Robotic metamorphosis by origami exoskeletons

Changing the inherent physical capabilities of robots by metamorphosis has been a long-standing goal of engineers. However, this task is challenging because of physical constraints in the robot body, each component of which has a defined functionality. To date, self-reconfiguring robots have limitations in their on-site extensibility because of the large scale of today’s unit modules and the complex administration of their coordination, which relies heavily on on-board electronic components. We present an approach to extending and changing the capabilities of a robot by enabling metamorphosis using self-folding origami “exoskeletons.” We show how a cubical magnet “robot” can be remotely moved using a controllable magnetic field and hierarchically develop different morphologies by interfacing with different origami exoskeletons. Activated by heat, each exoskeleton is self-folded from a rectangular sheet, extending the capabilities of the initial robot, such as enabling the manipulation of objects or locomotion on the ground, water, or air. Activated by water, the exoskeletons can be removed and are interchangeable. Thus, the system represents an end-to-end (re)cycle. We also present several robot and exoskeleton designs, devices, and experiments with robot metamorphosis using exoskeletons

Adaptive Hierarchical Origami Metastructures

Shape-morphing capabilities are crucial for enabling multifunctionality in both biological and artificial systems. Various strategies for shape morphing have been proposed for applications in metamaterials and robotics. However, few of these approaches have achieved the ability to seamlessly transform into a multitude of volumetric shapes post-fabrication using a relatively simple actuation and control mechanism. Taking inspiration from thick origami and hierarchies in nature, we present a new hierarchical construction method based on polyhedrons to create an extensive library of compact origami metastructures. We show that a single hierarchical origami structure can autonomously adapt to over 103 versatile architectural configurations, achieved with the utilization of fewer than 3 actuation degrees of freedom and employing simple transition kinematics. We uncover the fundamental principles governing theses shape transformation through theoretical models. Furthermore, we also demonstrate the wide-ranging potential applications of these transformable hierarchical structures. These include their uses as untethered and autonomous robotic transformers capable of various gait-shifting and multidirectional locomotion, as well as rapidly self-deployable and self-reconfigurable architecture, exemplifying its scalability up to the meter scale. Lastly, we introduce the concept of multitask reconfigurable and deployable space robots and habitats, showcasing the adaptability and versatility of these metastructures

An Origami-Inspired Reconfigurable Suction Gripper for Picking Objects with Variable Shape and Size

Gripper adaptability to handle objects of different shape and size brings high flexibility to manipulation. Gripping flat, round, or narrow objects poses challenges to even the most sophisticated robotic grippers. Among various gripper technologies, the vacuum suction grippers provide design simplicity, yet versatility at low cost, however, their application is limited to their fixed shape and size. Here, we present an origami-inspired reconfigurable suction gripper to address adaptability with robotic suction grippers. Constructed from rigid and soft components and driven by compact shape memory alloy actuators, the gripper can effectively self-fold into three shape modes to pick large and small flat, narrow cylindrical, triangular and spherical objects. The 10-g few centimeters gripper, lifts loads up to 5 N, 50 times its weight. We also present an under-actuated prototype, demonstrating the versatility of our design and actuation methods

Rotorigami: A rotary origami protective system for robotic rotorcraft

Applications of aerial robots are progressively expanding into complex urban and natural environments. Despite remarkable advancements in the field, robotic rotorcraft is still drastically limited by the environment in which they operate. Obstacle detection and avoidance systems have functionality limitations and substantially add to the computational complexity of the onboard equipment of flying vehicles. Furthermore, they often cannot identify difficult-to-detect obstacles such as windows and wires. Robustness to physical contact with the environment is essential to mitigate these limitations and continue mission completion. However, many current mechanical impact protection concepts are either not sufficiently effective or too heavy and cumbersome, severely limiting the flight time and the capability of flying in constrained and narrow spaces. Therefore, novel impact protection systems are needed to enable flying robots to navigate in confined or heavily cluttered environments easily, safely, and efficiently while minimizing the performance penalty caused by the protection method. Here, we report the development of a protection system for robotic rotorcraft consisting of a free-to-spin circular protector that is able to decouple impact yawing moments from the vehicle, combined with a cyclic origami impact cushion capable of reducing the peak impact force experienced by the vehicle. Experimental results using a sensor-equipped miniature quadrotor demonstrated the impact resilience effectiveness of the Rotary Origami Protective System (Rotorigami) for a variety of collision scenarios. We anticipate this work to be a starting point for the exploitation of origami structures in the passive or active impact protection of robotic vehicles

Towards understanding of climbing, tip-over prevention and self-righting behaviors in Hexapoda

Die vorliegende Dissertation mit dem Titel “Towards understanding of climbing, tip-over prevention and self-righting behaviors in Hexapoda” untersucht in drei Studien exemplarisch, wie (i) Wüstenameisen ihre Beine einsetzen um An- und Abstiege zu überwinden, wie (ii) Wüsten- und Waldameisen ein Umkippen an steilen Anstiegen vermeiden, und wie sich (iii) Madagaskar-Fauchschaben, Amerikanische Großschaben und Blaberus discoidalis Audinet-Servill, 1839 aus Rückenlagen drehen und aufrichten. Neuartige biomechanischen Beschreibungen umfassen unter anderem: Impuls- und Kraftwirkungen einzelner Ameisenbeine auf den Untergrund beim Bergauf- und Bergabklettern, Kippmomente bei kletternden Ameisen, Energiegebirge-Modelle (energy landscapes) zur Quantifizierung der Körperform für die funktionelle Beschreibung des Umdrehens aus der Rückenlage

Smart Sensing in Advanced Manufacturing Processes: Statistical Modeling and Implementations for Quality Assurance and Automation

With recent breakthroughs in sensing technology, data informatics and computer networks, smart manufacturing with intertwined advanced computation, communication and control techniques promotes the transformation of conventional discrete manufacturing processes into the new paradigm of cyber-physical manufacturing systems. The cybermanufacturing systems should be predictive and instantly responsive to incident prevention for quality assurance. Thus, providing viable in-process monitoring approaches for real-time quality assurance is one essential research topic in cybermanufacturing system to allow a closed-loop control of the processes, ensure the quality of products, and consequently improve the whole shop floor efficiency. However, thus far, such in-process monitoring tools are still underdeveloped on the following counts: • For precision/ultraprecision machining processes, most sensor-based change detection approaches are reticent to the anomalies since they largely root in the stationary assumption whilst the underlying dynamics under precision machining processes exhibit intermittent patterns. Therefore, existing approaches are feeble to detect subtle variations which are detrimental to the process; • For shaping processes that realize complicated geometries, currently there is no viable tool to allow a noncontact monitoring on surface morphology evolution that measures critical dimensioning criteria in real time. • For precision machining processes, we aim to present advanced smart sensing approaches towards characterizations of the process, specifically, microdynamics reflecting the fundamental cutting mechanisms as well as variations of microstructure of the material surfaces. To address these gaps, this dissertation achieves the following contributions: • For precision and ultraprecision machining processes, an in-situ anomaly detection approach is provided which allows instant prevention from surface deterioration. The method could be applied to various (ultra)precision processes of which most underlying systems are unknow and always exhibit intermittency. Extensive experimental studies suggest that the developed model can detect in-situ anomalies of the underlying dynamic intermittency; • For shaping processes that require noncontact in-process monitoring, a vision-based monitoring approach is presented which rapidly measures the geometric features during forming process on sheet-based workpieces. Investigations into laser origami sheet forming processes suggest that the presented approach can provide precise geometric measurements as feedback in real time for the control loop of the sheeting forming processes in cybermanufacturing systems. • As for smart sensing for precision machining, an advanced in-process sensing/ monitoring approach [including implementations of Acoustic Emission (AE) sensor, the associated data acquisition system and developed advanced machine/deep learning methods] is introduced to connect the AE characteristics to microdynamics of the precision machining of natural fiber reinforced composites. The presented smart sensing framework shows potentials towards real-time estimations/predictions of microdynamics of the machining processes using AE features

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

Developing Design and Analysis Framework for Hybrid Mechanical-Digital Control of Soft Robots: from Mechanics-Based Motion Sequencing to Physical Reservoir Computing

The recent advances in the field of soft robotics have made autonomous soft robots working in unstructured dynamic environments a close reality. These soft robots can potentially collaborate with humans without causing any harm, they can handle fragile objects safely, perform delicate surgeries inside body, etc. In our research we focus on origami based compliant mechanisms, that can be used as soft robotic skeleton. Origami mechanisms are inherently compliant, lightweight, compact, and possess unique mechanical properties such as– multi-stability, nonlinear dynamics, etc. Researchers have shown that multi-stable mechanisms have applications in motion-sequencing applications. Additionally, the nonlinear dynamic properties of origami and other soft, compliant mechanisms are shown to be useful for ‘morphological computation’ in which the body of the robot itself takes part in performing complex computations required for its control. In our research we demonstrate the motion-sequencing capability of multi-stable mechanisms through the example of bistable Kresling origami robot that is capable of peristaltic locomotion. Through careful theoretical analysis and thorough experiments, we show that we can harness multistability embedded in the origami robotic skeleton for generating actuation cycle of a peristaltic-like locomotion gait. The salient feature of this compliant robot is that we need only a single linear actuator to control the total length of the robot, and the snap-through actions generated during this motion autonomously change the individual segment lengths that lead to earthworm-like peristaltic locomotion gait. In effect, the motion-sequencing is hard-coded or embedded in the origami robot skeleton. This approach is expected to reduce the control requirement drastically as the robotic skeleton itself takes part in performing low-level control tasks. The soft robots that work in dynamic environments should be able to sense their surrounding and adapt their behavior autonomously to perform given tasks successfully. Thus, hard-coding a certain behavior as in motion-sequencing is not a viable option anymore. This led us to explore Physical Reservoir Computing (PRC), a computational framework that uses a physical body with nonlinear properties as a ‘dynamic reservoir’ for performing complex computations. The compliant robot ‘trained’ using this framework should be able to sense its surroundings and respond to them autonomously via an extensive network of sensor-actuator network embedded in robotic skeleton. We show for the first time through extensive numerical analysis that origami mechanisms can work as physical reservoirs. We also successfully demonstrate the emulation task using a Miura-ori based reservoir. The results of this work will pave the way for intelligently designed origami-based robots with embodied intelligence. These next generation of soft robots will be able to coordinate and modulate their activities autonomously such as switching locomotion gait and resisting external disturbances while navigating through unstructured environments