Design method of a T-shaped passive compliant mechanism using assembly force prediction

Passive compliant mechanisms (PCMs) serve as critical components in micro assembly systems by providing autonomous force regulation during component interactions. This study presents an innovative T-shaped PCM (T-SPCM) design methodology that significantly enhances force modulation capabilities. Through analytical modeling of assembly forces across various operational states, the correlation between structural stiffness and resultant assembly forces is systematically investigated. The proposed framework enables precise parameter determination of T-SPCM to simultaneously satisfy compliance requirements and operational stability constraints. Experimental validation using a functional prototype demonstrates remarkable performance improvement, with maximum assembly force for 0.1° misaligned microobjects decreasing by 79.3 % (from 0.58 N to 0.12 N). These findings provides both theoretical insights and practical guidelines for developing advanced PCM architectures, particularly beneficial for handling delicate microobjects with low structural rigidity.