Advanced Design of Columnar-conical Feeler-type Optical Three-axis Tactile Sensor

AbstractAlthough the three-axis tactile sensor is capable of delicate measurement, it is weak for heavy contact force. In order to enhance resistance to a high degree of applied force, we attached a rubber skin onto the sensor surface to protect the sensing element. FEM analyses found that sensitivity is not significantly reduced and that the skin induces subsidiary effects such as the disappearance of insensible areas and the enhancement of stability of the columnar feeler. If the skin is substantially softer than the columnar-conical feeler, the sensor can measure three-axis force without reduction of sensitivity. Based on these simulated results, we produced a columnar-conical feeler-type three-axis tactile sensor with rubber skin. The experimental results show, as demonstrated by FEM analyses, that the sensor possesses three-axis sensing capability and that the insensible area vanishes

Body Lift and Drag for a Legged Millirobot in Compliant Beam Environment

Much current study of legged locomotion has rightly focused on foot traction forces, including on granular media. Future legged millirobots will need to go through terrain, such as brush or other vegetation, where the body contact forces significantly affect locomotion. In this work, a (previously developed) low-cost 6-axis force/torque sensing shell is used to measure the interaction forces between a hexapedal millirobot and a set of compliant beams, which act as a surrogate for a densely cluttered environment. Experiments with a VelociRoACH robotic platform are used to measure lift and drag forces on the tactile shell, where negative lift forces can increase traction, even while drag forces increase. The drag energy and specific resistance required to pass through dense terrains can be measured. Furthermore, some contact between the robot and the compliant beams can lower specific resistance of locomotion. For small, light-weight legged robots in the beam environment, the body motion depends on both leg-ground and body-beam forces. A shell-shape which reduces drag but increases negative lift, such as the half-ellipsoid used, is suggested to be advantageous for robot locomotion in this type of environment.Comment: First three authors contributed equally. Accepted to ICRA 201

Design, evaluation, and control of nexus: a multiscale additive manufacturing platform with integrated 3D printing and robotic assembly.

Additive manufacturing (AM) technology is an emerging approach to creating three-dimensional (3D) objects and has seen numerous applications in medical implants, transportation, aerospace, energy, consumer products, etc. Compared with manufacturing by forming and machining, additive manufacturing techniques provide more rapid, economical, efficient, reliable, and complex manufacturing processes. However, additive manufacturing also has limitations on print strength and dimensional tolerance, while traditional additive manufacturing hardware platforms for 3D printing have limited flexibility. In particular, part geometry and materials are limited to most 3D printing hardware. In addition, for multiscale and complex products, samples must be printed, fabricated, and transferred among different additive manufacturing platforms in different locations, which leads to high cost, long process time, and low yield of products. This thesis investigates methods to design, evaluate, and control the NeXus, which is a novel custom robotic platform for multiscale additive manufacturing with integrated 3D printing and robotic assembly. NeXus can be used to prototype miniature devices and systems, such as wearable MEMS sensor fabrics, microrobots for wafer-scale microfactories, tactile robot skins, next generation energy storage (solar cells), nanostructure plasmonic devices, and biosensors. The NeXus has the flexibility to fixture, position, transport, and assemble components across a wide spectrum of length scales (Macro-Meso-Micro-Nano, 1m to 100nm) and provides unparalleled additive process capabilities such as 3D printing through both aerosol jetting and ultrasonic bonding and forming, thin-film photonic sintering, fiber loom weaving, and in-situ Micro-Electro-Mechanical System (MEMS) packaging and interconnect formation. The NeXus system has a footprint of around 4m x 3.5m x 2.4m (X-Y-Z) and includes two industrial robotic arms, precision positioners, multiple manipulation tools, and additive manufacturing processes and packaging capabilities. The design of the NeXus platform adopted the Lean Robotic Micromanufacturing (LRM) design principles and simulation tools to mitigate development risks. The NeXus has more than 50 degrees of freedom (DOF) from different instruments, precise evaluation of the custom robots and positioners is indispensable before employing them in complex and multiscale applications. The integration and control of multi-functional instruments is also a challenge in the NeXus system due to different communication protocols and compatibility. Thus, the NeXus system is controlled by National Instruments (NI) LabVIEW real-time operating system (RTOS) with NI PXI controller and a LabVIEW State Machine User Interface (SMUI) and was programmed considering the synchronization of various instruments and sequencing of additive manufacturing processes for different tasks. The operation sequences of each robot along with relevant tools must be organized in safe mode to avoid crashes and damage to tools during robots’ motions. This thesis also describes two demonstrators that are realized by the NeXus system in detail: skin tactile sensor arrays and electronic textiles. The fabrication process of the skin tactile sensor uses the automated manufacturing line in the NeXus with pattern design, precise calibration, synchronization of an Aerosol Jet printer, and a custom positioner. The fabrication process for electronic textiles is a combination of MEMS fabrication techniques in the cleanroom and the collaboration of multiple NeXus robots including two industrial robotic arms and a custom high-precision positioner for the deterministic alignment process