A Dual-Cam Parallel Elastic Actuator with Shared Gas-Spring Compensation for Humanoid Ankles

Designing robots for high-torque, high-fidelity haptic interaction is challenging. Parallel Elastic Actuators (PEAs) use elastic elements in parallel to smaller motors to complement torques, and Series Elastic Actuators (SEAs) use elastic elements in series to decouple motor impedance and improve force control. Recent work combines SEAs and PEAs to obtain both benefits but requires separate elastic elements or clutching. This paper presents the Series Parallel Integrated Nonlinear Elastic Actuator (SPINEA), which merges SEA and PEA such that a single elastic element takes on dual roles simultaneously, parallel and series. This is achieved by a nonlinear transmission in which the motor and load have misaligned rotation axes and are elastically connected. This geometry enables both high peak torque and precise torque tracking. We apply SPINEA to actuate lean of a haptic bicycle simulator, which requires high moments and precise rendering for safe and realistic rider interactions. We realized a prototype and performed experiments, both with an external excitation setup and with riders cycling. Our results confirm SPINEA's low impedance and precise torque tracking, up to 4.25 Hz with the bicycle frame fixed and up to 4 Hz with riders. The benefits may transfer to other applications requiring compact, high-performance actuation.

Series and parallel elastic actuators offer complementary but mutually exclusive advantages, yet no existing actuator enables real-time transition between these topologies during operation. This paper presents a novel actuator design called the Dual-Topology Elastic Actuator (DTEA), which enables dynamic switching between SEA and PEA topologies during operation. A proof-of-concept prototype of the DTEA is developed to demonstrate the feasibility of the topology-switching mechanism. Experiments are conducted to evaluate the robustness and timing of the switching mechanism under operational conditions. The actuator successfully performed 324 topology-switching cycles under load without damage, demonstrating the robustness of the mechanism. The measured switching time between SEA and PEA modes is under 33.33 ms. Additional experiments are conducted to characterize the static stiffness and disturbance rejection performance in both SEA and PEA modes. Static stiffness tests show that the PEA mode is 1.53x stiffer than the SEA mode, with KSEA = 5.57 +/- 0.02 Nm/rad and KPEA = 8.54 +/- 0.02 Nm/rad. Disturbance rejection experiments show that the mean peak deflection in SEA mode is 2.26x larger than in PEA mode (5.2 deg vs. 2.3 deg), while the mean settling time is 3.45x longer (1380 ms vs. 400 ms). The observed behaviors are consistent with the known characteristics of conventional SEA and PEA actuators, validating the functionality of both modes in the DTEA actuator.

Ensuring intrinsic safety in physical human robot interaction (pHRI) is a critical requirement for social and service robots. While Series Elastic Actuators (SEAs) offer hardware based compliance, traditional metallic designs often require complex, multi part assemblies. This paper presents the design, finite element analysis (FEA), and experimental validation of a low stiffness, torsional spring for SEAs, manufactured via 3D printed thermoplastic polyurethane (TPU). The compliant element exhibits a highly linear torque deformation response (Ks = 0.066 Nm/degree), matching numerical predictions with under 3% deviation, a variance attributed to FDM structural anisotropy. To accommodate external interactions using standard position limited servomotors, a hybrid position controller with torque threshold switching was implemented. Experimental evaluations demonstrate the system ability to accurately track non stationary trajectories and safely yield to external disturbances. Furthermore, the inherent material damping of the TPU acts as a passive low pass filter, preventing high frequency oscillations during control mode transitions. The proposed architecture offers a cost effective, reliable, and easily manufacturable solution for safe pHRI.