Soft actuator and agile soft robot

Robots play an important part in many aspects of our society by doing repetitive, dangerous, or precision tasks. Most existing robots are made of rigid components, which lack passive compliance and pose a challenge in adapting to the environment and safe human-robot interaction. Rigid robots may be equipped with sensors and programmed with proprioceptive feedback control to achieve active compliance, but this may fail in the event of unforeseen situations or sensor failure. In contrast, animals have evolved flexible or soft body parts to help them adapt to changing environments. Soft robotics is an emerging field in robotics, drawing inspiration from nature by integrating soft material into the actuator and mechanical design. With the inclusion of soft material, soft actuators and robots can deform actively/passively, making it possible to sense, absorb impact, and adapt to its environment with deformation. However, while soft actuators/robots have superior properties to rigid ones, they are often challenging to manufacture and control precisely. In addition, they may suffer from slow speed and material degradation. Thus, in this thesis, we aim to address the issues in developing high-performance soft actuators and soft robots. The thesis is divided into two parts. In the first part, we focus on improving the manufacturability and performance of a self-contained soft actuator originated in the Creative Machines Lab. The soft actuator is composed of a cured silicone-ethanol mixture embedded with heating coils. When the coils are electrically actuated, ethanol trapped inside undergoes liquid-vapor transitions, and thus the actuator undergoes extreme volume change. While this actuator exhibits high strain and high stress, it is very slow to actuate, has limited life cycles, and requires molds to manufacture. The first part of the thesis will address these issues. Specifically, in chapter 2, we discuss using multi-material 3D printing to automate the manufacturing of silicone-ethanol composite. In chapter 3, we discuss using laser-cut flexible Kirigami patterns to improve the manufacturability of its heating element. Chapter 4 characterizes its actuation profile and addresses improvements to the thermal conductivity by infusing thermally conductive fillers. Soft actuation is an actively researched area; however, many high-performance soft actuators are challenging to manufacture and thus are less accessible to the general robotics community. Conventional actuators such as electric motors are widely available but lack flexibility. Therefore, the second part of the thesis aims at combining rigid motors with soft materials to design and control high-performance hybrid soft robots. Simulation is a good way to evaluate and optimize robot design and control. However, existing simulators that support motor-driven soft robots have limited features. Chapter 5 discusses this issue and presents a physically based real-time soft robot simulator capable of simulating motor-driven soft robots. In addition, chapter 5 presents the design and control of a 3D printed hybrid soft quadruped robot. Chapter 6 presents the design and control of a 3D printed hybrid soft humanoid robot. The two parts of the thesis aim to improve aspects in soft actuators and soft robots. In conclusion, we summarize the lessons learned in developing soft actuators/robots and new possibilities and challenges for advancing soft robotics research

A Massively-Parallel 3D Simulator for Soft and Hybrid Robots

Simulation is an important step in robotics for creating control policies and testing various physical parameters. Soft robotics is a field that presents unique physical challenges for simulating its subjects due to the nonlinearity of deformable material components along with other innovative, and often complex, physical properties. Because of the computational cost of simulating soft and heterogeneous objects with traditional techniques, rigid robotics simulators are not well suited to simulating soft robots. Thus, many engineers must build their own one-off simulators tailored to their system, or use existing simulators with reduced performance. In order to facilitate the development of this exciting technology, this work presents an interactive-speed, accurate, and versatile simulator for a variety of types of soft robots. Cronos, our open-source 3D simulation engine, parallelizes a mass-spring model for ultra-fast performance on both deformable and rigid objects. Our approach is applicable to a wide array of nonlinear material configurations, including high deformability, volumetric actuation, or heterogenous stiffness. This versatility provides the ability to mix materials and geometric components freely within a single robot simulation. By exploiting the flexibility and scalability of nonlinear Hookean mass-spring systems, this framework simulates soft and rigid objects via a highly parallel model for near real-time speed. We describe an efficient GPU CUDA implementation, which we demonstrate to achieve computation of over 1 billion elements per second on consumer-grade GPU cards. Dynamic physical accuracy of the system is validated by comparing results to Euler-Bernoulli beam theory, natural frequency predictions, and empirical data of a soft structure under large deformation

Conductive Fabric Heaters for Heat-Activated Soft Actuators

We examine electrically conductive fabrics as conductive heaters for heat-activated soft actuators. We have explored various fabric designs optimized for material properties, heat distribution and actuation/de-actuation characteristics of the soft actuators. We implemented this approach in the silicone/ethanol composite actuators, in which ethanol undergoes a thermally-induced phase change, leading to high actuation stress and strain. Various types of conductive fabrics were tested, and we developed a stretchable kirigami-based fabric design. We demonstrate a fabric heater that is capable of cyclic heating of the actuator to the required 80 °C. The fabric with the special kirigami design can withstand temperatures of up to 195 °C, can consume up to 30 W of power, and allows the actuator to reach >30% linear strain. This technology may be used in various systems involving thermally-induced actuation