Development and control of interactive reconfigurable robotic systems

While reconfigurable robots provide a new promising approach for interactive systems, the complexity of distributed actuation/sensing systems, coupled kinematics and desired functionalities also bring new challenges and questions both in control design and hardware development: What design approaches enable direct human-robot interactions to address the morphological transformations and constraints of multi-DoF distributed activated robotic system? How to implement in-situ, multi-stage, programmable, and controllable actuation for the desired range of motion and functionalities? How to design multi-DoF robotic systems and needed for operation in distinct, real-world applications? These challenges and research questions formulate the objective and framework of my thesis. Namely, I explore for the solutions to provide methodologies for not only building the hardware for reconfigurable interactive systems but also investigating the control algorithm considering human-in-the-loop and evaluating the effectiveness of the integrated system with different application scenarios. In order to address the challenges associated with the development of reconfigurable robotic systems for human interactions, I first outline the concept of an interactive interface between humans and robots. I study the design methods for intuitively and dynamically controlling multi-DoF reconfigurable systems and algorithms for integrating mechanical characteristics of the core robotic components. Then, we investigate the design space and limitation of gesture-based multi-modalities interactions for further exploring the controllability, scalability, and versatility in functions for reconfigurable robotic systems. To realize the reconfigurable interactive robotic system, the design, capability, and limitation of the hardware system need to be established and evaluated. One of my research goals is to take the advantage of current non-conventional manufacturing technologies and materials as well as overcome their limitations. I study and develop compact actuators and unique transmission mechanisms inspired by origami patterns that can be integrated with multi-DoF robotic systems. I start with the design, model, and experimental validation of core functional components. Then, we investigate the fabrication process which has an additive manufactured structure with subtractive manufactured functional components integrated for compact, light-weight, and distributed activated mechanisms. Lastly, I propose the strategies for configuring and controlling the functional components to achieve functionalities like multi-DoF distributed actuation, self-assembly, and tunable stiffness. The achievable functionalities are further examined with several application scenarios. The main contributions of this thesis are: Development of interactive control interface for reconfigurable robotic systems Design and validation of distributed actuation solution and transmission mechanisms for compact multi-DoF robotic systems Study the synergy of additive manufacturing techniques and smart materials for achieving customizable functionalities and overcoming the limitation for conventional robotic systems

Active origami platforms for human-robot interactions

Frédéric Henri Vaskin Giraud

Robots are employed to assist humans in lengthy, challenging, and repetitive tasks. However, the fields of rehabilitation, haptics, and assistive robotics have shown a significant need to support and interact with people in their everyday life. To facilitate these further needs, robots must overcome constraints in compactness, degrees of freedom (DoF), and mechanical performance. However, developing a robot with these characteristics is challenging for conventional mechanics. First, creating a meso-scale device requires the assembly of small components, which is laborious and increases manufacturing cost, time, and complexity. In addition, devices with several DoF and functionalities also require more parts to create numerous links and joints, actuators, and thus space, affecting the compactness of systems. Finally, aiming for mechanical performance in terms of force, speed, and motion range requires transmissions or bulky actuators, which also influence the size of the system. This thesis attempts to overcome the limitations of conventional mechanics by using origami robots, an alternative design approach for creating meso-scale structures with numerous folding joints. It consists in stacking layers of functional material to achieve low-profile and scalable structures that fold into 3D. Using this method, we developed three hybrid robots combining the decades of experience of conventional mechanics with the advantages of origami robotics. First, to enhance the performances of robots at the meso-scale, the creation of compact low-profile compliant transmissions benefiting from origami's minimal assembly of functional layers was explored. The transmissions obtained can reproduce conventional kinematics or generate unconventional motions using materials properties. Second, the development of multi-DoF compact robots was studied using the aforementioned low-profile compliant transmissions to create a multi-functional structure. The resulting robot is a fingertip haptic device called Haptigami that can render vibrotactile and three-DoF force feedback without compromising bulkiness. Then, this study aimed at creating a meso-scale, multi-DoF, and mechanically efficient robot. We combined the previous device contributions and developed Flexure Variable Stiffness Actuators (F-VSA), a novel compliant actuator that uses the origami flexure hinges' inherent stiffness to avoid hindering mechanical simplicity. Finally, we developed a software architecture that enables high-level control of the human-robot hardware and is compatible with multiple simulation engines. We used this architecture to control our robots and provide feedback to the user, based on interactions in a virtual environment. These novel robots rely on non-conventional structures, actuators, and kinematics that require exploring and testing suitable control strategies. Hence, kinematic and stiffness models were developed and used to tune the position, force, and stiffness of the end-effector. Several characterization platforms and experimental protocols suitable for testing our unique robotic systems were also developed to assess their precision and efficiency. Consequently, the results of this study pave the way for the development of robots that adapt to multiple environments, interactions, and application scenarios, compatible with the human bandwidth without hindering the user's motion and comfort in everyday life.

EPFL2022

Comprehensive Interactive Soft Interfaces for Wearable Tactile Feedback

Harshal Arun Sonar

As the field of robotics continues to grow outside the manufacturing environment into our daily lives, the interactions between humans and robots are increasingly becoming close and dynamic. This type of environment requires robots to be less rigid, multi-functional, safer, and compliant with human bodies. Such robotics interfaces are ideally suited for medical rehabilitation, elderly assistance to at-home entertainment devices. However, the traditional rigid robotic devices fail to address some of the design criteria posed for safety, compliance, and physical limitations on the mechanical design. In the case of wearable technologies, the robotic device additionally requires a lightweight, compliant, and safe interface to provide smooth communication and interaction with humans. The traditional robotic systems are fast, accurate, and can handle large torques. However, they are also, application-specific and not suitable as it is for the wearable scenario due to the contradictory design requirements. In the past decade, soft robotics has emerged as a novel approach to solve the complex problems faced by rigid robots using inherent softness and compliant material properties. The design for the future interactive wearable interfaces thus may lie in the intersection of developments in the fields of wearable technology and soft robotics.Designing a wearable interactive interface with soft materials for wearability, portability, cost-effectiveness, and modularity would be one of the ideal solutions to tackle the wearability challenge. It can be a cost-effective solution for at-home assistive rehabilitation or entertainment. It also allows developing novel methods of soft sensing, actuation, control strategies, and human in loop protocols to maximize the utility of inherent material properties and environment around the robotic device.In my Ph.D. research, I develop and create hardware and software towards an immersive interactive soft virtual-tactile environment focusing on the wearability, portability, easy customization, and modularity aspects. I developed a low profile soft pneumatic actuator-skin (SPA-skin) with distributed sensing and actuation capabilities for testing various levels of complex vibrotactile feedback: the multilayer composite of high-sensitivity PZT pressure sensors and vibratory SPA can produce up to 3 N output force at 0-100 Hz. This demonstrated that SPA-skin produces distinctive and dynamic haptic force feedback under modulated varying time, force, and spatial resolution. Furthermore, a complete framework for designing a tactile feedback skin for specific wearable applications is developed, starting from the material selection and actuator design, and concluding with the validation of the subjectâs perceived feedback. As soon as, the SPA-skin is required to be worn by humans, the complexity of the problem multiplies due to lack of proper grounding to ensure the blocked forces. The platform is further optimized for application space in fMRI compliant environment and a user study protocol for somatosensory thresholds is designed. The modulable and controllable nature of SPA-skinâs tactile feedback provides much-needed validation using BOLD signals from brain imaging. SPA-skin and findings presented herein, provide a foundational platform to further investigate the sensitivity of human skin and decipher mechanoreceptor reactions for a diverse range of human-robot interactions and wearable technology.

EPFL2021

Concept of Modular Kinematics to Design Ultra-high Precision Parallel Robots

Murielle Richard

Miniaturisation will be the key challenge for the next decade in numerous industrial fields, such as microelectronics, optics and biomedical engineering. Although most of their products already achieve footprints of some square millimeters, the trend towards the integration of a maximum number of elements in a minimal volume requires even more compact components. This tendency creates a growing need for industrial robots able to perform micromanipulation and microassembly tasks with a submicrometric precision. Nonetheless, the design of such machines is nowadays costly, both in time and money, mostly because of the twofold complexity of their development: first, from a kinematic standpoint, the use of a parallel structure consists in a particularly interesting approach to build ultra-high precision robots. However, the synthesis of such a kinematics proves especially challenging for machines presenting more than 3 degrees of freedom. Moreover, the resulting robots are scarcely flexible: if the industrial specifications are modified, which for example necessitates to add a degree of freedom or to change the position of a rotation centre, the design process has to be restarted, often from the very beginning. The second challenge consists in the mechanical design of flexure-based mechanisms: flexure hinges are joints which are based on the elasticity of the matter. They allow to perform motions which are without friction, backlash and wear; their use is thus mandatory to achieve the aimed submicrometric precision. Albeit the synthesis of planar and low-degree of freedom structures is now widely investigated, the development of a whole tridimensional flexure-based robot is still infrequent, especially in the industrial context. This thesis thus introduces a modular design methodology which significantly reduces the time-to-market of ultra-high precision robots. This procedure can be compared to a robotic Lego, where a finite number of conceptual building bricks allows to easily design and modify parallel robots. Furthermore, this work shows that the machines resulting from this approach present similar or even improved performances compared to robots developed more traditionally. The key aspect of this thesis consists in the concept of modular kinematics, which aims at facilitating the synthesis of parallel kinematics thanks to solution catalogues. At this step of the methodology, the conceptual building bricks and the kinematics are totally independent from any mechanical design: they can thus be used to synthesise a large variety of robots, from machine-tools to microscale robots. An exhaustive conceptual solution catalogue groups all kinematics generated by the combination of the building bricks. Then, a reduced solution catalogue for ultra-high precision is proposed: based on selection criteria linked with the design and machining of flexure-based mechanisms, it allows to reduce the total number of solutions and thus facilitates the practical use of the concept. The second part of this work details the mechanical design of the building bricks, whose main challenge consists in increasing the ratio between the working ranges of the mechanisms and their overall size. One or more flexure-based solutions have been developed for each motorised brick: a special emphasis is given to the original use of a Remote Centre of Motion, which allows to achieve high rotation angles while drastically reducing parasitic translations. The development of a standardised actuation sub-brick, common to all motorised bricks, introduces a new level of modularity, thus increasing even more the flexibility of the methodology. As for non-actuated bricks, original designs and uncommon uses of well-known mechanisms are proposed. A case study on a 5-degree of freedom robot, Legolas 5, finally illustrates the practical use of the methodology: first, the selection in the solution catalogue of a kinematics adapted to the specifications of the robot is detailed. Then, the development of the Legolas 5 prototype highlights the mechanical design of the necessary building bricks, as well as assembly subtleties, such as force alignment and gravity compensation, which allow to shrewdly design a high-performance robot. The measurements of this machine have shown motion resolution and repeatability of 50 nm in translation and 1.9 µrad in rotation (limited by the sensor resolution). This case study has generated the Legolas family, a new family of ultra-high precision parallel robots, which notably includes the orthogonal version of the Delta kinematics: using only 6 of the conceptual building bricks, one solution can be built for each of the 19 possible robot mobilities. The promising characterisation of the Legolas 5 tends to suggest that the robots from this family will be interesting candidates to fulfill the upcoming need for quickly designed and high-performance industrial ultra-high precision machines.

EPFL2012