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With the ability to navigate natural and man-made environments and utilize standard human tools, humanoid robots have the potential to transform emergency response and disaster relief applications by serving as first responders in hazardous scenarios. Such applications will require major advances in humanoid control, enabling robots to traverse difficult, cluttered terrain with both speed and stability. To advance the state of the art, this dissertation presents a complete dynamic locomotion and whole-body control framework for compliant (torque-controlled) humanoids. We develop low-level, mid-level, and high-level controllers to enable low-impedance balancing and walking on compliant and uneven terrain. For low-level control, we present a cascaded joint impedance controller for series elastic humanoids with parallel actuation. A distributed controller architecture is implemented using a dual-axis motor controller that computes desired actuator forces and motor currents using simple models of the joint mechanisms and series elastic actuators. An inner-loop force controller is developed using feedforward and PID control with a model-based disturbance observer, enabling naturally compliant behaviors with low joint impedance. For mid-level control, we implement an optimization-based whole-body control strategy assuming a rigid body model of the robot. Joint torque setpoints are computed using an efficient quadratic program (QP) given desired joint accelerations, spatial accelerations, and momentum rates of change. Constraints on the centroidal dynamics, contact forces, and joint limits ensure admissibility of the optimized setpoints. Using this approach, we develop compliant standing and stepping behaviors based on simple feedback controllers. For high-level control, we present a dynamic planning and control approach for humanoid locomotion using a novel time-varying extension of the Divergent Component of Motion (DCM). By varying the natural frequency of the DCM, we are able to achieve generic vertical center of mass (CoM) trajectories during walking. Complementary reverse-time integration and model predictive control (MPC) strategies are proposed to generate dynamically feasible DCM plans over a multi-step preview window, supporting locomotion on uneven terrain. The proposed approach is validated through experimental results obtained using THOR, a 34 degree of freedom (DOF) series elastic humanoid. Rough terrain locomotion is demonstrated in simulation, and compliant locomotion and push recovery are demonstrated in hardware. We discuss practical considerations that led to a successful implementation on the THOR hardware platform and conclude with an application of the presented control framework for humanoid firefighting onboard the ex-USS Shadwell, a decommissioned Navy ship. / Ph. D.

As a valuable asset in human augmentation and medical rehabilitation, exoskeletons have become a major area for research and development. They have shown themselves to be effective tools for training and rehabilitation of individuals suffering from limited mobility. However, most exoskeletons are not capable of balancing without the assistance of crutches from the user. Leveraging technology and techniques developed for force controlled humanoid robots, a project was undertaken to develop a fully self-balancing, compliant lower-body robotic exoskeleton. Due to their many beneficial features, series elastic actuators were utilized to power the joints on the exoskeleton. This thesis details the development of four linear series elastic actuators (LSEA) as part of this project. All 12-degrees of freedom will be powered by one of these four LSEA's. Actuator requirements were developed by examining human gait data and three robot-walking simulations. These four walking scenarios were synthesized into one set of power requirements for actuator development. Using these requirements, analytical models were developed to perform component trade studies and predict the performance of the actuator. These actuators utilize high-efficacy components, parallel electric motors, and liquid cooling to attain high power-to-weight ratios, while maintaining a small lightweight design. These analyses and trade studies have resulted in the design of a dual-motor liquid-cooled actuator capable of producing a peak force 8500N with a maximum travel speed of 0.267m/s, and three different single-motor actuators capable of producing forces up to 2450N continuously, with a maximum travel speeds up to 0.767m/s. / Master of Science

Robôs de reabilitação como próteses ativas e exoesqueletos necessitam de atuadores capazes de atender certos requisitos como baixa impedância de saída, backdrivability, geração de torques grandes e precisos, e uma estrutura leve e compacta. Este trabalho apresenta o projeto de um Atuador Elástico em Série rotacional (AESr) para ser usado em uma prótese ativa para auxiliar na flexão/extensão da articulação do joelho durante a fisioterapia. O dispositivo é constituído de um motor de corrente contínua, um redutor de velocidade do tipo coroa e rosca sem-fim e uma mola torcional personalizada. Uma vez que o elemento elástico é o componente mais importante no projeto do AESr, um procedimento de análise baseado no Método dos Elementos Finitos (MEF) é utilizado para cumprir os requisitos definidos para a reabilitação do joelho. Com uma massa total de 2,53 Kg, é possível montar diretamente o atuador proposto em uma estrutura de prótese de joelho. Controladores de torque e impedância são implementados para assegurar uma interação segura com o paciente, permitindo que novas estratégias de reabilitação sejam avaliadas. As especificações do projeto bem como o desempenho dos controladores são validados experimentalmente. / Wearable robots, like prostheses, active orthosis and exoskeletons need of actuators able to meet certain requirements as low output impedance, backdrivability, precise and large torque generation, and a compact and lightweight design. This work presents the design of a rotary Series Elastic Actuator (rSEA) to be used in an active orthosis to assist in flexion/extension of the knee joint during physical therapy. The device includes a DC motor, a worm gear and a customized torsion spring. Since the elastic element is the most important component in the design of the rSEA, an analysis procedure based on Finite Element Method (FEM) is used in order to meet the requirements for the specific application. With a total weight of 2.53 kg, it is possible to directly mount the actuator on the frame of a knee orthosis. Torque and impedance controllers are implemented to ensure secure interaction with the patient and enable new strategies for rehabilitation. The design specifications as well as the controllers performance are verified by experiments.

Robôs de reabilitação como próteses ativas e exoesqueletos necessitam de atuadores capazes de atender certos requisitos como baixa impedância de saída, backdrivability, geração de torques grandes e precisos, e uma estrutura leve e compacta. Este trabalho apresenta o projeto de um Atuador Elástico em Série rotacional (AESr) para ser usado em uma prótese ativa para auxiliar na flexão/extensão da articulação do joelho durante a fisioterapia. O dispositivo é constituído de um motor de corrente contínua, um redutor de velocidade do tipo coroa e rosca sem-fim e uma mola torcional personalizada. Uma vez que o elemento elástico é o componente mais importante no projeto do AESr, um procedimento de análise baseado no Método dos Elementos Finitos (MEF) é utilizado para cumprir os requisitos definidos para a reabilitação do joelho. Com uma massa total de 2,53 Kg, é possível montar diretamente o atuador proposto em uma estrutura de prótese de joelho. Controladores de torque e impedância são implementados para assegurar uma interação segura com o paciente, permitindo que novas estratégias de reabilitação sejam avaliadas. As especificações do projeto bem como o desempenho dos controladores são validados experimentalmente. / Wearable robots, like prostheses, active orthosis and exoskeletons need of actuators able to meet certain requirements as low output impedance, backdrivability, precise and large torque generation, and a compact and lightweight design. This work presents the design of a rotary Series Elastic Actuator (rSEA) to be used in an active orthosis to assist in flexion/extension of the knee joint during physical therapy. The device includes a DC motor, a worm gear and a customized torsion spring. Since the elastic element is the most important component in the design of the rSEA, an analysis procedure based on Finite Element Method (FEM) is used in order to meet the requirements for the specific application. With a total weight of 2.53 kg, it is possible to directly mount the actuator on the frame of a knee orthosis. Torque and impedance controllers are implemented to ensure secure interaction with the patient and enable new strategies for rehabilitation. The design specifications as well as the controllers performance are verified by experiments.

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[pt] Questões de segurança têm sido fatores cruciais para que robôs se tornem aptos a trabalhar em colaboração com seres humanos. Esse esforço envolve um controle de força mais refinado e uma certa flexibilidade nas juntas para que a adaptação dos robôs ao ambiente real e às atividades comuns dos seres humanos seja efetiva. Uma das tecnologias com esse objetivo é o Atuador Elástico em Série (SEA - Series Elastic Actuator), que apresenta um bom desempenho para controle de força, tolerância a impactos causados por agentes externos, baixa impedância, e a redução de vibrações mecânicas. Em um SEA, um elemento elástico passivo é adicionado entre o motor e o elo acionado, a fim de gerar flexibilidade. Este elemento pode ser uma mola, ou outro elemento deformável com flexibilidade caracterizada por sua geometria e pela elasticidade do material utilizado. Esta tese propõe um Atuador Elástico em Série Baseado em Elastômero (eSEA), cuja flexibilidade é obtida a partir de um elastômero depositado entre dois elementos metálicos: um interno acoplado ao atuador, e o outro externo acoplado ao elo. O eSEA foi projetado e avaliado por software de CAD e Elementos Finitos, com o intuito de obter a flexibilidade desejada para a aplicação. Foram produzidas duas versões do eSEA, com duas durezas diferentes: 10 e 55 Shore A. Testes estáticos com células de carga foram executados para caracterizar a rigidez dos eSEA. Os eSEA foram instalados em manipuladores robóticos especialmente desenvolvidos para essa tese. Experimentos compararam o desempenho das técnicas de controle com e sem a influência dos eSEA, mostrando que o uso dos eSEA diminuiu os erros de posicionamento do manipulador e possibilitou o controle de força sem a necessidade de sensores específicos. A fim de criar um modelo para que a estimativa do torque seja mais precisa a partir do eSEA, foram realizadas técnicas de identificação para estimar uma função de transferência que melhor representa o alongamento da borracha. E combinados com modelos NARX e NARMAX do erro de estimativa, gerou-se um modelo híbrido para o elemento elástico no qual soma-se a função de transferência com o erro modelado. / [en] Safety issues have been crucial factors for robots to become able to work in collaboration with humans. This effort involves more refined force control and a certain flexibility at the joints, for the robots to better adapt to real environments and common human tasks. A technology with this objective is the Series Elastic Actuator (SEA), which presents good performance for force control, tolerance to impacts caused by external agents, low impedance, and dampening of mechanical vibrations. In an SEA, a passive elastic element is added between the motor and the driven link, in order to generate a desired flexibility. This element can be a spring, or else another deformable element with flexibility characterized by its geometry and material elasticity. This thesis proposes an Elastomer-Based Series Elastic Actuator (eSEA), whose flexibility is obtained from an elastomer deposited between two metallic elements: an internal element attached to the actuator, and an external element attached to the link. The eSEA was designed and evaluated by CAD and Finite Element software, in order to obtain the desired flexibility for the application. Two versions of the eSEA were produced, with two different hardnesses: 10 and 55 Shore A. Static tests with load cells were then executed to characterize the stiffness of the eSEA. The eSEA elements were installed on robotic manipulators especially developed for this thesis. Experiments compared the performance of control techniques with and without the influence of eSEA, showing that the use of the eSEA reduced manipulator positioning errors and enabled force control without the need for specific sensors. In order to create a model for more accurate torque estimation from eSEA, identification techniques were performed to estimate a transfer function that best represents the rubber elongation. And combined with NARX and NARMAX models of the estimation error, a hybrid model was generated for the elastic element in which the transfer function is added together with the modeled error.

The implications of gait disorder, muscle weakness, and spinal cord injuries for work and age-related mobility degradation have increased the need for rehabilitation exoskeletons. Specifically, the hip rehabilitation exoskeletons due to a high percentage of the mechanical power is generated by this join during the gait cycle. Additionally, the prolonged hospitalisation after hip replacement and acetabular surgeries that affect human mobility, the social-economic impacts and the quality of life. For these reasons, a hip rehabilitation exoskeleton was our focus in this research, as it will contribute being a sustainable solution to take over the burden of physiotherapy and let patients perform their rehabilitation at home or outdoors.  This thesis details an approach of creating a hip rehabilitation exoskeleton, starting with modelling, simulating, and controlling the rehabilitation hip joint in a based-simulation environment. The mathematical model and the reason for using a series elastic actuator in the hip joint to execute the movement in a sagittal plane are more detailed. Because trajectory tracking is commonly used for controlling rehabilitation exoskeletons to ensure safe and reliable motion tracking methods; therefore, two desired torque signals were tested and analysed with the optimal linear quadratic regulator (LQR). The experiments were performed using two torque signals of a healthy hip joint—representing the sit-to-stand (STS) and the walking activity for their importance in lower limb movements. However, the mathematical model used as a basis of the optimal control strategy is usually influenced by multiple sources of uncertainties. Therefore, four case studies of various optimal control strategies were tested for a twofold reason: to choose the most optimal control strategy, and to test the energy consumption of these cases during the STS and walking movements, because the long-term goal is to produce a lightweight and reliable rehabilitation hip exoskeleton. The research showed compelling evidence that tuning the control strategy will not influence the robustness of an optimal controller only, but affect the energy consumption during the STS and walking activity, which needs to be considered in exoskeleton control design regarding its applications. / Behovet av exoskelett för rehabilitering har ökat p.g.a. komplikationer som uppstår vid arbete och åldersrelaterad försämring. Komplikationerna består bland annat av gångstörning, muskelsvaghet och ryggmärgsskador. Speciellt höftexoskelett avsett för rehabilitering är extra intressant på grund av att rehabilitering inom detta område omfattar långvarig sjukhusvistelse efter höftprotes- och acetabulära operationer. Höftleden är en av de leder som utsätts för relativt höga mekaniska påfrestningar och minskad rörelseförmåga leder inte sällan till socioekonomiska effekter och minskad livskvalité. Av denna anledning kommer höftexoskelett för rehabilitering vara det primära området i denna avhandling då det kommer att vara en lösning för att minska belastningen inom sjukvård och låta patienter utföra sin rehabilitering hemma på egen hand. Denna avhandling beskriver en metod för att skapa ett höftexoskelett avsett för rehabilitering med början i modellering, simulering och kontroll av en höftled av exoskelett i en simuleringsmiljö. Genom att använda ett serieelastiskt manöverdon för att utföra en höftledsrörelse i ett sagittalt så uppnås en mer detaljerad matematisk modell. Genom att använda banspårning, som vanligtvis används för att kontrollera exoskelett för rehabilitering för att säkerställa säkra och pålitliga rörelsespårningsmetoder, så analyserades två vridmomentssignaler mot en linjär kvadratisk regulator (LQR). Simuleringarna utfördes med hjälp av två vridmomentsignaler som representerar sitt-till-stå (STS) och gångaktivitet hos en frisk höftled. Den matematiska modellen som används för att hitta den optimala kontrollstrategin påverkas vanligtvis av flera osäkerhetskällor. Därför testades fyra fallstudier av olika optimala kontrollstrategier för två skäl: den ena för att välja den mest optimala kontrollstrategin emellan och den andra för att mäta energiförbrukningen för dessa STS och gångrörelse så att vi kan producera ett lätt och pålitligt höftexoskelett avsett för rehabilitering. Forskningen visar övertygande bevis för att inställning av styrstrategin inte bara kommer att påverka robustheten hos en optimal styrenhet utan även påverkar energiförbrukningen under STS och gångaktivitet vilket måste beaktas vid design av exoskelett.