Pulley-based McKibben actuator mechanism for adjustable soft hand rehabilitation splint

Hand rehabilitation robots were developed to assist in rehabilitation procedures conducted by rehabilitation professionals. However, current hand rehabilitation robots are mostly made from heavy and rigid structures that caused discomfort and fitting issues to the patients. McKibben actuator is a type of soft actuator that could be used in hand rehabilitation robots for its flexibility and light weight. However, it has a limited contraction ratio for the required range of motion for finger flexion. In this thesis, a pulley mechanism is proposed to improve McKibben actuator’s contraction ratio while providing the required contraction force. A double groove pulley made of a hybrid of gear and pulley is proposed to enhance McKibben’s actuator contraction ratio. Various pulley ratio was studied to find optimum contraction ratio and its relation to contraction force. A pulley ratio of 1:4 increases the contraction ratio from 19.85 % to 76.67 % but reduces the contraction force from 42.68 N to 9.69 N. Hence, pulley ratio of 1:2 was implemented to the McKibben linear actuator based on its optimized 39.72 % contraction ratio and 20 N contraction force for the soft splint application. Next, an adjustable finger size soft splint with fixed wrist motion was developed. It consists of three parts, namely pulley-based McKibben actuator, wrist component, and McKibben ring actuators. The wrist component was designed with an adjustable strap buckle while the finger insertion part utilized the elasticity of McKibben ring actuator during contraction to fit a wide range of sizes. The size range for wrist and hand circumference is 12 cm - 21.6 cm and 15.8 cm - 22.3 cm respectively, which fit 90 % of Malaysian young adults. The soft splint was tested on two healthy subjects. At 400 kPa supply pressure, the bending angle of the finger joints achieved was [71.8°, 72.8°, 18.70] for Metacarpophalangeal, Proximal Interphalangeal and Distal Interphalangeal respectively. The range of motion achieved by the soft splint is lower than the functional range of motion, but higher compared to other research works. The subjects were able to grasp and lift objects of different shapes including a box, cylinder, and irregular shape under 250 g while wearing the soft splint. The developed soft splint with adjustable McKibben ring actuators and pulley-based McKibben linear actuator could initiate finger motion and assist object grasping for a possible clinical hand rehabilitation assessment

Design, fabrication and stiffening of soft pneumatic robots

Although compliance allows the soft robot to be under-actuated and generalise its control, it also impacts the ability of the robot to exert forces on the environment. There is a trade-off between robots being compliant or precise and strong. Many mechanisms that change robots' stiffness on demand have been proposed, but none are perfect, usually compromising the device's compliance and restricting its motion capabilities. Keeping the above issues in mind, this thesis focuses on creating robust and reliable pneumatic actuators, that are designed to be easily manufactured with simple tools. They are optimised towards linear behaviour, which simplifies modelling and improve control strategies. The principle idea in relation to linearisation is a reinforcement strategy designed to amplify the desired, and limit the unwanted, deformation of the device. Such reinforcement can be achieved using fibres or 3D printed structures. I have shown that the linearity of the actuation is, among others, a function of the reinforcement density and shape, in that the response of dense fibre-reinforced actuators with a circular cross-section is significantly more linear than that of non-reinforced or non-circular actuators. I have explored moulding manufacturing techniques and a mixture of 3D printing and moulding. Many aspects of these techniques have been optimised for reliability, repeatability, and process simplification. I have proposed and implemented a novel moulding technique that uses disposable moulds and can easily be used by an inexperienced operator. I also tried to address the compliance-stiffness trade-off issue. As a result, I have proposed an intelligent structure that behaves differently depending on the conditions. Thanks to its properties, such a structure could be used in applications that require flexibility, but also the ability to resist external disturbances when necessary. Due to its nature, individual cells of the proposed system could be used to implement physical logic elements, resulting in embodied intelligent behaviours. As a proof-of-concept, I have demonstrated use of my actuators in several applications including prosthetic hands, octopus, and fish robots. Each of those devices benefits from a slightly different actuation system but each is based on the same core idea - fibre reinforced actuators. I have shown that the proposed design and manufacturing techniques have several advantages over the methods used so far. The manufacturing methods I developed are more reliable, repeatable, and require less manual work than the various other methods described in the literature. I have also shown that the proposed actuators can be successfully used in real-life applications. Finally, one of the most important outcomes of my research is a contribution to an orthotic device based on soft pneumatic actuators. The device has been successfully deployed, and, at the time of submission of this thesis, has been used for several months, with good results reported, by a patient

Development of soft modular robotics

This thesis covers the development and validation of soft robots in providing upper limb assistive motion. The main purpose of this research is to develop highly compliant and resilient actuators that generate motion for elbow and shoulder movements. To accomplish the purpose of the study, the fabrication, geometric construction along with experimental data of pressure, torque and range of motion of all developed actuators are described. The main contribution of this thesis is the development of soft actuators that transfer force via elastic deformation in order to generate assistive motion; features such as flexibility and soft contact with the skin ensure excellent safety potential of the actuators. To reduce the instability phenomenon attributed to the elastic response of rubber under large deformations that leads to bulging, the implementation of a pleated network design and embedded braided mesh network is presented. Bulging was reduced and torque output was increased with the integration of braided mesh into the silicone rubber actuator. The soft actuators developed for elbow and shoulder motion was tested on ten healthy participants thereby demonstrating its comfort, ease of use, fitting and removal as well as its practicality as an assistive apparatus for stroke patients. The use of soft robotics to provide shoulder motion was also assessed by the integration of soft robotics with a gravity compensated exoskeleton. The developed soft actuators were powered with electro-pneumatic hardware components presented in a compact, embedded form. Positive and negative air pressure control was implemented by a piecewise linear control algorithm with the performance of the controller shown. The design of a novel muscle made entirely of silicone rubber that contract upon actuation was described together with the manufacturing procedure, design parameters and measurement results of performance of these muscles such as the velocity of shortening, isometric contraction and maximal obtainable muscle force (without shortening). The muscles are manufactured to mimic the skeletal muscles present in the human body. These muscles are composed of a number of wedge-like units in series, the number of these wedge units increase the contraction. The soft muscles were characterized in order to find optimum design parameters that results in more contraction and speed; the muscles were tested on a model hinge joint to execute flexion/extension of the forearm at the elbow. Aside from contracting, the muscle has an interesting capability of producing bidirectional bending by the regulation of internal positive and negative air pressure in each wedge unit. In order to measure performance data relating to range of motion from bending, rotary and muscle actuators, computer vision processing was made use of. Soft robots are made with materials that experience large deformations, the sensors used to obtain measurement data can either be through the use of embedded sensors or visual processing. The use of embedded sensors can be cumbersome, resulting in limitation of its performance. The visual processing algorithms implemented to measure performance data such as angle of motion, bending angle and contraction ratio in real-time using a Webcam is described. Visual processing concepts such as colour tracking, template matching, camera calibration were applied. The developed vision system was applied to execute vision based motion control which is able to move the soft robot to a desired position using high level vision control and lower level pressure control. The material described in the preceding paragraphs are presented in an interrelated format. A concise introduction to the thesis is presented in the first chapter. An extensive survey of the field of soft robotics including materials, manufacturing procedure, actuation principles, primary accomplishments, control and challenges are presented in the literature review chapter, together with a review of rehabilitation devices. Since this work focused on the use of silicone rubber as actuator material, a brief introduction to working with silicone rubber as an engineering material is presented in the third chapter. The conclusions of the work and suggestions for future research are provided at the last chapter of this thesis

Upper limb soft robotic wearable devices: a systematic review

Introduction: Soft robotic wearable devices, referred to as exosuits, can be a valid alternative to rigid exoskeletons when it comes to daily upper limb support. Indeed, their inherent flexibility improves comfort, usability, and portability while not constraining the user’s natural degrees of freedom. This review is meant to guide the reader in understanding the current approaches across all design and production steps that might be exploited when developing an upper limb robotic exosuit. Methods: The literature research regarding such devices was conducted in PubMed, Scopus, and Web of Science. The investigated features are the intended scenario, type of actuation, supported degrees of freedom, low-level control, high-level control with a focus on intention detection, technology readiness level, and type of experiments conducted to evaluate the device. Results: A total of 105 articles were collected, describing 69 different devices. Devices were grouped according to their actuation type. More than 80% of devices are meant either for rehabilitation, assistance, or both. The most exploited actuation types are pneumatic (52%) and DC motors with cable transmission (29%). Most devices actuate 1 (56%) or 2 (28%) degrees of freedom, and the most targeted joints are the elbow and the shoulder. Intention detection strategies are implemented in 33% of the suits and include the use of switches and buttons, IMUs, stretch and bending sensors, EMG and EEG measurements. Most devices (75%) score a technology readiness level of 4 or 5. Conclusion: Although few devices can be considered ready to reach the market, exosuits show very high potential for the assistance of daily activities. Clinical trials exploiting shared evaluation metrics are needed to assess the effectiveness of upper limb exosuits on target users

Soft Gloves: A Review on Recent Developments in Actuation, Sensing, Control and Applications

Interest in soft gloves, both robotic and haptic, has enormously grown over the past decade, due to their inherent compliance, which makes them particularly suitable for direct interaction with the human hand. Robotic soft gloves have been developed for hand rehabilitation, for ADLs assistance, or sometimes for both. Haptic soft gloves may be applied in virtual reality (VR) applications or to give sensory feedback in combination with prostheses or to control robots. This paper presents an updated review of the state of the art of soft gloves, with a particular focus on actuation, sensing, and control, combined with a detailed analysis of the devices according to their application field. The review is organized on two levels: a prospective review allows the highlighting of the main trends in soft gloves development and applications, and an analytical review performs an in-depth analysis of the technical solutions developed and implemented in the revised scientific research. Additional minor evaluations integrate the analysis, such as a synthetic investigation of the main results in the clinical studies and trials referred in literature which involve soft gloves

Modeling and Analysis of a High-Displacement Pneumatic Artificial Muscle With Integrated Sensing

We present a high-displacement pneumatic artificial muscle made of textiles or plastics that can include integrated electronics to sense its pressure and displacement. Compared to traditional pneumatic muscle actuators such as the McKibben actuator and other more recent soft actuators, the actuator described in this paper can produce a much higher (40~65%) contraction ratio. In this paper, we describe the design, fabrication, and evaluation of the actuator, as well as the manufacturing process used to create it. We demonstrate the actuator design with several examples that produce 120 and 300 N at pressures of 35 and 105 kPa, respectively, and have contraction ratios of 40–65%

Biomimetic leg design and passive dynamics of Dolomedes aquaticus

Spiders provide working models for agile, efficient miniature passive-dynamic robots. Joints are extended by haemoplymph (hydraulic) pressure and flexed by muscle-tendon systems. Muscle contraction in the prosoma leads to an increase in hydraulic pressure and subsequently leg extension. Analysis of body kinematics the New Zealand fishing spider, Dolomedes aquaticus indicates that elastic plates around the joints absorb energy from the ground reaction force when the force vector points backwards (i.e. would decelerate the spider’s body in the direction of locomotion) and release it to provide forward thrust as the leg swings backwards. In addition to improving energy efficiency, this mechanism improves stability by passively absorbing energy from unpredictable foot-ground impacts during locomotion on uneven terrain. These principles guided an iterative design methodology using a combination of 3D modelling software and 3D printing techniques. I compared and contrasted compliant joints made of a variety of plastic materials. The final 3D-printed spider leg prototype has a stiff ABS exoskeleton joined by a compliant polypropylene backbone. The entire structure envelopes a soft silicone pneumatic bladder. FEA analysis was used to determine the ideal shape and behavior of the pneumatic bladder to actuate the exoskeleton. The spider leg can be flexed and contracted depending on the input pressure. To laterally actuate this pneumatic spider leg I designed and developed a fabrication system that uses vacuum injection molding to produce an integrated mesh sleeve/elastomer pneumatic actuator. I designed an apparatus to measure pressure and contraction of silicone and latex pneumatic muscles when inflated. I analyzed the non-linear pressure-contraction relationships of silicone versus latex pneumatic muscles, and also derived force-contraction relationships. From efficiency studies, both media muscles proved to be inefficient and the measuring apparatus needs to be more robust to prevent leaking air. The fabrication process still offers the possibility of a quick and efficient method of creating pneumatic muscles. A spider-like robot that implements these pneumatic muscles and pneumatic leg design could be used to explore the efficiency and stability of passive dynamic legged locomotion in spider-like robots