Human-robot collaboration is becoming increasingly popular in the manufacturing industry, opening the door to a large range of applications by combining the complementary skills of the human worker and the robot. Collaborative robots are also a solution to decrease the operator workload and indirectly reduce the risk of occupational injuries such as musculoskeletal disorders (MSDs). The latter represents one of the major causes of absenteeism at work. Thanks to the development of human tracking devices, it is possible to monitor the operator, analyze the postures, and assess the associated MSD risk. In this paper, we present a novel ergonomics optimization framework that performs postural optimization based on the virtual element method. A feedback interface is developed whereby the user is informed about non-ergonomic postures and an improved body pose is proposed. The workpiece position controller module acts on the cobot end-effector and indirectly on the co-manipulated part in such a way that the operator’s posture is improved. The framework was validated by a user study performed on a human-robot collaboration task whereby the subject polishes a part hold by the robot. The conducted study of the user’s perception and REBA scores showed promising results.Note to Practitioners—This paper is motivated by the problem of non-ergonomic posture of workers in hybrid workcells. The proposed approach makes use of virtual elements (springs and dampers) to build a mechanical model of the human body posture and perform postural optimization. The obtained body joint angles are fed into two modules of the framework. First, a graphical interface displays the current pose of the user and proposes to him the improved posture. Second, a controller adapts the pose of the workpiece hold by the collaborative robot. This is realized by computing a displacement vector between the wrist current and optimized positions. The use of such a framework was demonstrated on a collaborative polishing task whereby the robot adjusts the position of the workpiece. After a user study test with 10 participants, joint data were collected and the REBA scores of different subtasks were measured and compared. The results from these preliminary experiments showed that the proposed approach improves the human body postures and offers a promising solution to enhance ergonomics by the robot assistance in case of robotic workcells. The conducted survey also shows an overall positive subject’s perception of the system.

On novel actuator research in the field of cellular muscle-inspired actuators, skeletal muscles are often used as inspiration due to their modular and compact design and seemingly effortless control. Amongst others, the remaining challenges to tackle are robust designs, energy consumption minimization and control strategies. We have developed a discrete muscle-inspired actuator, in which solenoids can be overpowered and locked to recruit springs in series. This paper describes the spring and electronics design and proposes a binary actuator segmentation for increased resolution. Next, we propose and simulate a control strategy based on a lookup table, to cope with multiple discrete inputs, uni-directional force inputs and solenoid cooling time. Currently, the actuation units and springs are modular and can be tailored easily for specific applications. The resolution is maximized without under utilization of the actuator's capabilities, and our control strategy can currently control 12 motor units in real-time, which can be increased to 30. The experiments confirm the working of the control strategy.

Modern actuation schematics become increasingly ingenious by deploying springs and locking mechanisms in series and/or parallel. Many of these solutions are, however, tailored for a specific application and a general schematic that allows for drastic energy reduction remains a challenge. We have developed a series-parallel elastic actuator (SPEA) based on a symbiosis of multiple motors, springs and locking mechanisms in parallel, which we call +SPEA. This paper introduces the novel +SPEA concept. We present a first prototype, a +SPEA model and a control strategy that optimizes the energy consumption, and experiments to verify the working principle and recruitment strategy. The experiments show a good fit with the model and currently the actuator reduces the required energy in blocked output experiments by more than a factor 4.

Natural organisms have a unique property not yet available in robotics, i.e., a self-healing (SH) ability. This powerful biological healing function has inspired chemists to impart similar properties to synthetic materials to create “SH materials.” Recent developments in SH polymers led us to investigate the potential of using these materials in robotics. This paper presents an innovative approach of using SH polymers, based on the reversible Diels-Alder (DA) reaction, in a compliant actuator. Using DA polymers, a sacrificial SH mechanical fuse (SH-MF) is designed, developed, and validated by placing it in a cable-driven robotic system. The fuse is designed as weakest element and will sacrificially fail if a damaging overload occurs, protecting the compliant element and other components of the system. The experimental results showed that this SH-MF could be healed at a relatively low temperature, recovering the initial mechanical properties. This first working prototype indicates the feasibility to use SH materials in robotics. “SH robotics” will lead to more sustainable and lighter systems, and eventually to more efficient designs.

The Mechanically Adjustable Compliance and Controllable Equilibrium Position Actuator (MACCEPA) is a Variable Stiffness Actuator (VSA) where both equilibrium position and stiffness of the actuator can be controlled independently. It uses only one linear spring and has a simple design but its compactness is limited by the spring. For this reason a MACCEPA utilizing torsion spiral springs was designed, reducing the planar dimensions of the actuator. Torsion spiral springs are placed around the joint axis, allowing a more compact VSA in comparison to previous designs. To the authors' best knowledge, this is the first VSA based on torsion springs. This paper firstly presents the design of the actuator as the static equations and secondly discusses the design and production of the torsion spiral springs. The newly presented actuator is built and experiments are conducted to validate the model and feasibility of the torsion MACCEPA.

Series-Parallel Elastic Actuators (SPEA) enable variable recruitment of parallel springs and variable load cancellation. In previous work, we validated a MACCEPA-based SPEA prototype with a self-closing intermittent mechanism, to reduce motor load and improve energy efficiency. However, the mechanism only allowed for 4 parallel springs and a limited equilibrium angle range, which limits the variable load cancellation and operation range. Therefore, we developed a novel cylindrical cam mechanism for unlimited subsequent spring recruitment. This paper describes and validates the working principle of the cylindrical cam mechanism. Furthermore, the latest MACCEPA-based SPEA is presented with a maximum output torque of 40Nm and variable stiffness. Additive and traditional manufacturing techniques go hand in hand to overcome the actuator's complexity. The experiments endorse the working principle, demonstrate the variable stiffness, and prove the motor torque can be reduced to 5Nm while an output torque of 40Nm can be achieved.

Last 15 years, a wide range of self-healing (SH) materials has been developed and recently these materials are increasingly used in applications in multiple fields, like the automotive industry and aerospace. However, so far this material technology is not yet explored in robotics. The introduction of these materials in robotics will potentially reduce the over-dimensioning of current robotic systems, leading to lighter systems and eventually to more efficient designs. Compliant elements used in next generation soft robots, can be constructed from available SH-materials, making them able to autonomously heal cuts and perforations caused by sharp objects in unstructured environments. In addition, the use of SH-materials will have a beneficial impact on the life span of robotic components, reducing the required maintenance drastically. This paper presents the innovative concept of implementing a SH-mechanism in compliant actuators, using dynamic covalent polymer network systems based on the reversible Diels-Alder (DA) reaction. For two entirely different compliant actuators, a series elastic actuator (SEA) and a soft pneumatic actuator (SPA), an analysis is presented on the integration of the DA-polymers in the actuator designs. For both actuator types, a prototype was designed, developed and validated.

Two leading qualities of skeletal muscle that produce good performance in uncertain environments are damage tolerance and the ability to modulate impedance. For this reason, robotics researchers are greatly interested in discovering the key characteristics of muscles that give them these properties and replicating them in actuators for robotic devices. This paper describes a method to harness the redundancy present in muscle-like actuation systems composed of multiple motor units and shows that they have these same two qualities. By carefully choosing which motor units are recruited, the impedance viewed from the environment can be modulated while maintaining the same overall activation level. The degree to which the impedance can be controlled varies with total activation level and actuator length. Discretizing the actuation effort into multiple parts that work together, inspired by the way muscle fibers work in the human body, produces damage-tolerant behavior. This paper shows that this not only produces reasonably good resolutions without inordinate numbers of units, but gives the control system the ability to set the impedance along with the drive effort to the load.

High-performance actuators are required for numerous novel applications such as human-robot assistive devices. The torque-to-weight ratio and energy efficiency of current actuation technology is often too low, which limits the performance of novel robots. Therefore, we developed a Series-Parallel Elastic Actuator (SPEA) which enables variable recruitment of parallel springs and variable load cancellation. Finding suitable intermittent mechanisms for the SPEA is however still challenging. This paper reports on the innovative design of an intermittent self-closing mechanism for a MACCEPA-based SPEA that can deliver bi-directional output torque and variable stiffness, while minimizing friction levels. Experiments on a one-layer intermittent self-closing mechanism are conducted to validate the working principle and the proposed model. A demonstrator of the MACCEPA-based SPEA with intermittent self-closing mechanism is presented and the experiments validate the modeled output torque and lowered motor torque for different stiffness settings.

Future robots will need to perform complex and versatile tasks comparable to those of humans. Due to the unavailability of suitable actuators, however, novel intelligent and agile robots are often restricted in their performances and development. The limited output torque range and low energy efficiency of current robotic actuators are the main bottlenecks. We have developed a SPEA with intermittent mechanism that addresses these problems. The SPEA is a novel compliant actuator concept that enables variable recruitment of parallel elastic elements and adaptive load cancellation. This paper describes how a SPEA lowers the motor torque and increases the energy efficiency. Experiments on the first proof of concept set-up endorse the practicability of the SPEA concept and the modeled trend of a lowered motor torque and increased energy efficiency. We expect that features of the biologically inspired SPEA with intermittent mechanism will prove exceedingly useful for robotics applications in the future.