The goal of this thesis is to develop a soft multiple-degree-of-freedom (multi-DOF) load cell that is robust and light weight for use in robotics applications to sense three axes of force and a single axis of torque. The displacement of the magnet within the elastomer changes the magnetic flux density which is sensed by two 3-axis Hall effect sensors. Experimental measurements of magnetic flux density within the area of interest were used to formulate analytic expressions that relate magnet field strength to the position of the magnet. The displacement and orientation measurement and the material properties of the elastomer are used to calibrate and calculate the applied load. The ability to measure 3-DOF force and axial torque was evaluated with combined loading applied by a robotic arm (KUKA, LBR r820 iiwa). The decoupled results show the 4-DOF load cell was able to distinguish 3-axis force and 1-axis torque with 6.9% averaged error for normal force, 4.3% and 2.6% for shear force in the X and Y axis and 8.6% for the torque. The results show good accuracy for a soft multi-axis sensor that would be applicable in many robotic applications where high accuracy is not required.

Growing needs for precise manipulation in medical surgery, manufacturing automation and structural health monitoring have motivated development of high accuracy, bandwidth and cost-effective sensing systems. Among these is a class of multi-axis electromagnetic devices where embedded magnetic fields can be capitalized for compact position estimation eliminating unwanted friction, stiction and inertia arising from dedicated and separate sensing mechanisms. Using fields for position measurements, however, is a challenging 'inverse problem' since they are often modeled in the 'forward' sense and their inverse solutions are often highly non-linear and non-unique. A general method to design a multisensor system that capitalizes on the existing magnetic field in permanent magnet (PM) actuators is presented. This method takes advantage of the structural field symmetry and meticulous placement of sensors to discretize the motion range of a PM-based device into smaller magnetic field segments, thereby reducing the required characterization domain. Within these localized segments, unique field-position correspondence is induced using field measurements from a network of multiple-axis sensors. A direct mapping approach utilizing trained artificial neural networks to attain multi-DOF positional information from distributed field measurements is employed as an alternative to existing computationally intensive model based methods which are unsuitable for real-time control implementation. Validation and evaluation of this technique are performed through field simulations and experimental investigation on an electromagnetic spherical actuator. An inclinometer was used as a performance comparison and experimental results have corroborated the superior tracking ability of the field-based sensing system. While the immediate application is field-based orientation determination of an electromagnetic actuator, it is expected that the design method can be extended to develop other sensing systems that harnesses other scalar, vector and tensor fields.

This thesis has been motivated by the growing needs for multi-degree of freedom (M-DOF) electromagnetic actuators capable of smooth and accurate multi-dimensional driving motions. Because high coercive rare-earth permanent-magnets (PMs) are widely available at low cost, their uses for developing compact, energy-efficient M-DOF actuators have been widely researched. To facilitate design analysis and optimization, this thesis research seeks to develop a general method based on distributed source models to characterize M-DOF PM-based actuators and optimize their designs to achieve high torque-to-weight performance with compact structures To achieve the above stated objective, a new method that is referred to here as distributed multi-level current (DMC) utilizes geometrically defined point sources has been developed to model electromagnetic components and phenomena, which include PMs, electromagnets (EMs), iron paths and induced eddy current. Unlike existing numerical methods (such as FEM, FDM, or MLM) which solve for the magnetic fields from Maxwell’s equations and boundary conditions, the DMC-based method develops closed-form solutions to the magnetic field and force problems on the basis of electromagnetic point currents in a multi-level structure while allowing trade-off between computational speed and accuracy. Since the multi-level currents can be directly defined at the geometrically decomposed volumes and surfaces of the components (such as electric conductors and magnetic materials) that make up of the electromagnetic system, the DMC model has been effectively incorporated in topology optimization to maximize the torque-to-weight ratio of an electromechanical actuator. To demonstrate the above advantages, the DMC optimization has been employed to optimize the several designs ranging from conventional single-axis actuators, 2-DOF linear-rotary motors to 3-DOF spherical motors. The DMC modeling method has been experimentally validated and compared against published data. While the DMC model offers an efficient means for the design analysis and optimization of electromechanical systems with improved computational accuracy and speed, it can be extended to a broad spectrum of emerging and creative applications involving electromagnetic systems.

Electrical switches are ubiquitous. Performance requirement for a switch is stringent. The operating mechanism mostly decides the performance of an electromechanical switch. However, design of such mechanisms, which involve discontinuous motions, is not much addressed in literature. The present work proposes a systematic procedure to design and analyze toggle based switching mechanisms. The work defined the toggle phenomenon rigorously, and, based on the behaviour of the toggles, provided a classification scheme for the switch mechanisms. The existing switches fall in two major categories viz., single-toggle and double-toggle switches. The double toggle mechanism is more suitable for high power breaking as it can isolate the system’s behaviour from the operator’s behaviour. The kinematic and geometric attributes of the operating mechanism which affect the toggle sequence and timings have been identified. A systematic simulation based study has been performed to identify the influence of different kinematic and dynamic parameters on the functionality of a double toggle switching mechanism. The influence of the variable moment of inertia and mechanism singularities arising out of introduction of the four bar sub chain on the performance of the system have been studied in detail. It is observed that the performance of the double toggle systems is less susceptible, though not immune to the user behaviour; in extreme scenarios the switching performance could become erratic. The use of an additional spring in an existing system enhanced the system performance; but, connecting the main spring with the coupler link altered the system performance more dramatically. Thus it established that the influence of the kinematic configuration on the performance of a switching mechanism is more pronounced than the dynamic characteristics of a comparable system. For the ab initio design of double toggle switching mechanisms, necessary structural criteria for a mechanism to exhibit double toggle phenomenon have been identified and verified with various 2 d.o.f. systems. It is also established that any double toggle mechanism cannot be used directly as a switching mechanism; the link dimensions, link arrangements and the stopper locations have to be chosen properly. Towards that end, three necessary kinematic criteria for a switching mechanism are identified. A few mechanisms which satisfy all structural and kinematic criteria are identified; the switching and toggle behaviour of these mechanisms are examined through simulations using Pro/Mechanism. Finally, considering all the conditions a is constructed with consideration of mass and geometric shape of the links. Thus, it established that the proposed methodology can systematically generate novel, structurally distinct electrical switches.