Udo Berg

Tools and methods for automated assembly of miniaturized gear systems

The assembly of gear systems with the size of a pin head is almost beyond the bound of human tactile skills. The magic formula for series fabrication of this hybrid micro systems is the automation of the assembly process. As a contribution, this paper presents and discusses three different assembly methods comprising specifically developed tools for different types of planetary gears with outer diameters of 1.9 mm. Because of the huge importance for the complete micro assembly process, particular attention will be dedicated to the feeding and magazining of the micro gear components. Starting with metallic gear wheels as bulk good, an extremely miniaturized gear system of the Wolfram type has been automatically assembled by employing the strategy of tolerance compensation movement. As a key component, a modular tong gripper with specifically adapted gripping jaws produced by LIGA technology has been used. Further detailed investigations were spend on handling and assembly of micro injection moulded gear wheels made of POM for a three state planetary gear system. One strategy, following the idea of in situ observation, focuses on the intensive use of electronic pattern recognition. Alternatively, an unusual method based on a novel plastic wafer magazine will be discussed in detail. Hereby the exact position and orientation of injection moulded micro components will be presented from the manufacturing process up to the final micro assembly procedure. By simplifying the moulding of the micro gears as well as their handling, storing and assembly, this method has the potential to revolutionize the series fabrication of products with dimensions in the microscopic range in general.

Electromagnetic driving units for complex microrobotic systems

Electromagnetic actuators play an important role in macroscopic robotic systems. In combination with motion transformers, like reducing gear units, angular gears or spindle-screw drives, electromagnetic motors in large product lines ensure the rotational or linear motion of robot driving units and grippers while electromagnets drive valves or part conveyors. In this paper micro actuators and miniaturized motion transformers are introduced which allow a similar development in microrobotics. An electromagnetic motor and a planetary gear box, both with a diameter of 1.9 mm, are already commercially available from the cooperation partner of IMM, the company Dr. Fritz Faulhaber GmbH in Schonaich, Germany. In addition, a motor with a diameter of 2.4 mm is in development. The motors successfully drive an angular gear and a belt drive. A linear stage with a motion range of 7 mm and an overall size as small as 5 X 3.5 X 24 mm3 has been realized involving the motor, a stationary spur gear with zero backlash and a spindle-screw drive. By the use of these commercially available elements complex microrobots can be built up cost-efficiently and rapidly. Furthermore, a batch process has been developed to produce the coils of micro actuator arrays using lithographic techniques with SU-8 resin. In applying these components, the modular construction of complex microrobotic systems becomes feasible.

Fabrication of plastic microparts on wafer level

In the recent years micromolding has become one of the most important key technologies of microengineering. At the current state of art, the mass fabrication of plastic microparts for a wide range of applications like telecommunications, sensors, medical technology and biochemistry is feasible. Here a micro motor, plastic optical waveguides, a micro pump, and nanotiterplates are presented.