abstract: Locomotion is of prime importance in enabling human beings to effectively respond in space and time to meet different needs. Approximately 2 million Americans live with an amputation with most of those amputations being of the lower limbs. To advance current state-of-the-art lower limb prosthetic devices, it is necessary to adapt performance at a level of intelligence seen in human walking. As such, this thesis focuses on the mechanisms involved during human walking, while transitioning from rigid to compliant surfaces such as from pavement to sand, grass or granular media. Utilizing a unique tool, the Variable Stiffness Treadmill (VST), as the platform for human walking, rigid to compliant surface transitions are simulated. The analysis of muscular activation during the transition from rigid to different compliant surfaces reveals specific anticipatory muscle activation that precedes stepping on a compliant surface. There is also an indication of varying responses for different surface stiffness levels. This response is observed across subjects. Results obtained are novel and useful in establishing a framework for implementing control algorithm parameters to improve powered ankle prosthesis. With this, it is possible for the prosthesis to adapt to a new surface and therefore resulting in a more robust smart powered lower limb prosthesis. / Dissertation/Thesis / Masters Thesis Biomedical Engineering 2019

The high cost of experimentation and product development in the field of microelectromechanical systems (MEMS) has led to a greater emphasis on simulation-based design for increasing first-pass design success and reliability. The use of compliant or flexible mechanisms can help eliminate friction, wear, and backlash, but compliant MEMS are sensitive to variations in material properties and geometry. This dissertation proposes approaches for design stage uncertainty analysis, model validation, and robust optimization of nonlinear compliant MEMS to account for critical process uncertainties including residual stress, layer thicknesses, edge bias, and material stiffness. Methods for simulating and mitigating the effects of non-idealities such joint clearances, semi-rigid supports, non-ideal loading, and asymmetry are also presented. Approaches are demonstrated and experimentally validated using bistable micromechanisms and thermal microactuators as examples.

This work develops and examines design strategies for reducing the stiffness of 3D-printed compliant mechanisms. The three aspects of a flexure that determine its stiffness are well known: material, boundary conditions, and geometry. In a highly constrained design space however, flexure stiffness may remain unacceptably high even while arriving at the limits of design constraints. In this work, changes to geometry and boundary conditions are examined that lead to drastically reduced stiffness behavior without changing flexure thickness, width, or length. Changes to geometry can result in very complex mechanisms. However, 3D printing enables almost arbitrarily complex geometries. This dissertation presents three design strategies for stiffness reduction: static balancing, lattice flexures, and compound joints. Static balancing refers to changes in the boundary conditions that result in a near-zero net change in potential energy storage over the useful deflection of a flexure. In this work, I present a method for static balancing that utilizes non-dimensional parameters to quickly synthesize a joint design with stiffness reduced by nearly 90%. This method is not only simple and straightforward, it is applicable to a wide range of flexure topologies. The only requirements on the joint to be balanced are that it must be approximated as a pin joint and torsion spring, and it must have a well-understood stiffness when subjected to a compressive load. Lattice flexures result from modifications to geometry that reduce cross-sectional area without changing width or thickness. However, the reduction in stiffness is greater than the reduction in cross sectional area. This can occur because the bending load is now carried by beams partially in torsion. Two lattice geometries are proposed and analyzed in detail using analytic and numeric techniques. It is shown that the off-axis stiffness behavior of lattice flexures can be better than that of conventional blade flexures while bending stiffness is reduced >60%. Compound joints are those that consist of arrays of flexures arranged co-axially. This arrangement provides increased range of motion, generally decreased stiffness, and improved stability. Additionally, a method is herein presented to reduce the parasitic center shift of a compound joint to nearly zero at a specified deflection. The penultimate chapter demonstrates how all three strategies can be used together, and includes new results to facilitate their combination.

In this thesis, the mechanical characterization of thin films, bulk materials, compliant MEMS and Microfluidics has been discussed. In chapter1 and chapter 2, the Indentation Size Effect (ISE) has been studied for single crystal aluminum and the substrate effect has also been studied for 200 nm gold film on mica substrate and 50 nm gold film on (100) silicon wafer substrate. The mechanical characterization of super hard SiC films (prepared by CVD) has also been discussed. In chapter 3, the actuation of compliant MEMS devices with a nanoindentation apparatus has been investigated. Friction forces become important at the device level, and the conical tip always makes a crack at the edge of the sliders, thus the slider design needs to be optimized to account for the probe geometry. In chapter 4, the measurement of electrowetting has been outlined. The "airscratch" mode was used to capture the lateral force and normal force during an electrowetting test. With the appearance of surface delamination on the solid surface, the unexpected normal forces can been measured.

We make two main contributions in this thesis. First, we present our approach to robot manipulation, which emphasizes the benefits of making contact with the world across all the surfaces of a manipulator with whole-arm tactile sensing and compliant actuation at the joints. In contrast, many current approaches to mobile manipulation assume most contact is a failure of the system, restrict contact to only occur at well modeled end effectors, and use stiff, precise control to avoid contact. We develop a controller that enables robots with whole-arm tactile sensing and compliant actuation at the joints to reach to locations in high clutter while regulating contact forces. We assume that low contact forces are benign and our controller does not place any penalty on contact forces below a threshold. Our controller only requires haptic sensing, handles multiple contacts across the surface of the manipulator, and does not need an explicit model of the environment prior to contact. It uses model predictive control with a time horizon of length one, and a linear quasi-static mechanical model that it constructs at each time step. We show that our controller enables both a real and simulated robots to reach goal locations in high clutter with low contact forces. While doing so, the robots bend, compress, slide, and pivot around objects. To enable experiments on real robots, we also developed an inexpensive, flexible, and stretchable tactile sensor and covered large surfaces of two robot arms with these sensors. With an informal experiment, we show that our controller and sensor have the potential to enable robots to manipulate in close proximity to, and in contact with humans while keeping the contact forces low. Second, we present an approach to give robots common sense about everyday forces in the form of probabilistic data-driven object-centric models of haptic interactions. These models can be shared by different robots for improved manipulation performance. We use pulling open doors, an important task for service robots, as an example to demonstrate our approach. Specifically, we capture and model the statistics of forces while pulling open doors and drawers. Using a portable custom force and motion capture system, we create a database of forces as human operators pull open doors and drawers in six homes and one office. We then build data-driven models of the expected forces while opening a mechanism, given knowledge of either its class (e.g, refrigerator) or the mechanism identity (e.g, a particular cabinet in Advait's kitchen). We demonstrate that these models can enable robots to detect anomalous conditions such as a locked door, or collisions between the door and the environment faster and with lower excess force applied to the door compared to methods that do not use a database of forces.

Main objective of this study is to design a compliant mechanism with high frequency and high mechanical amplification ratio to be used for amplifying the stroke of a piezostack actuator. In this thesis, first of all, related literature is investigated and then alternative conceptual designs are established utilizing the mechanisms found in literature survey. Once best conceptual design is selected, detailed design of this mechanism is done. For detailed design of the compliant mechanism, topology optimization method is used in this study. To design the mechanism, first a design domain is defined and then a finite element model of the design domain is prepared to be used in topology optimization runs. After running the topology optimization model by using TOSCA with ANSYS, results are imported to ANSYS, where final performance of the mechanism design is checked. After finalizing design of the mechanism, it is produced and its performance is tested through experiments.

Main objective of this study is to design a compliant mechanism with high frequency and high mechanical amplification ratio to be used for amplifying the stroke of a piezostack actuator. In this thesis, first of all, related literature is investigated and then alternative conceptual designs are established utilizing the mechanisms found in literature survey. Once best conceptual design is selected, detailed design of this mechanism is done. For detailed design of the compliant mechanism, topology optimization method is used in this study. To design the mechanism, first a design domain is defined and then a finite element model of the design domain is prepared to be used in topology optimization runs. After running the topology optimization model by using TOSCA with ANSYS, results are imported to ANSYS, where final performance of the mechanism design is checked. After finalizing design of the mechanism, it is produced and its performance is tested through experiments.

A compliant mechanism gains its motion from the deflection of flexible members or the deformation of one portion of materials with respect to other portions. Design and operation of compliant mechanisms are very important, as most of the natural objects are made of compliant materials mixed with rigid materials, such as the bird wings. The most serious problem with compliant mechanisms is their fatigue problem due to repeating deformation of materials in compliant mechanisms. This thesis presents a study on the computational framework for designing a compliant mechanism under fatigue strength control. The framework is based on the topology optimization technique especially ground structure approach (GSA) together with the Genetic Algorithm (GA) technique. The study presented in this thesis has led to the following conclusions: (1) It is feasible to incorporate fatigue strength control especially the stress-life method in the computational framework based on the GSA for designing compliant mechanisms and (2) The computer program can well implement the computational framework along with the general optimization model and the GA to solve the model. There are two main contributions resulting from this thesis: First one is provision of a computational model to design compliant mechanisms under fatigue strength control. This model also results in a minimum number of elements of the compliant mechanism in design, which means the least weight of mechanisms and least amount of materials. Second one is an experiment for the feasibility of implementing the model in the MATLAB environment which is widely used for engineering computation, which implies a wide applicability of the design system developed in this thesis.

This thesis presents the development of a model for analyzing the design of an automated live-bird transfer system (LBTS) developed at Georgia Tech. One of the most fundamental tasks in the automated transferring is to design and control a grasping system that is capable of accommodating a specified range of objects without causing damage. However, unlike grasping in robotic research that focuses on dexterous manipulation of a single object, repetitive transfer of live objects in a production line requires continuous grasping at high-speed. This thesis research investigates the use of rotating fingers (capable of undergoing large deflections) to cradle live birds on a moving conveyor for subsequent handling. As compared to fingers with multiple active joints, flexible fingers have many merits, for they are lightweight and have no relative individually moving parts. Their ability to accommodate a limited range of varying sizes, shapes, and the natural reactions of some objects makes rubber fingers an attractive candidate for use as graspers in a high-speed production setting. However, the advantages of flexible fingers are seldom exploited for grasping because of the complex analysis involved in the design. In order to reduce the number of birds and hardware/software design configurations to be tested, a good understanding of the object dynamics throughout the grasping process is necessary. In this thesis, a quasi-static model has been developed for predicting the contact force between a moving object and a rotating finger. The model has been validated with the experimentally measured data and the computed results using finite element (FE) methods. Finally, an illustrative application of the validated model has been demonstrated in the design of a rotating hand used in the automated LBTS. As illustrated in the simulation results, the computed contact forces can be used as a basis for predicting potential bruises on the bird that may be caused by the rotating fingers. The analytical model presented in this paper provides a rational basis for optimizing the design of the grasping system and developing a controller for a high-speed transfer system. It is expected that the analysis presented here can be readily extended to other dynamic systems involving the use of flexible beams.

In this study analysis and design procedures of partially compliant mechanisms using two degree of freedom mechanism model are developed. The flexible segments are modeled as revolute joints with torsional springs. While one freedom is controlled by the input to the mechanism, the motion of the parts are governed both by the kinematics and the force balance. The procedure developed for the analysis of such mechanisms is shown on two different mechanisms: a five link mechanism with crank input and slider output (five-bar mechanism) / a five link mechanism with crank input and rocker output. Design charts are prepared according to output-link oscillation and dimensionless design parameters