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Northeastern's Transformative Robotics Lab
CapstanClutchNew_edited.jpg

Capstan Clutch
Spring 2024

Scope: 8 months

 

Role: Research Assistant

 

Problem: Design, manufacture, and test a market viable Electrostatic Capstan Clutch with a 100 Nm holding torque using optimized values

Final design CAD

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Overall Size: 58 mm Diameter, 140mm length

 

Previous tests have been conducted on the theory of a Capstan Clutch. Specifically, there is research on the Johnsen-Rahbek effect with electrostatic adhesion, as well as the capstan effect and the use of tension for increased friction. This Capstan Clutch was the first design optimized for a 100Nm holding torque.

 

The shaft is designed to connect to a 300V power source, while the band, which attaches around the shaft, is connected to ground. When powered, the band grabs on to the shaft, acting as a clutch.

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Includes:

  • A stainless-steel band, acting similarly to a spring, with band width, gap length, and depth measured using optimized values, that wraps around an aluminum shaft

  • Springs used to allow adjustment of the pretension, to help with initial connection between the band and shaft

  • Input and output mounting plates

Capstan Clutch Sketch.jpeg

Initial design sketch - section view

CapstanClutchSimulation.jpeg

Deformation simulation results

CapstanClutchSectionViewNew.png

   Tools:

  • Fusion360

  • Ansys

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   Skills: ​

  • Design for Manufacturing

  • Design for Assembly

  • 3D Printing

  • Finite Element Analysis

  • Material Selection

Capstan Clutch CAD section view

Contributions:

  • Designed many iterations of the Capstan clutch that were presented during weekly design reviews

  • Focused on efficient and compact insulation using 3d printed parts, ceramic inserts, and ceramic bearings to ensure safety for users 

  • Ran simulations to ensure that the clutch was durable enough to withstand up to a 100Nm torque if made with aluminum

  • Called and worked with many different manufacturing companies to ensure manufacturing feasibility

    • specifically for the band, which includes precise cuts and measurements

CapstanClutchspreadNew.png

CAD exploded view

IMG_3614_edited.jpg

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  • Applied a PBI polymer layer and carbon tape to the shaft for help with adhesion

  • Assembled the Clutch and began initial testing with small applied torques

  • Adjusted the insulation and pretension for better results

  • Testing and adjustments are currently in progress to achieve 100Nm of holding torque

Final assembly reults

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