Topology optimization is recently employed for the design of light-weight manipulator-link that enhances energy-efficiency. However, the optimized topology at one angular-position is non-optimal for others because of dynamic loading. In this work, two approaches are proposed to synthesize ‘a single optimized topology’ that performs best for all angular-positions. The first approach is based on a weighted-density parameter, where highly sensitive elements are given high weightage to the final topology. The second approach is based on the superimposition of optimized topologies, followed by normalization and re-penalization to achieve desired volume fraction. An image-processing based techniques are also performed for reduction of stresses and geometrical complexities. 1-degree-of-freedom (DOF) manipulator-link is considered for topology optimization using an objective function as minimum compliance; deflection, stress, and torque are selected as performance values. The dynamic model is prepared considering the link-trajectory of 360° rotation. A 3-phase AC-servomotor and programmable logic controller based experimental setup are devised with online measurement of strain, torque, current, and position. The theoretical performance of the synthesized link using MATLAB code is validated through simulations (ANSYS-Workbench) and experiments. The synthesized-link through the proposed approaches shows similar deflection and 36% less stress compared to the conventional method. A reduction of 50% volume fraction minimizes joint torque by 43.6% within the permissible levels of a rigid link. The proposed method is illustrated on a 1-DOF link, which can be extended to the multi-DOF system and 3-dimensional links.

拓扑优化最近被用于设计轻量级机械臂链接，以提高能源效率。然而，由于动态加载，一个角度位置的优化拓扑对其他人来说不是最佳的。在这项工作中，提出了两种方法来合成对所有角度位置都表现最佳的“单一优化拓扑”。第一种方法基于加权密度参数，其中高度敏感的元素被赋予最终拓扑的高权重。第二种方法基于优化拓扑的叠加，然后进行归一化和重新惩罚以实现所需的体积分数。还执行基于图像处理的技术以减少应力和几何复杂性。考虑使用 1 自由度 (DOF) 机械手链接进行拓扑优化，使用目标函数作为最小合规性；挠度、应力和扭矩被选为性能值。考虑到 360° 旋转的连杆轨迹，准备了动力学模型。设计了基于三相交流伺服电机和可编程逻辑控制器的实验装置，可在线测量应变、扭矩、电流和位置。通过仿真 (ANSYS-Workbench) 和实验验证了使用 MATLAB 代码的综合链路的理论性能。与传统方法相比，通过所提出方法的合成链接显示出类似的偏转和 36% 的应力。在刚性连杆的允许水平内，体积分数减少 50% 可使关节扭矩最小化 43.6%。