Optimization Design of Kinematic Couplings for Improving Repetitive Positioning Accuracy of Opto-mechanical Assemblies

Abstract Kinematic coupling, as an efficient form of connection, is frequently employed for the repeated assembly and accurate positioning of replaceable opto-mechanical assemblies within high-power solid-state laser systems. During the kinematic coupling process, uncertainties in the mechanical behavior within the contact region often hinder the attainment of consistent positioning accuracy, potentially leading to an inability to meet operational requirements. This study aims to enhance the repetitive positioning precision of opto-mechanical assemblies kinematic couplings. To achieve this goal, a predictive model for repetitive positioning accuracy is established, accounting for uncertainties in contact region forces. Based on this model, an optimization design of kinematic couplings is conducted to mitigate these challenges. Initially, accounting for uncertainties in mechanical parameters within the contact region, we formulate a static analysis computational model to elucidate the probabilistic distribution of these parameters. Subsequently, employing Hertz contact theory and Holm-Archard wear theory, we quantify the elastic deformation and equivalent wear for each contact region through the calculation of normal pressures. Building upon this foundation, we establish a predictive model for repetitive positioning accuracy. Finally, optimization design is carried out on the friction coefficient of contact surfaces and the structural dimensions of positioning elements. The proposed optimization design is validated through experimental verification. The findings demonstrate that optimization of structural dimensions and contact surface friction coefficients resulted in enhanced repetitive positioning accuracy of 35.9%, effectively ameliorating the assembly quality. This study contributes a quantifiable analytical approach to the prediction and optimization design of repetitive positioning accuracy in kinematic couplings.