Compact Optical Single-axis Joint Torque Sensor Using Redundant Photo-Reflectors and Quadratic-Programming Calibration

Direct torque sensing is a growing need in the robotics community to enable precise control and interactions where torque estimation from motor current is not sufficient. This paper presents a novel disk-shaped magnetoelastic torque sensor with a compact axial envelope of about 1 cm, suitable for integration in robotic joints. A four-magnetometer architecture is used to measure the field modulated by the stress affecting a narrow magnetized region while rejecting the effects of parasitic cross forces. A custom-designed magnetic shield enhances the torque sensitivity while reducing the external stray fields by a factor 7x. The device measures the torque with an accuracy of 1.34 %FS relative to the 50 Nm full scale (FS). The paper details the development of the sensor through the mechanical design, the magnetization procedure, and the experimental validation. The results demonstrate the potential of the proposed sensor for robotic applications.

Tactile sensing is essential for physical interaction in robotics and human--machine systems. However, combining rich tactile information with compact hardware, low cost, and low computational overhead remains challenging. This work presents SpectraTac, a compact, camera-free optical tactile sensor that combines active red--green--blue (RGB) illumination with spatially distributed color sensing. Contact deforms a compliant transparent elastomer and modulates its internal light field, producing spatially differentiated changes in color and intensity. Three distributed color sensors capture these responses as low-dimensional spatio-spectral features, avoiding cameras, imaging optics, and high-dimensional image processing. The device measures 19.2 mm in diameter and 4 mm in height, with a material cost below USD~5. A data-driven decoding framework simultaneously estimates three-dimensional (3D) force and the contact region from the optical measurements. For 3D force prediction, the sensor achieved mean absolute errors (MAEs) of 0.161, 0.164, and 0.429 N along the x-, y-, and z-axes, respectively. The nine-region contact-classification accuracy was 99.9%. We further evaluated real-time 3D force tracking and contact-region-based human--machine interaction through an interactive control task. These results indicate that distributed color-resolved optical sensing offers a compact, low-cost alternative to camera-based tactile sensing for robotics, wearable sensing, and interactive systems.

Hybrid force/motion control requires knowledge of the interaction force and of a task frame defining the force- and motion-controlled directions. These quantities are usually obtained from force/torque sensing or model-based residuals, often assuming also a nominal environment model. This work addresses the online estimation of the contact force and a possibly time-varying task frame using only soft optical tactile sensing, under the assumption of locally planar contact with a negligible contact moment. The proposed method maps a single image of the deformed elastomer of a soft optical tactile sensor to observable contact variables: indentation depth, two surface-to-sensor tilt angles, and 3D contact force, each with a per-sample uncertainty estimate. The mapping is learned through a self-labeling acquisition procedure, in which a manipulator imposes controlled contacts while an auxiliary Force/Torque sensor is used offline to provide ground-truth labels. The tactile measurement is then fused with robot proprioceptive data in an Extended Kalman Filter, producing a continuously updated estimate of the contact task frame and of the interaction force. Control experiments with a DigiTac sensor mounted on a UR10 manipulator demonstrate closed-loop contact force regulation against a flat rigid board in linear and angular motion by a human operator, with touch as the only exteroceptive feedback.