Design, Manufacturing, and Locomotion Studies of Ambulatory Micro-Robots

Biological research over the past several decades has elucidated some of the mechanisms behind highly mobile, efficient, and robust locomotion in insects such as the cockroach. Roboticists have used this information to create biologically-inspired machines capable of running, jumping, and climbing robustly over a variety of terrains. To date, little work has been done to develop an at-scale insect-inspired robot capable of similar feats, due to limitations in fabrication, actuation, and electronics integration at small scales. This thesis addresses these challenges, focusing on the mechanical design and fabrication of a sub-2g walking robot, the Harvard Ambulatory MicroRobot (HAMR). The development of HAMR includes modeling and parameter selection for a two degree of freedom leg powertrain that enables locomotion. In addition, a design inspired by pop-up books that enables fast and repeatable assembly of the miniature walking robot is presented. Finally, a method to drive HAMR resulting in speeds up to 37cm/s is presented, along with simple control schemes.Engineering and Applied Science

Scaling down an insect-size microrobot, HAMR-VI into HAMR-Jr

Here we present HAMR-Jr, a \SI{22.5}{\milli\meter}, \SI{320}{\milli\gram} quadrupedal microrobot. With eight independently actuated degrees of freedom, HAMR-Jr is, to our knowledge, the most mechanically dexterous legged robot at its scale and is capable of high-speed locomotion (\SI{13.91}{bodylengths~\second^{-1}}) at a variety of stride frequencies (\SI{1}{}-\SI{200}{\hertz}) using multiple gaits. We achieved this using a design and fabrication process that is flexible, allowing scaling with minimum changes to our workflow. We further characterized HAMR-Jr's open-loop locomotion and compared it with the larger scale HAMR-VI microrobot to demonstrate the effectiveness of scaling laws in predicting running performance.Comment: IEEE International Conference on Robotics and Automation 2020 (accepted

Enabling technologies for precise aerial manufacturing with unmanned aerial vehicles

The construction industry is currently experiencing a revolution with automation techniques such as additive manufacturing and robot-enabled construction. Additive Manufacturing (AM) is a key technology that can o er productivity improvement in the construction industry by means of o -site prefabrication and on-site construction with automated systems. The key bene t is that building elements can be fabricated with less materials and higher design freedom compared to traditional manual methods. O -site prefabrication with AM has been investigated for some time already, but it has limitations in terms of logistical issues of components transportation and due to its lack of design exibility on-site. On-site construction with automated systems, such as static gantry systems and mobile ground robots performing AM tasks, can o er additional bene ts over o -site prefabrication, but it needs further research before it will become practical and economical. Ground-based automated construction systems also have the limitation that they cannot extend the construction envelope beyond their physical size. The solution of using aerial robots to liberate the process from the constrained construction envelope has been suggested, albeit with technological challenges including precision of operation, uncertainty in environmental interaction and energy e ciency. This thesis investigates methods of precise manufacturing with aerial robots. In particular, this work focuses on stabilisation mechanisms and origami-based structural elements that allow aerial robots to operate in challenging environments. An integrated aerial self-aligning delta manipulator has been utilised to increase the positioning accuracy of the aerial robots, and a Material Extrusion (ME) process has been developed for Aerial Additive Manufacturing (AAM). A 28-layer tower has been additively manufactured by aerial robots to demonstrate the feasibility of AAM. Rotorigami and a bioinspired landing mechanism demonstrate their abilities to overcome uncertainty in environmental interaction with impact protection capabilities and improved robustness for UAV. Design principles using tensile anchoring methods have been explored, enabling low-power operation and explores possibility of low-power aerial stabilisation. The results demonstrate that precise aerial manufacturing needs to consider not only just the robotic aspects, such as ight control algorithms and mechatronics, but also material behaviour and environmental interaction as factors for its success.Open Acces

Mechanical Intelligence in Millimeter-Scale Machines

Advances in millimeter-scale fabrication processes have enabled rapid progress towards the development of flapping wing micro air vehicles with wing spans of several centimeters and a system mass on the order of 100mg. Concerning flight stability and control mechanisms for these mass and power limited devices, this dissertation explores the use of underactuated “mechanically intelligent” systems to passively regulate forces and torques encountered during flight. Several experiments demonstrate passive torque regulation in physical flapping wing systems. Finally, this dissertation concludes with a detailed description of the Printed Circuit MEMS manufacturing process, developed to address the practical problem of building complex insect-scale machines.Engineering and Applied Science

Development of walking robot using compliance mechanism

Walking robot is a trend in this 21st century as Industrial Revolution 4.0 which involved automation has become a hot topic. Unlike ordinary moving robots, walking robots that take humans and animals as references can move on unpaved surfaces. Compliance mechanism is a flexible mechanism that transfers input force into output force through plastic deformation of certain members in the structure. A compliant structure can be classified as a monolithic structure that deforms elastically without any joint or linkage between the members. Unlike motorised robot legs requiring an input motion in each joint and link, a single input force can operate a compliant leg. Therefore, this research aims to develop a 3D printed compliant leg. This project is challenging because there is no reference for the single-piece compliant leg development using Three-Dimensional(3D) printing technology. The application of Jansen Linkage in the development of the compliant leg also results in difficulties because there is no standard equation for the calculation of each member in the Jansen Linkage. Hence, the development of the Jansen Linkage using different dimensions will solve these problems by varying the difference occurring upon changing the dimension. We also make Finite Element Analysis (FEA) of the product. The thesis will be supported by the walking motion pattern, force vs time graph and FEA analysis results for the product

Microrobots for wafer scale microfactory: design fabrication integration and control.

Future assembly technologies will involve higher automation levels, in order to satisfy increased micro scale or nano scale precision requirements. Traditionally, assembly using a top-down robotic approach has been well-studied and applied to micro-electronics and MEMS industries, but less so in nanotechnology. With the bloom of nanotechnology ever since the 1990s, newly designed products with new materials, coatings and nanoparticles are gradually entering everyone’s life, while the industry has grown into a billion-dollar volume worldwide. Traditionally, nanotechnology products are assembled using bottom-up methods, such as self-assembly, rather than with top-down robotic assembly. This is due to considerations of volume handling of large quantities of components, and the high cost associated to top-down manipulation with the required precision. However, the bottom-up manufacturing methods have certain limitations, such as components need to have pre-define shapes and surface coatings, and the number of assembly components is limited to very few. For example, in the case of self-assembly of nano-cubes with origami design, post-assembly manipulation of cubes in large quantities and cost-efficiency is still challenging. In this thesis, we envision a new paradigm for nano scale assembly, realized with the help of a wafer-scale microfactory containing large numbers of MEMS microrobots. These robots will work together to enhance the throughput of the factory, while their cost will be reduced when compared to conventional nano positioners. To fulfill the microfactory vision, numerous challenges related to design, power, control and nanoscale task completion by these microrobots must be overcome. In this work, we study three types of microrobots for the microfactory: a world’s first laser-driven micrometer-size locomotor called ChevBot，a stationary millimeter-size robotic arm, called Solid Articulated Four Axes Microrobot (sAFAM), and a light-powered centimeter-size crawler microrobot called SolarPede. The ChevBot can perform autonomous navigation and positioning on a dry surface with the guidance of a laser beam. The sAFAM has been designed to perform nano positioning in four degrees of freedom, and nanoscale tasks such as indentation, and manipulation. And the SolarPede serves as a mobile workspace or transporter in the microfactory environment

Modular soft pneumatic actuator system design for compliance matching

The future of robotics is personal. Never before has technology been as pervasive as it is today, with advanced mobile electronics hardware and multi-level network connectivity pushing âsmartâ devices deeper into our daily lives through home automation systems, virtual assistants, and wearable activity monitoring. As the suite of personal technology around us continues to grow in this way, augmenting and offloading the burden of routine activities of daily living, the notion that this trend will extend to robotics seems inevitable. Transitioning robots from their current principal domain of industrial factory settings to domestic, workplace, or public environments is not simply a matter of relocation or reprogramming, however. The key differences between âtraditionalâ types of robots and those which would best serve personal, proximal, human interactive applications demand a new approach to their design. Chief among these are requirements for safety, adaptability, reliability, reconfigurability, and to a more practical extent, usability. These properties frame the context and objectives of my thesis work, which seeks to provide solutions and answers to not only how these features might be achieved in personal robotic systems, but as well what benefits they can afford. I approach the investigation of these questions from a perspective of compliance matching of hardware systems to their applications, by providing methods to achieve mechanical attributes complimentary to their environment and end-use. These features are fundamental to the burgeoning field of Soft Robotics, wherein flexible, compliant materials are used as the basis for the structure, actuation, sensing, and control of complete robotic systems. Combined with pressurized air as a power source, soft pneumatic actuator (SPA) based systems offers new and novel methods of exploiting the intrinsic compliance of soft material components in robotic systems. While this strategy seems to answer many of the needs for human-safe robotic applications, it also brings new questions and challenges: What are the needs and applications personal robots may best serve? Are soft pneumatic actuators capable of these tasks, or âusefulâ work output and performance? How can SPA based systems be applied to provide complex functionality needed for operation in diverse, real-world environments? What are the theoretical and practical challenges in implementing scalable, multiple degrees of freedom systems, and how can they be overcome? I present solutions to these problems in my thesis work, elucidated through scientific design, testing and evaluation of robotic prototypes which leverage and demonstrate three key features: 1) Intrinsic compliance: provided by passive elastic and flexible component material properties, 2) Extrinsic compliance: rendered through high number of independent, controllable degrees of freedom, and 3) Complementary design: exhibited by modular, plug and play architectures which combine both attributes to achieve compliant systems. Through these core projects and others listed below I have been engaged in soft robotic technology, its application, and solutions to the challenges which are critical to providing a path forward within the soft robotics field, as well as for the future of personal robotics as a whole toward creating a better society

HydroDog: A Quadruped Robot Actuated by Soft Fluidic Muscles

This report presents the very first effort aimed to develop a legged terrestrial robot actuated by Hydro Muscles, which are elastic tubes actuated by fluid, constrained by fabric that extend and contract emulating life-like performance of biological muscles. The team designed and manufactured a 30-pound quadruped “dog” using versatile aluminum extrusions and minimally machined components. The team tested and observed a variety of bounding gaits that resulted from different skeletal/muscular geometries and actuation times. These tests yielded varying jump heights and robot forward velocities. Future projects should extensively research optimal leg kinematics to maximize the mechanical power the muscles apply on the robot

HydroDog: A Quadruped Robot Actuated by Soft, Fluidic Muscles

This report presents the very first effort aimed to develop a legged terrestrial robot actuated by Hydro Muscles, which are elastic tubes actuated by fluid, constrained by fabric that extend and contract emulating life-like performance of biological muscles. The team designed and manufactured a 30-pound quadruped “dog” using versatile aluminum extrusions and minimally machined components. The team tested and observed a variety of bounding gaits that resulted from different skeletal/muscular geometries and actuation times. These tests yielded varying jump heights and robot forward velocities. Future projects should extensively research optimal leg kinematics to maximize the mechanical power the muscles apply on the robot