Developing a Novel Miniature 3D-Printed TLBS with High Mechanical Efficiency and Better Controllability

Area of Science:

• Mechanical Engineering
• Additive Manufacturing
• Robotics

Background:

• Traditional ball screws and lead screws face limitations in miniaturization and customization.
• The need for high-precision motion control in compact applications is growing.

Purpose of the Study:

• To develop and analyze a 3D-printed threadless ball screw (TLBS) for miniaturized, customizable, and controllable applications.
• To present a novel theoretical model for analyzing TLBS mechanical efficiency.
• To investigate the unique torque loss characteristics of the TLBS.

Main Methods:

• Development of a novel 3D-printed one-piece preloaded TLBS nut.
• Creation of a theoretical model to identify key factors affecting mechanical efficiency.
• Experimental validation of the TLBS performance and efficiency.

Main Results:

• The developed TLBS achieves a mechanical efficiency close to 90%, surpassing lead screws and rivaling traditional ball screws.
• Experimental results closely match theoretical predictions with a 3.16% normalized root mean square error.
• The TLBS exhibits a unique characteristic of weak load-dependent torque loss.

Conclusions:

• The 3D-printed TLBS is a viable solution for applications requiring miniaturization, customization, and high accuracy.
• The novel design and theoretical model contribute to improved efficiency and controllability.
• The load-independent torque loss offers significant advantages for precision control across varying loads.