Design of a Sensitive Balloon Sensor for Safe Human–Robot Interaction

As the safety of a human body is the main priority while interacting with robots, the field of tactile sensors has expanded for acquiring tactile information and ensuring safe human–robot interaction (HRI). Existing lightweight and thin tactile sensors exhibit high performance in detecting their surroundings. However, unexpected collisions caused by malfunctions or sudden external collisions can still cause injuries to rigid robots with thin tactile sensors. In this study, we present a sensitive balloon sensor for contact sensing and alleviating physical collisions over a large area of rigid robots. The balloon sensor is a pressure sensor composed of an inflatable body of low-density polyethylene (LDPE), and a highly sensitive and flexible strain sensor laminated onto it. The mechanical crack-based strain sensor with high sensitivity enables the detection of extremely small changes in the strain of the balloon. Adjusting the geometric parameters of the balloon allows for a large and easily customizable sensing area. The weight of the balloon sensor was approximately 2 g. The sensor is employed with a servo motor and detects a finger or a sheet of rolled paper gently touching it, without being damaged

Polyimide Encapsulation of Spider-Inspired Crack-Based Sensors for Durability Improvement

In mechanical sensory systems, encapsulation is one of the crucial issues to take care of when it comes to protection of the systems from external damage. Recently, a new type of a mechanical strain sensor inspired by spider’s slit organ has been reported, which has incredibly high sensitivity, flexibility, wearability, and multifunctional sensing abilities. In spite of many of these advantages, the sensor is still vulnerable in harsh environments of liquids and/or high temperature, because it has heat-vulnerable polyethylene terephthalate (PET) substrate without any encapsulation layer. Here, we present a mechanical crack-based strain sensor with heat, water and saline solution resistance by alternating the substrate from polyester film to polyimide film and encapsulating the sensor with polyimide. We have demonstrated the ability of the encapsulated crack-based sensor against heat, water, saline solution damage through experiments. Our sensor exhibited reproducibility and durability with high sensitivity to strain (gauge factor above 10,000 at strain of two percent). These results show a new potential of the crack-based sensory system to be used as a wearable voice/motion/pulse sensing device and a high-temperature strain sensor

Effect of Metal Thickness on the Sensitivity of Crack-Based Sensors

Among many attempts to make a decent human motion detector in various engineering fields, a mechanical crack-based sensor that deliberately generates and uses nano-scale cracks on a metal deposited thin film is gaining attention for its high sensitivity. While the metal layer of the sensor must be responsible for its high performance, its effects have not received much academic interest. In this paper, we studied the relationship between the thickness of the metal layer and the characteristics of the sensor by depositing a few nanometers of chromium (Cr) and gold (Au) on the PET film. We found that the sensitivity of the crack sensor improves/increases under the following conditions: (1) when Au is thin and Cr is thick; and (2) when the ratio of Au is lower than that of Cr, which also increases the transmittance of the sensor, along with its sensitivity. As we only need a small amount of Au to achieve high sensitivity of the sensor, we have suggested more efficient and economical fabrication methods. With this crack-based sensor, we were able to successfully detect finger motions and to distinguish various signs of American Sign Language (ASL)

FEP Encapsulated Crack-Based Sensor for Measurement in Moisture-Laden Environment

Among many flexible mechanosensors, a crack-based sensor inspired by a spider’s slit organ has received considerable attention due to its great sensitivity compared to previous strain sensors. The sensor’s limitation, however, lies on its vulnerability to stress concentration and the metal layers’ delamination. To address this issue of vulnerability, we used fluorinated ethylene propylene (FEP) as an encapsulation layer on both sides of the sensor. The excellent waterproof and chemical resistance capability of FEP may effectively protect the sensor from damage in water and chemicals while improving the durability against friction

Foot Plantar Pressure Measurement System Using Highly Sensitive Crack-Based Sensor

Measuring the foot plantar pressure has the potential to be an important tool in many areas such as enhancing sports performance, diagnosing diseases, and rehabilitation. In general, the plantar pressure sensor should have robustness, durability, and high repeatability, as it should measure the pressure due to body weight. Here, we present a novel insole foot plantar pressure sensor using a highly sensitive crack-based strain sensor. The sensor is made of elastomer, stainless steel, a crack-based sensor, and a 3D-printed frame. Insoles are made of elastomer with Shore A 40, which is used as part of the sensor, to distribute the load to the sensor. The 3D-printed frame and stainless steel prevent breakage of the crack-based sensor and enable elastic behavior. The sensor response is highly repeatable and shows excellent durability even after 20,000 cycles. We show that the insole pressure sensor can be used as a real-time monitoring system using the pressure visualization program

Ultra-stable and tough bioinspired crack-based tactile sensor for small legged robots

Abstract For legged robots, collecting tactile information is essential for stable posture and efficient gait. However, mounting sensors on small robots weighing less than 1 kg remain challenges in terms of the sensor’s durability, flexibility, sensitivity, and size. Crack-based sensors featuring ultra-sensitivity, small-size, and flexibility could be a promising candidate, but performance degradation due to crack growing by repeated use is a stumbling block. This paper presents an ultra-stable and tough bio-inspired crack-based sensor by controlling the crack depth using silver nanowire (Ag NW) mesh as a crack stop layer. The Ag NW mesh inspired by skin collagen structure effectively mitigated crack propagation. The sensor was very thin, lightweight, sensitive, and ultra-durable that maintains its sensitivity during 200,000 cycles of 0.5% strain. We demonstrate sensor’s feasibility by implementing the tactile sensation to bio-inspired robots, and propose statistical and deep learning-based analysis methods which successfully distinguished terrain type