motion. To demonstrate the effectiveness of the proposed design, the gripper module is mounted on a six-axis robotic arm to pick and place a variety of objects. The results show that objects with the sizes between 42 and 141 mm can be grasped by the developed soft robotic gripper. The maximum payload for the gripper is 2.1 kg. The proposed compliant gripper is a low-cost design that can be used in grasping of size-varied vulnerable objects.

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This study presents a topology optimization method to synthesize an innovative compliant finger for grasping objects with size and shape variations. The design domain of the compliant finger is a trapezoidal area with one input and two output ports. The topology optimized finger design is prototyped by three-dimensional (3D) printing using flexible filament, and be used in the developed gripper module, which consists of one actuator and two identical compliant fingers. Both fingers are actuated by one displacement input, and can grip objects through elastic deformation. The gripper module is mounted on an industrial robot to pick and place a variety of objects to demonstrate the effectiveness of the proposed design. The results show that the developed compliant finger can be used to handle vulnerable objects without causing damage to the surface of grasped items. The proposed compliant finger is a monolithic and low-cost design, which can be used to resolve the challenge issue for robotic automation of irregular and vulnerable objects.

This paper presents an evolutionary soft-add topology optimization method for synthesis of compliant mechanisms. Unlike the traditional hard-kill or soft-kill approaches, a soft-add scheme is proposed in this study where the elements are equivalent to be numerically added into the analysis domain through the proposed approach. The objective function in this study is to maximize the output displacement of the analyzed compliant mechanism. Three numerical examples are provided to demonstrate the effectiveness of the proposed method. The results show that the optimal topologies of the analyzed compliant mechanisms are in good agreement with previous studies. In addition, the computational time can be greatly reduced by using the proposed soft-add method in the analysis cases. As the target volume fraction in topology optimization for the analyzed compliant mechanism is usually below 30% of the design domain, the traditional methods which remove unnecessary elements from 100% turn into inefficient. The effect of spring stiffness on the optimized topology has also been investigated. It shows that higher stiffness values of the springs can obtain a clearer layout and minimize the one-node hinge problem for two-dimensional cases. The effect of spring stiffness is not significant for the three-dimensional case.