Mobile legged robots have the potential to restructure many aspects of our lives in the near future. Whether for applications in household care, entertainment, or disaster response, these systems depend on high-performance actuators to improve their basic capabilities. The work presented here focuses on developing new high-performance actuators, specifically series elastic actuators, to address this need. We adopt a system-wide optimization approach, dealing with factors which influence performance at the levels of mechanical design, electrical system design, and control. Using this approach and based on a set of performance metrics, we produce an actuator, the UT-SEA, which achieves leading empirical results in terms of power-to-weight, force control, size, and system efficiency. We also develop general high-performance control techniques for both force- and position-controlled actuators, some of which were adopted for use on NASA-JSC's Valkyrie Humanoid robot and were used during DARPA's DRC Trials 2013 robotics competition. / text

This thesis designed and realized a two-degree of freedom wrist and two finger manipulator that completes the six-degree of freedom Sensitive Manipulation Platform, the arm of which was previously developed. This platform extends the previous research in the field of robotics by covering not only the end effector with deformable tactile sensors, but also the links of the arm. Having tactile sensors on the arm will improve the dynamic model of the system during contact with its environment and will allow research in contact navigation to be explored. This type of research is intended for developing algorithms for exploring dynamic environments. Unlike traditional robots that focus on collision avoidance, this platform is designed to seek out contact and use it to gather important information about its surroundings. This small desktop platform was designed to have similar proportions and properties to a small human arm. These properties include compliant joints and tactile sensitivity along the lengths of the arms. The primary applications for the completed platform will be research in contact navigation and manipulation in dynamic environments. However, there are countless potential applications for a compliant arm with increased tactile feedback, including prosthetics and domestic robotics. This thesis covers the details behind the design, analysis, and evaluation of the two degrees of the Wrist and two two-link fingers, with particular attention being given to the integration of series elastics actuators, the decoupling of the fingers from the wrist, and the incorporation of tactile sensors in both the forearm motor module and fingers.

We present work to transfer decentralized neuromuscular control strategies of human locomotion to powered segmented robotic legs. State-of-the-art robotic locomotion control approaches, like centralized planning and tracking in fully robotic systems and predefined motion pattern replay in prosthetic systems, do not enable the dynamism and reactiveness of able-bodied humans. Animals largely realize dexterous segmented leg performance with leg-encoded biomechanics and local feedback controls that bypass central processing. A decentralized neuromuscular controller was recently developed that enables robust locomotion for a simulated multi-segmented planar humanoid. A portion of this controller was used in an active ankle-foot prosthesis to modulate ankle torque during stance, enabling level and inclined ground walking. While these results suggest that the neuromuscular controller is a promising alternative control method for both fully robotic systems and powered prostheses, it is unclear if the controller can be transferred to multi-segmented robotic legs. The goal of this thesis is to investigate the feasibility of controlling a multi-segmented robotic leg with the proposed neuromuscular control approach, which may enable robots and powered prostheses to react to locomotion disturbances dynamically and in a human-like way. Specifically, work in this thesis investigates two hypotheses. Hypothesis one posits that the proposed decentralized swing-leg controllers enable more robust foot placements into ground targets than state-of-the-art impedance controls. Hypothesis two posits that neuromuscular swing-leg control enables more human-like motion than state-of-the-art impedance control. To transfer neuromuscular controls to powered segmented robotic legs, we use a model-based design approach. The initial transfer is focused on neuromuscular swing-leg controls, important for maintaining dynamic stability of both fully robotic systems and powered prostheses in the presence of unexpected locomotion disturbances, such as trips and pushes. We first present the design of RNL, a three segment, cable-driven, antagonistically actuated robotic leg with joint compliance. The robot’s size, weight, and actuation capabilities correspond to dynamically scaled human values. Next, a highfidelity simulation of the robot is created to investigate the feasibility of transferring neuromuscular controls, pre-tune hardware gains via optimization, and serve as a benchmark for hardware experiments. An idealized version of the swing-leg controller with mono-articular actuation, as well as the neuromuscular interpretation of this controller with multi-articular actuation is then transferred to RNL and evaluated with foot placement experiments. The results suggest that the proposed swing-leg controllers can accurately regulate foot placement of robotic legs during undisturbed and disturbed motions. Compared to impedance control, the proposed controls achieve foot placements over a range of ground targets with a single set of gains, which make them attractive candidates for regulating the motion of legged robots and prostheses in the real-world. Furthermore, the ankle trajectory traced out by the robot under neuromuscular control is more human-like than the trajectories traced out under the proposed idealized control and impedance control. In parallel to this control transfer, a synthesis method for creating compact nonlinear springs with user-defined torque-deflection profiles is presented to explore methods for improving RNL’s series elastic actuators. The springs use rubber as their elastic element, which, while enabling a compact spring design, introduce viscoelastic behavior in the spring that needs to be accounted for with additional control. To accurately estimate force developed in the rubber, an empirically characterized constitutive rubber model is developed and integrated into the series elastic actuator controller used by the RNL test platforms. Benchtop experiments show that in conjunction with an observer, the nonlinear spring prototype achieves desired behavior at actuation frequencies up to 2 Hz, after which spring behavior degrades due to rubber hysteresis. These results show that while the presented methodology is capable of realizing compact nonlinear springs, careful rubber selection that mitigates viscoelastic behavior is necessary during the spring design process.

Esta dissertação apresenta o projeto e a construção de atuadores elásticos em série para o acionamento das juntas de um exoesqueleto para membros inferiores, baseado em uma órtese comercial. Inicialmente, considerou-se como dispositivo de testes a parte do exoesqueleto referente à junta do tornozelo, ou seja, a construção de uma órtese tornozelo-pé ativa. Atuadores elásticos em série são considerados neste trabalho, pois tais dispositivos apresentam características ideais para a sua utilização em órteses ativas: controle de força, controle de impedância (possibilidade de impedância baixa), absorção de impactos, baixo atrito e largura de banda que se aproxima da movimentação muscular. Um primeiro protótipo do atuador elástico em série foi construído e resultados experimentais de controle de força, impedância e posição foram obtidos com sucesso, através de uma interface de acionamento e controle entre o atuador, os sensores (encoders e sensores de força) e o computador. Também foi construída uma órtese tornozelo-pé ativa acionada pelo atuador elástico em série construído, sendo apresentados os primeiros resultados experimentais obtidos com este dispositivo. / This dissertation deals with the design and construction of series elastic actuators for driving the joints of an exoskeleton for lower limbs, based on a commercial orthosis. Initially, it was considered the construction of the exoskeleton\'s ankle joint, that is, the construction of an active ankle-foot orthosis. Series elastic actuators are considered in this work since these devices have ideal characteristics for use in active orthoses: force control, impedance control (possibility of low impedance), impact absorption, low friction and bandwidth that approximates the muscle movement. A first prototype of the series elastic actuator was constructed and experimental results of force, impedance, and position control were successfully obtained trough of a control interface between the actuators, the sensors (encoders and force sensors) and the computer. Also, an active ankle-foot orthosis, driven by the series elastic actuator, was constructed and the first experimental results achieved with this device are presented.

Esta dissertação apresenta o projeto e a construção de atuadores elásticos em série para o acionamento das juntas de um exoesqueleto para membros inferiores, baseado em uma órtese comercial. Inicialmente, considerou-se como dispositivo de testes a parte do exoesqueleto referente à junta do tornozelo, ou seja, a construção de uma órtese tornozelo-pé ativa. Atuadores elásticos em série são considerados neste trabalho, pois tais dispositivos apresentam características ideais para a sua utilização em órteses ativas: controle de força, controle de impedância (possibilidade de impedância baixa), absorção de impactos, baixo atrito e largura de banda que se aproxima da movimentação muscular. Um primeiro protótipo do atuador elástico em série foi construído e resultados experimentais de controle de força, impedância e posição foram obtidos com sucesso, através de uma interface de acionamento e controle entre o atuador, os sensores (encoders e sensores de força) e o computador. Também foi construída uma órtese tornozelo-pé ativa acionada pelo atuador elástico em série construído, sendo apresentados os primeiros resultados experimentais obtidos com este dispositivo. / This dissertation deals with the design and construction of series elastic actuators for driving the joints of an exoskeleton for lower limbs, based on a commercial orthosis. Initially, it was considered the construction of the exoskeleton\'s ankle joint, that is, the construction of an active ankle-foot orthosis. Series elastic actuators are considered in this work since these devices have ideal characteristics for use in active orthoses: force control, impedance control (possibility of low impedance), impact absorption, low friction and bandwidth that approximates the muscle movement. A first prototype of the series elastic actuator was constructed and experimental results of force, impedance, and position control were successfully obtained trough of a control interface between the actuators, the sensors (encoders and force sensors) and the computer. Also, an active ankle-foot orthosis, driven by the series elastic actuator, was constructed and the first experimental results achieved with this device are presented.

Recent advancements in actuator technologies, computation, and control have led to major leaps in capability and have brought humanoids ever closer to being feasible solutions for real-world applications. As the capabilities of humanoids increase, they will be called on to operate in unstructured real world environments. This realization has driven researchers to develop more dynamic, robust, and adaptable robots. Compared to state-of-the-art robots, biological systems demonstrate remarkably better efficiency, agility, adaptability, and robustness. Many recent studies suggest that a core principle behind these advantages is compliance, yet there are very few compliant humanoids that have demonstrated successful walking. The work presented in this dissertation is based on several years of developing novel actuators for two full-scale linearly actuated compliant humanoid robots, SAFFiR and THOR. Both are state-of-the-art robots intended to operate in the extremely challenging real world scenarios of shipboard firefighting and disaster response. The design, modeling, and control of actuators in robotics application is critical because the rest of the robot is often designed around the actuators. This dissertation seeks to address two goals: 1) advancing the design of compliant linear actuators that are well suited for humanoid applications, and 2) developing a better understanding of how to design and model compliant linear actuators for use in humanoids. Beyond just applications for compliant humanoids, this research tackles many of the same design and application challenges as biomechanics research so it has many potential applications in prosthetics, exoskeletons, and rehabilitation devices. / Ph. D.

Exoskeletons and humanoid robots require high-power, low-weight, and back-driveable actuators. This paper describes the design and analysis of a high-force linear series elastic actuator for a lower body exoskeleton. The actuator is powered by two motors and utilize a liquid cooling system to increase its maximum continuous torque. The actuator is capable of outputting a maximum continuous force of 4800N and a maximum speed of 0.267 m/s with a maximum continuous motor current of 18A. The Titanium leaf spring was used in the actuator to provide compliance. The spring has a median stiffness of 587 N/mm with standard deviation of 38 N/mm, validated by experiments. Dynamic model was created to analyze the normal modes and can be used for developing model-based controllers. / Master of Science / Compliant Linear actuators with ball screw have become popular for humanoids robots and exoskeleton. The use of ball screw lead to high efficiency, high gear ratio and high back-drivability. The compliance or the ''softness'' of the actuator comes from Titanium leaf spring, which can storage energy during gait cycle and protect motor and the ball screw from impacts of walking. The custom liquid cooling system improves the force density for the actuator. Beam theory analysis, heat transfer analysis, and dynamics analysis were performed to provides insights for the actuator system.

This thesis presents the design of uBot-7, the latest version of a dexterous mobile manipulator. This platform has been iteratively developed to realize a high performance-to-cost dexterous whole body manipulator with respect to mobile manipulation. The semi-anthropomorphic design of the uBot is a demonstrated and functional research platform for developing advanced autonomous perception, manipulation, and mobility tasks. The goal of this work is to improve the uBot’s ability to sense and interact with its environment in order to increase the platforms capability to operate dexterously, through the incorporation of joint torque feedback, and safely, through the implementation of passive and active compliance. This is accomplished through incorporating series elastic actuators in its arms and torso joints, improving the mechanical design to reduce backlash, and incorporating impedance controllers in the robot. The focus of this thesis is the development of the mechanical, sensor, and controller design for the uBot-7 platform. An impedance controller is developed and evaluated on a bench top prototype series elastic actuator.

Series elastic actuators (SEAs) have numerous benefits for force controlled robotic applications. This thesis presents the design and assembly of a set of compact, lightweight, low-friction linear SEAs for the legs of the Tactical Hazardous Operations Robot (THOR). The THOR SEA pairs a ball screw driven linear actuator with a configurable titanium leaf spring. A removable pivot changes the effective cantilever length, setting the compliance to either 372 or 655 kN/m. Unlike typical SEAs which measure actuator load through spring deflection, an in-line axial load cell directly measures actuator forces up to the commandable peak of 2225 N. The continuous operating range of the actuator is computed, along with an evaluation of the range of motion and torque profiles for the parallel hip and ankle joints. With a focus on a large power-to-weight ratio and small packaging size, the THOR SEAs are well-suited for accurate torque control of the parallel joints on the robot. Linearly actuated joints, especially ones driven through a crank arm, tend to suffer from a loss of mechanical advantage toward the ends of its limited range of motion. To augment the range of motion and mechanical advantage profile on THOR, an inverted Hoeken's linkage straight line mechanism is paired with a linear SEA at the hip and knee pitch joints on the robot. The resulting linkage assembly is capable of delivering nearly constant peak torque of 115 Nm across its 150 degree range of motion. The mechanical advantage profile of the Hoeken's linkage actuator is computed for the nominal case, as well the deviation resulting from maximum deflection of the titanium beam. / Master of Science