Hybrid Rigid-Soft Robotic Gripper with Shape Adaptation, Uniform Force Distribution, and Self-Locking Capabilities
Authors: Xi Chen, Yun Wang, Lichao Yang, Haitao Li, Ya Xiong
Abstract
Conventional robotic grippers face a significant challenge in agricultural automation: the trade-off between compliant, adaptive grasping, pressure balancing among all joints, and high load capacity, often at the cost of high energy consumption. This paper presents a novel hybrid rigid-soft gripper that integrated low-cost, membrane-based pneumatic actuators with 3D-printed dual ratchet-pawl mechanisms to simultaneously achieve shape adaptation, uniform force distribution, and energy-free self-locking. The dual-ratchet structure assembled in an offset configuration significantly increased the angular resolution of the joint locking mechanism. Key experimental results demonstrated the gripper's superior performance: a remarkable maximum load capacity of 4200 g, far exceeding that of conventional soft grippers (45-210 g); more uniform force distribution across object sizes (1.75-35.29% difference ratio) compared to a rigid gripper (56.77-66.44%), with peak contact forces remaining below surface damage thresholds; and a 50.05% reduction in total energy consumption to 42.6 J per grasp cycle, achieved by eliminating the need for continuous pneumatic pressure through the self-locking mechanism, compared to 85.28 J for a conventional soft gripper. The combination of additive manufacturing for ratchets and commercially available materials for pneumatic chambers ensured a low-cost and easily fabricated design. These findings validated that the proposed gripper successfully bridged the gap between soft compliance and rigid reliability, offering a robust and efficient solution for scalable agricultural harvesting and manipulation tasks.
Soft robots have seen widespread adoption in interactive tasks due to their inherent compliance and adaptability. However, these advantages often come at the cost of stability, posing challenges in a dynamic environment. This limitation is especially critical in soft grippers, where instability under acceleration or external disturbances can result in grasp failure. In this study, we present a continuously stable structure through plastic deformation (CSSPD), integrated into a soft gripper. By leveraging the mechanism of plastic deformation, the gripper maintains continuous configurations without energy input, while the added stiffness ensures both static and dynamic stability. We introduce a bioinspired paw pad that significantly enhances stability and enables sensing-based rapid object grasping. Then we develop the mathematical model and optimize the kirigami structure of the metal layer. Experimental results show that the gripper can sustain a passive holding force of up to 16 N without energy input, achieving performance comparable to pneumatic actuation at 0.3 MPa. When combined with pneumatic actuation, it remains stable under pulsed accelerations of up to 400 m/s^2. It can also passively perch on tree branches for extended periods without power, demonstrating promise for mobile robotic applications.
Conventional robotic grippers often use high-ratio transmissions to generate grasping torque and external force sensors to measure physical interaction. High-ratio transmissions increase friction, reflected inertia, and mechanical impedance, while external sensors add hardware complexity. To address these trade-offs, this study proposes a novel 9-DOF, three-fingered Differential Direct-Drive (DDD) gripper that combines DD motors with a low-ratio (1:2) differential transmission. The mechanism centralizes actuator mass at the base to minimize moving-link inertia, while the differential architecture couples two motors in parallel to amplify torque during flexion. Experiments show that the prototype delivers a nominal grasping force of approximately 18 N and a fingertip force of 4.7 N, while maintaining a low motor contribution to system inertia (0.236%) and low passive mechanical impedance, with a maximum measured value of 50.1 N/m when the motors are unpowered. The proposed hardware addresses the trade-offs among torque, physical transparency, and kinematic dexterity, providing a foundation for high-bandwidth interaction and sensorless proprioceptive force estimation.
Fin Ray-inspired soft grippers offer a promising solution for gently handling delicate, irregular objects, especially in agriculture. The objective of this research is to design, fabricate, and model a Fin Ray Effect (FRE) soft gripper finger to enable precise force control in future applications. This design aims to gently grasp delicate agricultural products, such as tomatoes, that require both adaptability and accurate force application. To address the inherent challenges of soft robotics, including nonlinear behavior, infinite degrees of freedom, and variable material properties, the Finite Rigid Elements Method (FREM) was employed for modeling. This method preserves analytical accuracy while providing a reliable foundation for the development of a force controller in later stages. A detailed Finite Element Model (FEM) was created using ANSYS, and the analytical results were validated through simulation and experimental testing. The gripper's fingers were optimized based on four key criteria: tip displacement, total deflection, stress distribution, and contact force. The optimal finger configuration includes a length of 30 mm, rib spacing of 10 mm, seven ribs angled at -15 deg, and a rib thickness of 1 mm. Theoretical modeling using the FREM predicted finger deformation with a 3% error, while the ANSYS numerical model achieved 2% error.