Development of a Bionic Bistable Compliant Mechanism for the LDI Machine

Rigid mechanisms (RMs) are widely adopted in the vision-based measurement (VBM) system of laser direct imaging (LDI) machines. Constant-stiffness compliant mechanisms (CMs) improve the performance of traditional RMs. Unfortunately, constant-stiffness CMs still exhibit high energy consumption and limited adaptability during fast focusing. Inspired by the hierarchical structure and mechanical behavior of ligaments and tendons, this paper proposes a bionic bistable compliant mechanism (BBCM) to replace constant-stiffness CMs. The BBCM exhibits dynamic stiffness characteristics throughout the focusing stroke, with low stiffness in the transition phase to reduce energy consumption during rapid focusing and high local stiffness near the stable positions to maintain focusing stability. A numerical model is established to analyze the variable-stiffness and bistable characteristics of the proposed BBCM. Prototype tests demonstrate the bistable response, dynamic feasibility, and energy-saving potential of the mechanism. Under the tested camera-loaded flying-shot condition, compared with the constant-stiffness CM, the BBCM reduces electrical and mechanical energy consumption by 12.37% and 9.74%, respectively. The target recognition results indicate that the BBCM-based system maintains comparable visual measurement performance. These results demonstrate that the proposed BBCM provides a feasible mechanism-level solution for energy-efficient dual-position focusing in LDI machines.