3D printed pneumatic soft actuators and sensors: their modeling, performance quantification, control and applications in soft robotic systems

Continued technological progress in robotic systems has led to more applications where robots and humans operate in close proximity and even physical contact in some cases. Soft robots, which are primarily made of highly compliant and deformable materials, provide inherently safe features, unlike conventional robots that are made of stiff and rigid components. These robots are ideal for interacting safely with humans and operating in highly dynamic environments. Soft robotics is a rapidly developing field exploiting biomimetic design principles, novel sensor and actuation concepts, and advanced manufacturing techniques. This work presents novel soft pneumatic actuators and sensors that are directly 3D printed in one manufacturing step without requiring postprocessing and support materials using low-cost and open-source fused deposition modeling (FDM) 3D printers that employ an off-the-shelf commercially available soft thermoplastic poly(urethane) (TPU). The performance of the soft actuators and sensors developed is optimized and predicted using finite element modeling (FEM) analytical models in some cases. A hyperelastic material model is developed for the TPU based on its experimental stress-strain data for use in FEM analysis. The novel soft vacuum bending (SOVA) and linear (LSOVA) actuators reported can be used in diverse robotic applications including locomotion robots, adaptive grippers, parallel manipulators, artificial muscles, modular robots, prosthetic hands, and prosthetic fingers. Also, the novel soft pneumatic sensing chambers (SPSC) developed can be used in diverse interactive human-machine interfaces including wearable gloves for virtual reality applications and controllers for soft adaptive grippers, soft push buttons for science, technology, engineering, and mathematics (STEM) education platforms, haptic feedback devices for rehabilitation, game controllers and throttle controllers for gaming and bending sensors for soft prosthetic hands. These SPSCs are directly 3D printed and embedded in a monolithic soft robotic finger as position and touch sensors for real-time position and force control. One of the aims of soft robotics is to design and fabricate robotic systems with a monolithic topology embedded with its actuators and sensors such that they can safely interact with their immediate physical environment. The results and conclusions of this thesis have significantly contributed to the realization of this aim

Novel soft bending actuator based power augmentation hand exoskeleton controlled by human intention

This article presents the development of a soft material power augmentation wearable robot using novel bending soft artificial muscles. This soft exoskeleton was developed as a human hand power augmentation system for healthy or partially hand disabled individuals. The proposed prototype serves healthy manual workers by decreasing the muscular effort needed for grasping objects. Furthermore, it is a power augmentation wearable robot for partially hand disabled or post-stroke patients, supporting and augmenting the fingers’ grasping force with minimum muscular effort in most everyday activities. This wearable robot can fit any adult hand size without the need for any mechanical system changes or calibration. Novel bending soft actuators are developed to actuate this power augmentation device. The performance of these actuators has been experimentally assessed. A geometrical kinematic analysis and mathematical output force model have been developed for the novel actuators. The performance of this mathematical model has been proven experimentally with promising results. The control system of this exoskeleton is created by hybridization between cascaded position and force closed loop intelligent controllers. The cascaded position controller is designed for the bending actuators to follow the fingers in their bending movements. The force controller is developed to control the grasping force augmentation. The operation of the control system with the exoskeleton has been experimentally validated. EMG signals were monitored during the experiments to determine that the proposed exoskeleton system decreased the muscular efforts of the wearer

Hybrid fluidic actuation for a foam-based soft actuator

Actuation means for soft robotic structures are manifold: despite actuation mechanisms such as tendon-driven manipulators or shape memory alloys, the majority of soft robotic actuators are fluidically actuated - either purely by positive or negative air pressure or by hydraulic actuation only. This paper presents the novel idea of employing hybrid fluidic - hydraulic and pneumatic - actuation for soft robotic systems. The concept and design of the hybrid actuation system as well as the fabrication of the soft actuator are presented: Polyvinyl Alcohol (PVA) foam is embedded inside a casted, reinforced silicone chamber. A hydraulic and pneumatic robotic syringe pump are connected to the base and top of the soft actuator. We found that a higher percentage of hydraulics resulted in a higher output force. Hydraulic actuation further is able to change displacements at a higher rate compared to pneumatic actuation. Changing between Hydraulic:Pneumatic (HP) ratios shows how stiffness properties of a soft actuator can be varied

Novel pneumatic circuit for the computational control of soft robots

Soft robots are of significant research interest in recent decades due to their adaptability to unstructured environments and safe interaction with humans. Soft pneumatic robots, one of the most dominant subsets of soft robots, utilize the interaction between soft elastomeric materials and pressurized air to achieve desired functions. However, the systems currently used for signal computation and pneumatic regulation often make use of rigid valves, pumps, syringe drivers, microcontrollers et al. These bulky and non-integrable devices limit the performance of pneumatically-driven soft robots, carrying challenges for the robot to be miniaturized, untethered, and agile. This DPhil aims to develop pneumatic circuits that can be integrated into the soft robot bodies while performing both onboard computation and control. This thesis presents our contributions towards the aforementioned objective step by step. Firstly, we designed a 3D-printable bistable valve with tunable behaviours for controlling soft pneumatic robots. As an integrable control device, the valve stores one bit of binary information without requiring a constant energy supply and correspondingly controls a pneumatic chamber. Secondly, in order to reduce the number of valves required to control multi-chamber soft robots, we introduced a modular approach to design multi-channel bistable valves based on the previous work. Thirdly, in order to achieve continuous pressure modulation with integrable devices, we designed a soft proportional valve, utilizing the continuous deformation of Magnetorheological Elastomer (MRE) under magnetic flux. Apart from the analogue activation manner, this design also ensures a fast response time, operating at a time scale of tens of milliseconds, much shorter than the mechanical response time of most soft pneumatic actuators. Fourthly, to achieve onboard proportional control of multi-chamber soft robots, we developed an MRE valve array with an embedded cooling chamber. Physical experiments showed that our MRE valve array ensured the independence and accuracy of each valve unit within it, with a significantly lowered temperature of 73.9 $^o$C under 5 minutes of operation. Lastly, we developed an open-source software toolbox supporting the design of integrable pneumatic logic circuits to enhance their accessibility and performance. The toolbox comes with a graphical user interface (GUI) to take users' desired logic functions in the form of a truth table and a set of 2D space constraints related to the available space onboard the robot. It then schedules the pneumatic circuit which performs the desired computation within the space constraints and produces a 3D-printable CAD file that can be fabricated and used directly. The work presented in this thesis enables the community to simplify the process of integrating control devices into soft pneumatic robots, thereby paving the way for a new generation of fully untethered and autonomous soft robots

The design and mathematical modelling of novel extensor bending pneumatic artificial muscles (EBPAMs) for soft exoskeletons

This article presents the development of a power augmentation and rehabilitation exoskeleton based on a novel actuator. The proposed soft actuators are extensor bending pneumatic artificial muscles. This type of soft actuator is derived from extending McKibben artificial muscles by reinforcing one side to prevent extension. This research has experimentally assessed the performance of this new actuator and an output force mathematical model for it has been developed. This new mathematical model based on the geometrical parameters of the extensor bending pneumatic artificial muscle determines the output force as a function of the input pressure. This model is examined experimentally for different actuator sizes. After promising initial experimental results, further model enhancements were made to improve the model of the proposed actuator. To demonstrate the new bending actuators a power augmentation and rehabilitation soft glove has been developed. This soft hand exoskeleton is able to fit any adult hand size without the need for any mechanical system changes or calibration. EMG signals from the human hand have been monitored to prove the performance of this new design of soft exoskeleton. This power augmentation and rehabilitation wearable robot has been shown to reduce the amount of muscles effort needed to perform a number of simple grasps