Search Results (33)

Work-related shoulder disorders during overhead assembly represent a persistent occupational challenge. We evaluated a quasi-direct-drive (QDD) active upper-limb exoskeleton during simulated overhead work, providing simultaneous metabolic, electromyographic, and kinematic assessment of QDD actuation under static and dynamic conditions. Seven healthy males completed within-subject comparisons of without-exoskeleton (WO) and with-exoskeleton (WE) conditions during dynamic screwing (5 min) and static holding (2.5 min, 3 kg). During static holding, the exoskeleton achieved substantial shoulder offloading (Upper Trapezius: −68.2%, 6/6 participants, p = 0.031, d = 3.61; Anterior Deltoid: −43.6%) and improved postural stability (32–41% variability reduction). However, metabolic cost increased during both static (+57.2%) and dynamic (+30.6%) tasks, while movement smoothness degraded. These findings extend prior task-dependent exoskeleton observations to QDD actuation, revealing that intrinsic backdrivability does not eliminate whole-body energy penalties from device mass. The exoskeleton exhibits task-dependent effectiveness: potentially suitable for prolonged static overhead holding but not currently recommended for dynamic assembly without mass reduction and control refinement. Full article

Effective upper-extremity rehabilitation requires intensive and precise movement training, yet conventional therapies lack accurate motion tracking. Robotic exoskeletons address this limitation but are often hindered by ergonomic misalignment and limited adaptability. The AssistOn-Arm, a novel self-aligning exoskeleton, integrates ergonomic design and back-drivable actuation to enhance comfort and facilitate natural user interaction. This study aimed to assess the usability and ergonomics of the device in healthy participants and to conduct a pilot clinical evaluation in individuals with upper-extremity impairments. Thirty healthy participants and twelve patients with shoulder impairments performed predefined tasks under participant-active and device-active conditions. Kinematic data captured concurrently with AssistOn-Arm and Xsens MVN demonstrated strong agreement between conditions. Quantitative analysis revealed no significant differences (p > 0.05) in flexion, elevation, abduction–adduction, and external rotation, indicating reliable alignment with natural joint axes. Significant differences (p < 0.05) were observed only in sagittal hyperextension and internal rotation, reflecting device mechanical constraints. The study confirms the clinical feasibility of AssistOn-Arm as a sensor-driven, self-aligning exoskeleton that bridges engineering innovation and precision rehabilitation, paving the way for its integration into clinical practice. Full article

An incision point acts as the pivot point when a minimally invasive surgery procedure is applied. The assistive robot arms employed for such operation must have the capability to perform a remote center of motion (RCM) at this pivot point. Other than designing RCM mechanisms, a common practice is to use a readily available spatial serial robot arm and control it to impose this RCM constraint. When this assistive robot is required to be backdriven by the surgeon, the relation between the interaction forces/moments and the motion with RCM constraint becomes challenging. This paper carefully formulates a hybrid position/force control scheme for this relationship when any readily available robot arm that is coupled with a force/torque sensor is used for an RCM task. The verification of the formulation is carried out on a readily available robot arm by implementing the additional constraints that are derived from a surgical robot application. Full article

Series elastic actuators (SEAs) represent a key technological solution to enhance safety, performance, and adaptability in robotic devices for physical training. Their ability to decouple the rigid actuator’s mechanical impedance from the load, combined with passive absorption of external disturbances, makes them particularly suitable for pediatric applications. In children aged 2 to 5 years—where motor control is still developing and movements can be unpredictable or unstructured—SEAs provide a compliant mechanical response that ensures user protection and enables safe physical interaction. This study explores the role of SEAs as a central component for imparting compliance and backdrivability in robotic systems designed for upper-limb training. A dynamic model is proposed, incorporating interaction with the user’s limb, along with a computed torque control strategy featuring integral action. The system’s performance is validated through simulations and experimental tests, demonstrating stable trajectory tracking, disturbance absorption, and effective impedance decoupling. The results support the use of SEAs as a foundational technology for developing safe adaptive robotic solutions in pediatric contexts capable of responding flexibly to user variability and promoting secure interaction in early motor development environments. Full article

Extraterrestrial exploration presents unique challenges for robotic systems, as traditional rigid rovers face limitations in stowage volume, traction on unpredictable terrain, and susceptibility to damage. Soft robotics offers promising solutions through bio-inspired designs that can mimic natural locomotion mechanisms. Here, we present an optimised, spider-inspired soft jumping robot for extraterrestrial exploration that addresses key challenges in soft robotics: actuation efficiency, controllability, and deployment. Drawing inspiration from spider physiology—particularly their hydraulic extension mechanism—we develop a lightweight limb capable of multi-modal behaviour with significantly reduced energy requirements. Our 3D-printed soft actuator leverages pressure-driven collapse for efficient retraction and pressure-enhanced rapid extension, achieving a power-to-weight ratio of 249 W/kg. The integration of a non-backdriveable clutch mechanism enables the system to hold positions with zero energy expenditure—a critical feature for space applications. Experimental characterisation and a subsequent optimisation methodology across various materials, dimensions, and pressures reveal that the robot can achieve jumping heights of up to 1.86 times its body length. The collapsible nature of the soft limb enables efficient stowage during spacecraft transit, while the integrated pumping system facilitates self-deployment upon arrival. This work demonstrates how biologically inspired design principles can be effectively applied to develop versatile robotic systems optimised for the unique constraints of extraterrestrial exploration. Full article

In this paper, we present the details of the actuator design for our humanoid robot, Mithra. Mithra has been designed to match an average adult human in terms of kinematic and kinetic characteristics. This poses various challenges in actuator design that we have addressed in this work. First, we discuss how the high-level design can help in achieving anthropomorphic traits. Next, the detailed design is verified and finalized using stress and fatigue analyses. Further, we conduct experiments to validate the actuator’s bandwidth and backdrivability, and discuss the outcomes in comparison with human characteristics. The results show that Mithra’s actuators have sufficient structural strength to withstand high running forces, and at the same time, provide human-like traits and capabilities to accommodate human-inspired control paradigms. Full article

High-torque-density motors are essential in humanoid, wearable, and rehabilitation robots due to their ability to minimize gear ratios, improve back-drivability, and support compact joint design. However, their inherently high back-EMF limits speed performance, and safety regulations often constrain supply voltages to below 50 V in human-interactive environments. To overcome these limitations, this study introduces a novel winding strategy called parallel open-end winding (POEW), which combines the benefits of two individual approaches: Parallel Connected Winding (PCW) and Open-End Winding (OEW). PCW reduces phase resistance and inductance, thereby mitigating voltage drop and back-EMF, while OEW eliminates the neutral point, allowing full-phase voltage utilization. Experimental results show that the POEW configuration achieves a 3.5-fold increase in maximum speed compared to the conventional Series-Connected Winding (SCW), without altering the rotor or stator structure. Torque constant measurements confirm that all proposed configurations maintain torque output with minimal variation. Although the motor constant slightly decreases due to the higher current in parallel paths, the significant speed enhancement under low-voltage conditions demonstrates the practicality and effectiveness of POEW for advanced robotic applications requiring both high torque and speed. Full article

A high-gear-ratio anti-backlash 3K planetary gearbox with a preloaded flexure-based carrier is a suitable reducer for robot joints owning to its compact design and high transmission accuracy. However, to design such a 3K planetary gearbox with high bidirectional efficiencies for backdrivable robot joints, it is critical to develop an accurate transmission efficiency model to predict the effects of the preloaded flexure-based carrier on the efficiency of the 3K planetary gearbox. To determine the meshing forces of gear pairs in the 3K planetary gearbox, a quasi-static model is formulated according to tangential displacements of planet gears resulting from the preloaded flexure-based carrier. Considering the reverse meshing forces in the anti-backlash 3K planetary gearbox, a modified efficiency model is developed and the bidirectional transmission efficiencies are analyzed. Simulation results show that both forward and backward transmission efficiencies of the anti-backlash 3K planetary gearbox decrease as the preload increases, while they all increase with the increasing load torque. It is also revealed that the preload primarily affects the meshing efficiency of the sun–planet gear pair. Four different carrier prototypes are fabricated for experiments. The average errors between the predicted and measured results for forward and backward transmission efficiencies are 2.30% and 4.01%, respectively. Full article

The recent advancements in wearable exoskeletons have highlighted their effectiveness in assisting humans for both rehabilitation and augmentation purposes. These devices interact with the user; therefore, their actuators and power transmission mechanisms are crucial for enhancing physical human–robot interaction (pHRI). The advanced progression of 3D printing technology as a valuable method for creating lightweight and efficient gearboxes enables the exploration of multiple reducer designs. However, to the authors’ knowledge, only sporadic implementations with relatively low reduction ratios have been reported, and the respective experimental validations usually vary, preventing a comprehensive evaluation of different design and implementation choices. In this paper, we design, develop, and examine experimentally multiple 3D-printed gearboxes conceived for wearable assistive devices. Two relevant transmission ratios (1:30 and 1:80) and multiple designs, which include single- and double-stage compact cam cycloidal drives, compound planetary gearboxes, and cycloidal and planetary architectures, are compared to assess the worth of 3D-printed reducers in human–robot interaction applications. The resulting prototypes were examined by evaluating their weight, cost, backdrivability, friction, regularity of the reduction ratio, gear play, and stiffness. The results show that the developed gearboxes represent valuable alternatives for actuating wearable exoskeletons in multiple applications. Full article

Enhancing the transparency of high-transmission-ratio linear actuators is crucial for improving the safety and capability of high-force robotic systems having physical contact with humans in unstructured environments. However, realizing such enhancement is challenging. A proposed solution for active body weight support systems involves employing a macro–mini linear actuator incorporating an electrorheological-fluid brake to connect a high-force unit with an agile, highly back-drivable unit. This paper introduces the use of an electromagnetic (EM) brake with reduced rotor inertia to address this challenge. The increased torque capacity of the EM brake enables integration with a low-gear-ratio linear transmission. The agile translation of the endpoint is propelled by a low-inertia motor (referred to as the “mini”) via a pulley-belt mechanism to achieve high transparency. The rotor of the EM brake is linked to the pulley. Damping modulation under high driving force is achieved through the adjustment of the brake torque relative to the rotational speed of the pulley. When the brake is engaged, it prevents any relative motion between the endpoint and the moving carrier. The endpoint is fully controlled by the ball screw of the high-force unit, referred to as the “macro”. A scaled prototype was constructed to experimentally characterize the damping force generated by the mini motor and the EM brake. The macro–mini linear actuator, equipped with an intrinsic failsafe feature, can be utilized for active body weight support systems that demand high antigravity force. Full article

Frontal plane ankle motion is important for balance in walking but is seldom controlled in robotic prostheses. This article describes the design, control and performance of a semi-active two-degree-of-freedom robotic prosthetic ankle. The mechanism uses a non-backdrivable wedge cam system based on rotating inclined planes, allowing actuation only during swing phases for low power, light weight and compactness. We present details of the mechanism and its kinematic and mechatronic control, and a benchtop investigation of the system’s speed and accuracy in ankle angle control. The two-axis ankle achieves angular reorientation movements spanning ±10 deg in any direction in less than 0.9 s. It achieves a plantarflexion/dorsiflexion error of 0.35 ± 0.27 deg and an inversion/eversion error of 0.29 ± 0.25 deg. Backdriven motion during walking tests is negligible. Strengths of the design include self-locking behavior for low power and simple kinematic control. Two-axis ankle angle control could enable applications such as balance augmentation, turning assistance, and wearable perturbation training. Full article

Coaxial magnetic gears have piqued the interest of researchers due to their numerous benefits over mechanical gears. These include reduced noise and vibration, enhanced efficiency, lower maintenance costs, and improved backdrivability. However, their adoption in industry has been limited by drawbacks like lower torque density and slippage at high torque levels. This work presents an analytical 2D model to compute the magnetic potential in Halbach array coaxial magnetic gears for every rotational angle, geometry configuration, and magnet specifications. This model calculates the induced torques and torque ripple in both rotors using the Maxwell Stress Tensor. The results were confirmed through Finite Element Analysis (FEA). Unlike FEA, this analytical model directly produces harmonics values, leading to faster computational times as it avoids torque calculations at each time step. In a case study, a standard coaxial magnetic gear was compared to one with a Halbach array, revealing a 14.3% improvement in torque density and a minor reduction in harmonics that cause torque ripple. Additionally, a case study was conducted to examine slippage in both standard and Halbach array gears during transient operations. The Halbach array coaxial magnetic gear demonstrated a 13.5% lower transmission error than its standard counterpart. Full article

This paper studies the working principles of antagonistic magneto-rheological (MR) actuators, i.e., a combination of an electric motor and a pair of MR clutches in an antagonistic configuration, for compliant actuation in robotics. The study focuses on the unique boundedness property exhibited by MR actuators, which limits the output torques delivered to the load, independent of the received input torque and/or control commands. This inherent property is of significant importance for ensuring human safety in human–robot interaction applications. Through a comprehensive analysis, we provide analytical proof of the inherent output boundedness of antagonistic MR actuators and validate our findings through experimental results. Our research demonstrates that these actuators are well-suited for safe operations in robotic applications, eliminating the need for additional sensor measurements or complex control strategies. This promising capability enables the avoidance of trade-offs between actuator performance, complexity, and cost. The insights gained from this study contribute to advancing compliant actuation technology, paving the way for high-performance and human-safe robotic systems. Full article

This paper presents a haptic interface with modular linear actuators that addresses the limitations of conventional devices based on rotary joints. The proposed haptic interface is composed of parallel linear actuators that provide high backdrivability and small inertia. The performance of the haptic interface is compared to those of conventional mechanisms in terms of force capability, reflected inertia, and structural stiffness. High stiffness, large range of motion, and high force capability, which are in trade-off relationships in traditional haptic interfaces, are achieved. The device can apply up to 83 N continuously, i.e., three-fold more than most haptic devices. The theoretical minimum haptic force density and stiffness of the proposed mechanism are 1.3 to 1.9 and 37 times those of the conventional mechanisms under similar conditions, respectively. The system is scalable because the structural stiffness depends on only the timing belt stiffness, whereas that of conventional haptic interfaces is inversely proportional to the cube of the structural length. The modular actuator enables changes in the degrees of freedom (DOFs) for different applications. The proposed haptic interface was tested through an interaction experiment in a virtual environment with virtual walls. Full article

In this paper, a back-drivable and miniature rotary series elastic actuator (RSEA) is proposed for robotic adaptive grasping. A compact arc grooves design has been proposed to effectively reduce the dimension of the RSEA system. The elastic elements could be reliably embedded in the arc grooves without any additional installation structures. The whole RSEA system is characterized as compact, miniature, and modular. The actuating force is controlled via a PI controller by tracking the deformation trajectory of the elastic elements. An underactuated finger mechanism has been adopted to investigate the effectiveness of the RSEA in robotic adaptive grasping. Results reveal that the underactuated finger mechanism could achieve adaptive grasping via the RSEA in a back-drive approach without the requirement of a fingertip force sensor. The RSEA could also exhibit an actuating compliance and a self-sensing characteristic. The actuating compliance characteristic helps in in guaranteeing the safety of human–robot interaction. The RSEA could estimate the external disturbance due to its self-sensing characteristic, which has the potential to replace the fingertip force sensor in grasping force perception applications. Full article