Design and Experimental Validation of a 3D Printed Torsional Series Elastic Actuator for Safe Human Robot Interaction

Safety and comfort in human-robot physical in-teractions are essential aspects in the development of social technologies, where natural gestures, such as handshakes, represent a challenge due to their direct physical contact. The implementation of series elastic actuators (SEA) to absorb impacts is proposed as a design strategy that favors safer interactions. This paper presents an experimental study aimed at evaluating how the incorporation of SEAs in robotic arms influences perceived safety and the interaction experience dur-ing handshaking. The design allows a direct comparison of the effect of rigidity versus the incorporation of elastic elements, in order to identify the advantages of SEAs in improving the physical safety and social acceptance of robotic systems in everyday contexts. The experiment was carried out with 10 volunteers (6 men and 4 women), who performed two interactions with each robotic arm: one with rigid joints and the other with flexible joints using SEA. During testing, objective data on end-effector trajectories were collected, as well as subjective information through a perception survey focused on safety, naturalness, and confidence during the handshake. The survey results show increased perceptions of safety and comfort with the SEA-equipped arm, supporting its potential to facilitate safer and more socially accepted human-robot interactions.

Physical human-robot interaction requires yielding transiently to contact yet recovering the commanded reference under sustained load. Finite-stiffness impedance control retains a static deflection there, while predictive alternatives typically optimize a nonlinear robot or impedance model online. Operational-space cancellation instead exposes a translational error double integrator with a fixed transition matrix and a configuration-scheduled input map, making interaction a predictive quantity rather than a property re-derived per configuration. We build on it a compact offset-free interaction-error MPC for torque-controlled manipulators: a force-domain random-walk state estimates persistent interaction and model error, and a 30-variable convex QP maps the correction through the current task inertia while constraining the applied joint torque. Conditional results establish impedance equivalence of the unconstrained passive feedback, offset-free regulation at feasible frozen configurations, and quadratic stabilizability of the scheduled backbone. In a 1kHz MuJoCo simulation of a 7-DOF Franka FR3, the estimator cuts steady-state error under a repeated 15N step from 2.77mm to 0.042mm when added to the otherwise identical 100Hz MPC. A stiffness-and-damping-calibrated impedance baseline attains 2.59mm but briefly saturates and needs 3.3x the peak positive joint power. Adding ideal measured-force cancellation to that baseline gives 1.39mm, so constant-load rejection is not unique to MPC; the sensorless controller still reaches 0.042mm in the moving task, a 65x reduction without force sensing and without the baseline's saturation or power cost. Demonstrated in simulation under a shared actuator budget, the contribution is an efficient operational-space realization complementing rather than replacing broader interaction-control architectures.

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.