Design and Fabrication of Origami Elements for use in a Folding Robot Structure

The aim of the research is to investigate the methodology of the design and fabrication of folding robots that depend on the origami structures. The use of origami structures as a foundation to build reconfigurable and morphing robots that could assist in search and rescue (SAR) tasks are investigated. The design of the origami folding structures divided into three stages: consideration of the geometry of the origami structure, the hinge design, and the actuation system. The result of investigating three origami structures shows the ability to use the unit cell of the origami ball structure as a self-folding element. Furthermore, the novel type of origami structure for manipulation was created according to this result. This novel structure was designed to be a soft manipulation robot arm. Two approaches are used to design and fabricate flexure hinge. The first is by using a 3D printed multi-material technique. By this technique, the hinge printed using soft and solid material at the same time, which is Tango plus flx930 for soft material and Vero for solid material. The soft material act as a flexure hinge. Therefore, three tests were operated for it to calculate the tensile force, fatigue limit, and the required bend force. The second approach is by using acrylic and Kapton materials. Two types of actuation systems were studied: the external actuation system and embedded actuation system. The external actuation system was used for the Origami structure for manipulation, while the embedded actuation system was used for the self-folding structure. The shape memory alloy wires in torsion (TSW) and bending (BSW) was used in an embedded actuation system. A unit cell of origami ball was fabricated as a self-folding element by using three approaches: manually, acrylic, and Kapton and 3D printing. It is actuated by using shape memory alloy wire. Furthermore, an origami structure for manipulation was fabricated and actuated using an external actuation system. This novel type of origami structure provided an excellent bend motion ability

Analyzing the 3D Printed Material Tango Plus FLX930 for Using in Self-Folding Structure

Self-folding is the ability of the structure to fold and/or unfold without human intervention or any application of external manipulation. It is known that the structure of folding object consists of two essential parts. These parts are the faces and the creases. In this paper, it is assumed that the faces could be built by using solid materials, and the crease lines can be built using soft material which provides a high bent ability. Furthermore, these two materials should be combined built without using any connections between them. Fortunately, the 3D printer provides this capability. It can print two types of different materials at the same time for the same structure. Therefore, a 3D printer is chosen to fabricate a folding structure using two types of material. These types are the Vero for solid faces and Tango plus FLX930 for the soft creases lines. The soft material at hinge part (creases lines) subjected to the load directly when the structure folds. It should have a clear view of the mechanical properties of this material. Therefore, several mechanical tests for Tango FLX930 material are operated to calculate its mechanical properties and find the force that required to fold it

Bioinspired Origami: Information Retrieval Techniques for Design of Foldable Engineering Applications

The science of folding has inspired and challenged scholars for decades. Origami, the art of folding paper, has led to the development of many foldable engineering solutions with applications in manufacturing, materials, and product design. Interestingly, three fundamental origami crease patterns are analogous to folding observed in nature. Numerous folding patterns, structures, and behaviors exist in nature that have not been considered for engineering solutions simply because they are not well-known or studied by designers. While research has shown applying biological solutions to engineering problems is significantly valuable, various challenges prevent the transfer of knowledge from biology to the engineering domain. One of those challenges is the retrieval of useful design inspiration. In this dissertation work, information retrieval techniques are employed to retrieve useful biological design solutions and a text-based search algorithm is developed to return passages where folding in nature is observed. The search algorithm, called FoldSearch, integrates tailored biological keywords and filtering methods to retrieve passages from an extensive biological corpus. The performance of FoldSearch is evaluated using statistical methods for information retrieval and validated using inter-rater reliability analysis. The utility of FoldSearch is demonstrated through two case studies where the retrieved biological examples undergo a design abstraction process that leads to the development of bioinspired origami crease patterns and novel foldable structures. The design abstraction process is presented as an additional research contribution and demonstrates the potential to provide bioinspired design solutions for the growing research field of origami engineering

Development of a Fabrication Technique for Soft Planar Inflatable Composites

Soft robotics is a rapidly growing field in robotics that combines aspects of biologically inspired characteristics to unorthodox methods capable of conforming and/or adapting to unknown tasks or environments that would otherwise be improbable or complex with conventional robotic technologies. The field of soft robotics has grown rapidly over the past decade with increasing popularity and relevance to real-world applications. However, the means of fabricating these soft, compliant and intricate robots still poses a fundamental challenge, due to the liberal use of soft materials that are difficult to manipulate in their original state such as elastomers and fabric. These material properties rely on informal design approaches and bespoke fabrication methods to build soft systems. As such, there are a limited variety of fabrication techniques used to develop soft robots which hinders the scalability of robots and the time to manufacture, thus limiting their development. This research focuses towards developing a novel fabrication method for constructing soft planar inflatable composites. The fundamental method is based on a sub-set of additive manufacturing known as composite layering. The approach is designed from a planar manner and takes layers of elastomeric materials, embedded strain-limiting and mask layers. These components are then built up through a layer-by-layer fabrication method with the use of a bespoke film applicator set-up. This enables the fabrication of millimetre-scale soft inflatable composites with complex integrated masks and/or strain-limiting layers. These inflatable composites can then be cut into a desired shape via laser cutting or ablation. A design approach was also developed to expand the functionality of these inflatable composites through modelling and simulation via finite element analysis. Proof of concept prototypes were designed and fabricated to enable pneumatic driven actuation in the form of bending soft actuators, adjustable stiffness sensor, and planar shape change. This technique highlights the feasibility of the fabrication method and the value of its use in creating multi-material composite soft actuators which are thin, compact, flexible, and stretchable and can be applicable towards real-world application

Advanced Mobile Robotics: Volume 3

Mobile robotics is a challenging field with great potential. It covers disciplines including electrical engineering, mechanical engineering, computer science, cognitive science, and social science. It is essential to the design of automated robots, in combination with artificial intelligence, vision, and sensor technologies. Mobile robots are widely used for surveillance, guidance, transportation and entertainment tasks, as well as medical applications. This Special Issue intends to concentrate on recent developments concerning mobile robots and the research surrounding them to enhance studies on the fundamental problems observed in the robots. Various multidisciplinary approaches and integrative contributions including navigation, learning and adaptation, networked system, biologically inspired robots and cognitive methods are welcome contributions to this Special Issue, both from a research and an application perspective

Kinematics, Structural Mechanics, and Design of Origami Structures with Smooth Folds

Origami provides novel approaches to the fabrication, assembly, and functionality of engineering structures in various fields such as aerospace, robotics, etc. With the increase in complexity of the geometry and materials for origami structures that provide engineering utility, computational models and design methods for such structures have become essential. Currently available models and design methods for origami structures are generally limited to the idealization of the folds as creases of zeroth-order geometric continuity. Such an idealization is not proper for origami structures having non-negligible thickness or maximum curvature at the folds restricted by material limitations. Thus, for general structures, creased folds of merely zeroth-order geometric continuity are not appropriate representations of structural response and a new approach is needed. The first contribution of this dissertation is a model for the kinematics of origami structures having realistic folds of non-zero surface area and exhibiting higher-order geometric continuity, here termed smooth folds. The geometry of the smooth folds and the constraints on their associated kinematic variables are presented. A numerical implementation of the model allowing for kinematic simulation of structures having arbitrary fold patterns is also described. Examples illustrating the capability of the model to capture realistic structural folding response are provided. Subsequently, a method for solving the origami design problem of determining the geometry of a single planar sheet and its pattern of smooth folds that morphs into a given three-dimensional goal shape, discretized as a polygonal mesh, is presented. The design parameterization of the planar sheet and the constraints that allow for a valid pattern of smooth folds and approximation of the goal shape in a known folded configuration are presented. Various testing examples considering goal shapes of diverse geometries are provided. Afterwards, a model for the structural mechanics of origami continuum bodies with smooth folds is presented. Such a model entails the integration of the presented kinematic model and existing plate theories in order to obtain a structural representation for folds having non-zero thickness and comprised of arbitrary materials. The model is validated against finite element analysis. The last contribution addresses the design and analysis of active material-based self-folding structures that morph via simultaneous folding towards a given three-dimensional goal shape starting from a planar configuration. Implementation examples including shape memory alloy (SMA)-based self-folding structures are provided

Robotic Minimally Invasive Tools for Restricted Access Confined Spaces

A study has been performed in the design and fabrication of deployable borehole robots into confined spaces. Three robot systems have been developed to perform a visual survey of a subterranean space where for any reason humans could not enter. A 12mm diameter snake arm was designed with a focus on the cable tensions and the failure modes for the components that make the snake arm. An iterative solver was developed to model the snake arm and algorithmically calculate the snake arms optimal length with consideration of the failure modes. A robot was developed to extend the range capabilities of borehole robots using reconfigurable borehole robots based around established actuation and manufacturing techniques. The expected distance and weight requirements of the robot are calculated alongside the forces the robot is required to generate in order to achieve them. The whegged design incorporated into the tracks is also analysed to measure the capability of the robot over rough terrain. Finally, the experiments to find the actual driving forces of the tracks are performed and used to calculate the actual range of the robot in comparison to the target range. The potential of reconfigurable mobile robots for deployment through boreholes is limited by the requirement for conventional gears, motors, and joints. This chapter explores the use of smart materials and innovative manufacturing techniques to form a novel concept of a self-folding robotic joint for a self-assembling robotic system. The design uses shape memory alloys fabricated in laminate structures with heaters to create folding structures

Digital Fabrication Approaches for the Design and Development of Shape-Changing Displays

Interactive shape-changing displays enable dynamic representations of data and information through physically reconfigurable geometry. The actuated physical deformations of these displays can be utilised in a wide range of new application areas, such as dynamic landscape and topographical modelling, architectural design, physical telepresence and object manipulation. Traditionally, shape-changing displays have a high development cost in mechanical complexity, technical skills and time/finances required for fabrication. There is still a limited number of robust shape-changing displays that go beyond one-off prototypes. Specifically, there is limited focus on low-cost/accessible design and development approaches involving digital fabrication (e.g. 3D printing). To address this challenge, this thesis presents accessible digital fabrication approaches that support the development of shape-changing displays with a range of application examples – such as physical terrain modelling and interior design artefacts. Both laser cutting and 3D printing methods have been explored to ensure generalisability and accessibility for a range of potential users. The first design-led content generation explorations show that novice users, from the general public, can successfully design and present their own application ideas using the physical animation features of the display. By engaging with domain experts in designing shape-changing content to represent data specific to their work domains the thesis was able to demonstrate the utility of shape-changing displays beyond novel systems and describe practical use-case scenarios and applications through rapid prototyping methods. This thesis then demonstrates new ways of designing and building shape-changing displays that goes beyond current implementation examples available (e.g. pin arrays and continuous surface shape-changing displays). To achieve this, the thesis demonstrates how laser cutting and 3D printing can be utilised to rapidly fabricate deformable surfaces for shape-changing displays with embedded electronics. This thesis is concluded with a discussion of research implications and future direction for this work

Shape formation by self-disassembly in programmable matter systems

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Electrical Engineering and Computer Science, 2012.Cataloged from PDF version of thesis.Includes bibliographical references (p. 225-236).Programmable matter systems are composed of small, intelligent modules able to form a variety of macroscale objects with specific material properties in response to external commands or stimuli. While many programmable matter systems have been proposed in fiction, (Barbapapa, Changelings from Star Trek, the Terminator, and Transformers), and academia, a lack of suitable hardware and accompanying algorithms prevents their full realization. With this thesis research, we aim to create a system of miniature modules that can form arbitrary structures on demand. We develop autonomous 12mm cubic modules capable of bonding to, and communicating with, four of their immediate neighbors. These modules are among the smallest autonomous modular robots capable of sensing, communication, computation, and actuation. The modules employ unique electropermanent magnet connectors. The four connectors in each module enable the modules to communicate and share power with their nearest neighbors. These solid-state connectors are strong enough for a single inter-module connection to support the weight of 80 other modules. The connectors only consume power when switching on or off; they have no static power consumption. We implement a number of low-level communication and control algorithms which manage information transfer between neighboring modules. These algorithms ensure that messages are delivered reliably despite challenging conditions. They monitor the state of all communication links and are able to reroute messages around broken communication links to ensure that they reach their intended destinations. In order to accomplish our long-standing goal of programmatic shape formation, we also develop a suite of provably-correct distributed algorithms that allow complex shape formation. The distributed duplication algorithm that we present allows the system to duplicate any passive object that is submerged in a collection of programmable matter modules. The algorithm runs on the processors inside the modules and requires no external intervention. It requires 0(1) storage and O(n) inter-module messages per module, where n is the number of modules in the system. The algorithm can both magnify and produce multiple copies of the submerged object. A programmable matter system is a large network of autonomous processors, so these algorithms have applicability in a variety of routing, sensor network, and distributed computing applications. While our hardware system provides a 50-module test-bed for the algorithms, we show, by using a unique simulator, that the algorithms are capable of operating in much larger environments. Finally, we perform hundreds of experiments using both the simulator and hardware to show how the algorithms and hardware operate in practice.by Kyle William Gilpin.Ph.D

Proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress

Published proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress, hosted by York University, 27-30 May 2018