This dissertation presents the results of a series of studies on dynamic stabilisation of CoMan, which is actuated by series elastic actuators. The main goal of this dissertation is to dynamically stabilise the humanoid robot on the floor by the simplest multivariate feedback control for the purpose of walking. The multivariable scheme is chosen to take into account the joints' interactions, as well as providing a systematic way of designing the feedback system to improve the bandwidth and tracking performance of CoMan's existing PID control. A detailed model is derived which includes all the motors and joints state variables and their multibody interactions which are often ignored in the previous studies on bipedal robots in the literature. The derived dynamic model is then used to design multivariable optimal control feedback and observers with a mathematical proof for the relative stability and robustness of the closed loop system in face of model uncertainties and disturbances. In addition, two decentralized optimal feedback design algorithms are presented that explicitly take the compliant dynamics and the multibody interactions into account while providing the mathematical proof for the stability of the overall system. The purpose of the proposed decentralized control methods is to provide a systematic model based PDPID design to replace the existing PID controllers which are derived by a trial and error process. Moreover, the challenging constrained and compliant motion of the robot in double support is studied where a novel constrained feedback design is proposed which directly takes the compliance dynamics, interactions and the constraints into account to provide a closed loop feedback tracking system that drives the robot inside the constrained subspace. This method of control is particularly interesting since most control methods applied to closed kinematic chains (such as the double support phase) are over complicated for implementation purposes or have an ad-hoc approach to controller design. In terms of walking trajectory generation, an extension to the ZMP walking trajectory generation is proposed to utilise the CoMan's upper body to tackle the non-minimum phase behaviour that is faced in trajectory generation. Simple inverted pendulum models of walking are then used to study the maximum feasible walking speed and step size where parameters of CoMan are used to provide numerical upperbounds on the step size and walking speed. Use of straight knee and toe push-off during walking is shown to be beneficial for taking larger step lengths and hence achieving faster walking speeds. Subsequently, the designed tracking systems are then applied to a dynamic walking simulator which is developed during this PhD project to accurately model the compliant walking behaviour of the CoMan. A walking gait is simulated and visualized to show the effectiveness of the developed walking simulator. Moreover, the experimental results and challenges faced during the implementation of the designed tracking control systems are discussed where it is shown that the LQR feedback results in 50% less control effort and tracking errors in comparison with CoMan's existing independent PID control. This advantage directly affects the feasible walking speed. In addition, a set of standard and repeatable tests for CoMan are designed to quantify and compare the performance of various control system designs. Finally, the conclusions and future directions are pointed out.

This thesis investigates the potential benefits and challenges of using compliant mechanisms in the design of haptic interfaces. The benefits and challenges are presented with an emphasis on their inherent springback behavior and an active compensation approach. Design criteria for compliant mechanism joint candidates are reviewed and several joints are surveyed. Quantitative calculations of axial stiffness and maximum stress for five candidates are presented. Generalized analytical models of springback force and compensation torque are created to simulate the implementation of each joint candidate in a two degree-of-freedom planar pantograph. We use these models in the development and discussion of an analytical approach to predict the motor torques needed to actively compensate for the effects of springback.This approach relies on virtual work analyses of the haptic pantograph to determine the springback forces, compensation torques, haptic workspace, and available haptic force after compensation. A key to estimating the available haptic force is knowing that the force capability is different depending on the local springback force. If a component of the desired haptic force aligns with the springback force, then the two can work together, thus increasing the maximum magnitude of available haptic force beyond the nominal amount. Analytical and experimental results are presented. A detailed method of implementation is given along with a hardware demonstration of active compensation.

Wearable Health Devices (WHDs) are an emerging technology that enables continuous monitoring of vital signs during daily life. Issues with constant and consistent data acquisition have been found while WHD technology has developed. The force of the measurement area and movement of the sensors are key mechanical issues that need to be solved for WHDs to become a viable way to continuously monitor health conditions. This work explores Constant-Force Mechanisms (CFMs) as a solution to problems the current WHD industry faces. Additionally, the relationship between force provided from the mechanism, sensor pressure on the wrist, patient comfort, and sensor readings quality are explored and analyzed. Design requirements for a constant-force wristband were narrowed down to seven critical requirements (mechanism size vs. allowable travel, ability to be used on a curved surface, works well with existing clasps, ease of assembly, direction of travel, material, and force generation). These key requirements need to be considered for a WHD with an integrated CFM to be designed successfully. Two main concepts (buckling beams and tape springs) were prototyped and evaluated against the seven key requirements. The design and testing of a wrist worn sensing band used to gather relationship data among band tension, sensor pressure, patient comfort, and pulsatile signal quality is also presented. Human subject testing (IRB2020-268) was performed on a wristband with an integrated CFM and the wrist worn sensing band that were developed. The band with an integrated CFM compared pressure on the wrist for both a band with and without an integrated CFM for eight different movement activities. On average the band with the integrated CFM had a lower coefficient of variation for all except one of the activities. The data collected from the wrist worn sensing band shows that tension varies linearly with pressure, and that the pressure vs. tension slope increases with increasing wrist width. There also exists a linear relationship between tension and patient pain/comfort, but pressure does not show an effect on the patient discomfort or pain experienced. Signal quality when measured in the range of of 0-4 N and 0-20 kPa does not have a direct correlation to either tension or pressure.

Compliant mechanisms are useful for improving existing machines and creating new ones that were not previously possible. They also help us to think of new methods and technologies needed to both improve existing systems as well as manufacture systems that have not been done before. The purpose of this thesis is to show novel implementations of compliant mechanisms into folding systems, and to show new methods for fabricating such mechanisms with nontraditional materials and on difficult scales. Folding systems are shown in furniture applications with chairs, stools, and childcare furniture applications as results of research into how such structures could be created with compliant mechanisms to be deployed from a flat state. Compliant mechanisms are also shown to be folded by a laser into simple mechanisms and into a potentially more complex parabolic reflector. Small-scale flexible (or compliant) mechanisms are valuable in replacing rigid components while retaining comparable motion and behavior. However, fabricating such mechanisms on this scale (from 0.01 to 10 cm thick) proves difficult, especially with thin sheet metals. The manufacturing method of laser forming, which uses a laser to cut and bend metal into desired shapes, could facilitate this fabrication. However, specific methods for designing mechanisms formed by lasers need to be developed. This work presents laser forming as a means for creating compliant mechanisms on this scale with thin sheet metal. The unique challenges for designing mechanisms to be laser-formed are explored, and new adaptations of existing designs are fabricated and discussed. The design of basic "building blocks" and features are developed for several mechanisms: a parallel-guided mechanism, a cross-axis flexural pivot, a LET joint array, a split-tube flexure, and a bi-stable switch. These mechanisms are shown to perform repeatable behavior and motion comparable to existing non-laser-formed versions. The further possibilities for fabricating compliant mechanisms with laser forming are explored, as advanced applications can benefit from using lasers to create compliant mechanisms from thin sheet metal. One such possible system is a parabolic reflector, which is useful for making solar collectors and antennas. Such shapes have been developed in various patterns and typically manufactured out of rigid components. Applications for these systems could benefit from paraboloids that can fold up and be deployed into a final shape. This work presents a conceptual method for designing a flat-foldable paraboloid and a means for its fabrication using laser forming.

A novel hierarchical flexing and stretching strategy for rigid semiconducting substrates was devised. Architectures for comprehensively compliant semiconductors were created as a result. Si and GaN-on-Si have been segmented into both highly flexible and rigid segments. An advanced controlled cleavage technique has been integrated into the manufacturing process. The bending radius of the substrate has been decoupled from the substrate thickness thus allowing for higher mechanical stability, while achieving bending radii below 250 .m. Novel fabrication workflows have been created, one of which is completely compatible with CMOS fabrication techniques, while still being cost effective. Each of the rigid segments have been designed to carry in excess of its own weight. The reliability of the interconnecting springs was examined by rugged cyclic bending and twisting tests. Finite element simulations in COMSOL exhibited no stress for the rigid segments. For the first time a flexible and/or stretchable Si substrate has been integrated with pick and place tool technology. Additionally the platform serves as a More-than-Moore technology, by folding the monocrystalline substrate on top of itself, while routing power through the flexible segments. This More-than-Moore (MtM) technology has the advantages of System-in-Package (SiP) but does not have the additional costs. From this compliant approach a qubic 4D electronic platform was created. An aerially deployable electronic system was achieved by incorporating thermal paste into the qubic platform. Energy storage, sensing, and actuating were successfully tested on the system. Buried cavities for microfluidics were developed for on-chip chemical and biological processes. A platform was developed for µTF-SOFCs deposition. Cavities were interconnected subterraneously and columnar anodes were developed to enhance the fuel flow in the fuel cell electrode. The triple phase boundary (TPB) was enhanced by over an order of magnitude in comparison to standard processing techniques. A subsequent, microfluidic platform was developed for biological applications. The wettability of the platform gave good results for water, as well as for neurobasal media buffer. Tests indicate that neurons can grow directly on the platform.

Physically compliant (flexible) electronics are scientifically intriguing, mechanically complex, technologically challenging with huge socio-economical potential. The flexible electronics market is expected to grow from USD 23.92 Billion in 2018 to USD 40.37 Billion by 2023. Until now the target applications for flexible electronics have been limited to displays, solar cells, and printed batteries. A fully flexible electronic system can open up a whole new era of novel applications. On the other hand, there has been a significant growth of IoT devices worldwide. In this Ph.D. research, expanding upon the horizon of applications for flexible electronics, I explore the integration of existing “things” into the IoT ecosystem. The overarching objective is to present low-cost solutions through the use of sustainable materials as active electronic materials and employ DIY integration strategies to build “Add on” standalone sensory systems, which can be attached to any existing things like a “decal”. The add-ons can be tagged on objects or living beings including humans. The objective of using DIY methods is benefited from the low cost readily available recyclable materials which allow anyone, with a little expertise, to create customized versions of add-on modules suited to their needs. The core of the system will have flexible silicon CMOS ICs for data management, instead of conventional rigid ICs. Today, when we think of improving the performance of anything, it has to be replaced by a much more costly and sophisticated new version. By using modular add-on modules, the functionality of most things can be enhanced further without the need of replacing it entirely. On one hand, I show a low-cost add-on module that adds “smart” capabilities to a normal prescription bottle while on the other hand a smart add-on module attached to a personal belonging helps protect it from theft. Finally, a paper-based acoustic sensor housed in Styrofoam packaging will be explored to perform chronic monitoring of respiratory disease while being attached non-invasively to the chest of a human. These modules can be potential lifesavers, while costing less than a few dollars, consequently becoming a critical utility for everyone.

No description available.

There are times when it is desirable for devices to be stowed compactly, ``transported'' to the location of their desired use, and then deployed to another stable shape or configuration to perform their designed function. Origami-based mechanisms are beneficial in these cases due to their compact, folded nature and large deployments. Unlike traditional mechanical design, compliant mechanism and origami-based design approaches inherently have coupled characteristics, creating complex design problems. The research presented here discusses metrics, methods, and designs to aid in the design of origami-adapted and compliant mechanisms, focusing on the design case of deployable space systems. First, the hexagonal twist origami pattern is used to develop performance metrics for next-generation deployable space arrays. These are shown using five different thickness accommodation techniques. The concepts are demonstrated through two applications: a deployable reflectarray antenna and a LiDAR telescope. Second, a highly compact stowable deployment is presented with the Deployable Euler Spiral Connectors (DESCs). These are compliant deployable flexures that can span gaps between segments in a mechanism and then lay flat when under strain in a stowed position. Additionally, a metamaterial is shown based on the combination of Euler spiral flexures (ESFs) to provide unique behaviors difficult to obtain in traditional materials, such as high compactability, decoupled motion and stiffness, tailorable Poisson's ratio, and multi-directional deployment. Third, this work presents a method for creating hinge-like motion for origami-adapted mechanisms using internal membranes attached between rigid panels. The goal is to remove adhesive requirements, preserve panel volume for use as hard stops, and reduce parasitic motion experienced by other membrane joint types, while keeping the stress in the membrane below the stress limits. Lastly, specific applications and examples of each of the above are shown throughout the work with a specific chapter highlighting more concise examples of creating metrics to determine the best origami patterns and to create compatible hinges. The presented techniques stand to greatly benefit the origami-adapted mechanisms design community.

The purpose of this research is to develop fundamentals of compliant mechanisms in deployable space systems. The scope was limited to creating methods for thick origami, developing compliant deployable solar arrays, and developing methods for stowing and deploying the arrays. The research on actuation methods was focused on a one-time deployment of the array. Concepts for both passive and active actuation were considered. The primary objective of this work was to develop approaches to accommodate thickness in origami-based deployable arrays with a high ratio of deployed-to-stowed diameter. The HanaFlex design was derived from the origami flasher model and is developed as a deployable solar array for large arrays (150 kW or greater) and CubeSat arrays (60 W). The origami folding concept enables compact stowage of the array, which would be deployed from a hexagonal prism into a flat array with about a 10-times increase in deployed diameter as compared to stowed diameter. The work on the origami pattern for the solar array was also applied to the folding of 80-100 m2 solar sails for two NASA CubeSat missions, NEA-Scout and Lunar Flashlight. The CubeSat program is a promising avenue to put the solar array or solar sails into space for testing and proving their functionality. The deployable array concept is easily scalable, although application to CubeSats changes some of the design constraints. The thickness-to-diameter ratio is larger, making the issues of thickness more pronounced. Methods of actuation are also limited on CubeSats because of the rigorous size and weight constraints. This dissertation also includes the development of a compact, self-deploying array based on a tapered map fold design. The tapered map fold was modified by applying an elastic membrane to one side of the array and adequately spacing the panels adjacent to valley folds. Through this approach, the array can be folded into a fully dense stowed volume. Potential applications for the array include a collapsible solar array for military or backpacking applications. Additional compliant mechanism design was done in support of the HanaFlex array. This included a serpentine flexure to attach the array to the perimeter truss for deployment, and a bistable mechanism that may be used in the deployment of the array or sail.

Two compliant bistable micro-mechanisms have been developed which can be switched in either direction using on-chip thermal actuation. The energy storage and bistable behavior of the mechanisms are achieved through the elastic deflection of compliant segments. The pseudo-rigid-body model was used for the compliant mechanism design, and for analysis of the large-deflection flexible segments. To achieve on-chip actuation, the mechanism designs were optimized to reduce their required rotation, allow them to be switched using linear-motion thermal actuators. The modeling theory and analysis are presented for several design iterations. Each iteration was successfully fabricated and tested using either the MUMPs or SUMMiT surface micromachining technology.