High Actuation Force Research Articles

4D printing of liquid crystal elastomer composites with continuous fiber reinforcement

Multifunctional composites have been continuously developed for a myriad of applications with remarkable adaptability to external stimuli and dynamic responsiveness. This study introduces a 4D printing method for liquid crystal elastomer (LCE) composites with continuous fibers and unveils their multifunctional actuation and exciting mechanical responses. During the printing process, the relative motion between the continuous fiber and LCE resin generates shear force to align mesogens and enable the monodomain state of the matrix materials. The printed composite lamina exhibits reversible folding deformations that are programmable by controlling printing parameters. With the incorporation of fiber reinforcement, the LCE composites not only demonstrate high actuation forces but also improved energy absorption and protection capabilities. Diverse shape-changing configurations of 4D composite structures can be achieved by tuning the printing pathway. Moreover, the incorporation of conductive fibers into the LCE matrix enables electrically induced shape morphing in the printed composites. Overall, this cost-effective 4D printing method is poised to serve as an accessible and influential approach when designing diverse applications of LCE composites, particularly in the realms of soft robotics, wearable electronics, artificial muscles, and beyond.

Modeling magnetic soft continuum robot in nonuniform magnetic fields via energy minimization

The emerging magnetic soft continuum robots (MSCRs) – a type of slender and soft rods with embedded hard-magnetic particles – hold great promise in endovascular intervention via remote magnetic actuation. Although numerous advantages of using permanent magnets have been demonstrated for manipulating MSCRs (e.g., simple systems with high actuation force, large operating workspace), the magneto-mechanical behavior of MSCRs in nonuniform magnetic fields, particularly those generated by permanent magnets, remains largely unexplored. In this work, a systematic study of MSCRs in the nonuniform field is presented, which includes theoretical modeling using hard-magnetic elastica theory, numerical analyses by energy minimization method, finite element simulations using ABAQUS user element (UEL), and experimental validation. Without solving governing differential equations, the large deflection of MSCRs is efficiently obtained via the minimization of the total potential energy using sequential quadratic programming (SQP). This efficient modeling method offers insights into the control of MSCRs using nonuniform magnetic fields. Two practical strategies are provided for precisely controlling MSCRs by manipulating a cubic magnet through the adjustment of the actuation distance, rotation angle, and spin angle, laying the foundation for applications of magnetically-assisted endovascular intervention.

Dual-Responsive MXene-Functionalized Wool Yarn Artificial Muscles.

Fiber-based artificial muscles are promising for smart textiles capable of sensing, interacting, and adapting to environmental stimuli. However, the application of current artificial muscle-based textiles in wearable and engineering fields has largely remained a constraint due to the limited deformation, restrictive stimulation, and uncomfortable. Here, dual-responsive yarn muscles with high contractile actuation force are fabricated by incorporating a very small fraction (<1wt.%) of Ti3C2Tx MXene/cellulose nanofibers (CNF) composites into self-plied and twisted wool yarns. They can lift and lower a load exceeding 3400 times their own weight when stimulated by moisture and photothermal. Furthermore, the yarn muscles are coiled homochirally or heterochirally to produce spring-like muscles, which generated over 550% elongation or 83% contraction under the photothermal stimulation. The actuation mechanism, involving photothermal/moisture-mechanical energy conversion, is clarified by a combination of experiments and finite element simulations. Specifically, MXene/CNF composites serve as both photothermal and hygroscopic agents to accelerate water evaporation under near-infrared (NIR) light and moisture absorption from ambient air. Due to their low-cost facile fabrication, large scalable dimensions, and robust strength coupled with dual responsiveness, these soft actuators are attractive for intelligent textiles and devices such as self-adaptive textiles, soft robotics, and wearable information encryption.

Dielectric elastomers with large actuation strain and high output force

AbstractDielectric elastomer actuator (DEA) is considered as an ideal artificial muscle with soft and light in nature, widespread application in soft robotics and sensors. Dielectric elastomer (DE), the core component of DEA, with high output force and large actuation strain under relatively low driving electric field is critical for high‐performance DEA. However, the widely used VHB series (3M) DE suffered from very large pre‐strain and high driving voltage to get their high actuation performance, limiting their scope of application. In this work, the DEs with good mechanical and dielectric properties were prepared via UV curing method consisting of acrylic acid (AA) with strong polar groups as functional monomer, n‐butyl acrylate (BA) as soft monomer and urethane acrylate as cross‐linker (c‐p(BA‐AA)). The c‐p(BA‐AA) DE films obtained the simultaneous increasing of dielectric constant and breakdown strength with the increasing content of AA, which guaranteed the good actuation performance. The c‐p(BA‐AA) film exhibited excellent actuating performance (44.11% actuation strain at 45 kV/mm) without pre‐strain. Besides, a simple linear actuator based on the c‐p(BA‐AA) film could easily output weight that is tens of times of its own active weight (654.1 mN/g at 30 kV/mm).

Design and modelling of a reversible shape memory alloy torsion hinge actuator

Conventional hinge actuators often face limitations including excessive weight, large size and unpleasant noise. Shape memory alloys (SMAs) offer a solution to address these issues due to their favorable characteristics, such as lightweight, high actuation force and small form factor. However, most existing SMA-based hinge actuators rely on the tension loading mode. Achieving an ideal actuation angle thereby necessitates the inclusion of long SMA wires, which inadvertently constrains the actuator size. Notably, the full potential of SMAs’ deformation capacities, encompassing torsion and bending, remains largely untapped and underutilized.In this research, a reversible torsion SMA hinge actuator is studied, which can reversibly open 60° during heating and cooling. The actuator weighs 2 g, and can produce actuation forces of up to 5 N. The mechanical performances of nitinol at different temperatures are measured. Based on the measurements, a model which can predict the opening and closing angle is proposed, with deviations of 13.5 ± 8.2 %. Gripper and butterfly demonstrators constructed by the hinge actuators are given as application examples. The actuators hold potential in many fields like soft robotics, aerospace and medical instruments.

Thermo-Pneumatic Artificial Muscle: Air-Based Thermo-Pneumatic Artificial Muscles for Pumpless Pneumatic Actuation.

To make robots more human-like and safer to use around humans, artificial muscles exhibiting compliance have gained significant attention from researchers. However, despite having excellent performance, pneumatic artificial muscles (PAMs) have failed to gain significant traction in commercial mobile applications due to their requirement to be tethered to a pneumatic source. This study presents a thermo-PAM called Thermo-PAM that relies on heating of a volume of air to produce a deformation. This allows for pneumatic actuation using only an electrical power source and thus enables pumpless pneumatic actuation. The actuator uses a high ratio between the heating volume and the deformable volume to produce a high actuation force throughout its entire motion and can produce either contractile or extension motions. The controllability of the actuator was demonstrated as well as its ability to handle heavy payloads. Moreover, it is possible to rely on either positive or negative pressure actuation modes where the positive pressure actuation mode actuates when heated and the negative pressure actuation mode relaxes when heated. The ability to use Thermo-PAMs for different modes of actuation with different operation methods makes the proposed actuator highly versatile and demonstrates its potential for advanced pumpless robotic applications.

Nasal steroid spray simulations using measured spray characteristics in healthy and rhinitic nasal passages

Intranasal corticosteroid sprays (ICSs) are frequently prescribed for allergic rhinitis (AR), which is the fifth most common chronic disease in the United States. This study aimed to investigate how the intranasal distribution of ICSs is affected by spray characteristics, patient use factors, and anatomical variation. Three-dimensional reconstructions of the nasal cavity were created from computed tomography (CT) scans of one healthy subject and one AR patient. A virtual spray nozzle was positioned in the nasal vestibule according to package insert instructions and subtracted from the nasal airspace. Hybrid tetrahedral-prism meshes were created and spray simulations were conducted in ANSYS Fluent™ with inspiratory airflow present and spray characteristics from in vitro experiments. Changes in regional corticosteroid deposition with variations in spray product, actuation force, inhalation rate, spray cone angle, nozzle insertion depth, nozzle position, and nasal side were assessed. The simulation results demonstrated that, in both models, target site deposition was mostly affected by changes in nozzle position and anatomy (left vs. right nostril). In the healthy subject, target site deposition increased with a higher actuation force, higher inhalation rate, and smaller nozzle depth, but was not significantly affected by changes in the spray cone angle. In the AR patient, target site deposition was not significantly different for changes in actuation force, inhalation rate, nozzle depth, or cone angle. The findings of this numerical study suggest that the intranasal distribution of ICSs is influenced mostly by nozzle position and nasal anatomy.

Photocontrollable Elongation Actuation of Liquid Crystal Elastomer Films with Well-Defined Crease Structures.

Although liquid crystal elastomers (LCEs) have demonstrated various applications in artificial muscles and soft robotics, their inherent flexibility and orientation-dependent forces limit their functions. For instance, LCEs can sustain a high actuation force when they contract but cannot elongate to drive loads with large displacements. In this study, it is demonstrated that photocontrollable elongation actuation with a large strain can be achieved in polydomain LCEs by programming the crease structures in a well-defined order to couple the actuation forces. Efficient photoactuation without overheating-induced damage to the materials is favored, based on the well-designed photosensitive molecular switch crosslinker via the synergy of photochemical and photothermal effects. The LCE actuator can jack up heavy loads, elongate freely, and contract back to manipulate distant objects. Theoretical analysis based on a finite element simulation of the deformation energy during the actuation process reveals a trade-off between the abilities of jacking-up and withstanding load. More importantly, this study simplifies the design of a single material with functions inherent only in other soft robotic devices based on the assembly of multiplemodules, thus providing a design strategy for surpassing instinctive properties of conventional soft materials to expand the functions of soft robotics.

Dried bonito flakes-inspired moisture-responsive actuator with a gradient structure for smart devices

Exploring high-performance soft actuators from biomass resources is significant for developing eco-friendly smart devices. Dried bonito (DB) flake is a common food as well as a biomass material, and it can produce irregular motion in changed moisture, just like dancing. Inspired by this intriguing phenomenon, a cost-effective, biocompatible, and biodegradable moisture-responsive DB film actuator with a gradient structure is developed. The DB film actuator exhibits rapid and reversible bending deformation triggered by a humidity gradient with a high bending speed (40° s–1) and a maximum bending angle (180°). Moreover, the DB film actuator shows large bending deformation (–71° to +51°) with a high actuation force (214.7 Pa) in response to changes in relative humidity. Furthermore, the actuation performance can be also tuned by adjusting the thickness of the film. Potential applications of this actuator, including smart grippers, crawling robots, and biomimetic flowers for visible humidity sensing, are demonstrated. More importantly, smart sweat-responsive wearables that automatically deform to promote sweat evaporation and convection during exercise are constructed based on the actuator, making it promising for adaptive personal thermal management. This work offers an easily processable, cost-effective, and environmentally benign strategy to construct moisture-responsive actuators for future eco-friendly smart devices.

Magneto-viscoelasticity of hard-magnetic soft-elastomers: Application to modeling the dynamic snap-through behavior of a bistable arch

Hard-magnetic soft-elastomeric materials show great potential for use in applications where the ability of remote actuation, together with high-flexibility and low-weight are important. One promising type of magnetic-actuator made from such a material is a bistable arch which can harness snap-through instabilities for short response times and high actuation forces. In this paper we formulate a continuum finite-deformation theory for magneto-viscoelasticity of hard-magnetic soft-elastomeric materials. We have numerically implemented the theory in a finite element program. We show that our theory, when suitably calibrated, can reproduce the results from several magnetically-induced snap-through experiments on a bistable arch reported recently by Tan et al. (2022). Finally, we demonstrate the broader usefulness of our theory and its numerical implementation by successfully simulating the complex and reversible magnetically-induced snap-through eversion of a hemispherical shell.

A Hydrogel-Based Self-Sensing Underwater Actuator.

Soft robots made of hydrogels are suited for underwater exploration due to their biocompatibility and compliancy. Yet, reaching high dexterity and actuation force for hydrogel-based actuators is challenging. Meanwhile, real-time proprioception is critical for feedback control. Moreover, sensor integration to mimic living organisms remains problematic. To address these challenges, we introduce a hydrogel actuator driven by hydraulic force with a fast response (time constant 0.83 s). The highly stretchable and conductive hydrogel (1400% strain) is molded into the PneuNet shape, and two of them are further assembled symmetrically to actuate bi-directionally. Then, we demonstrate its bionic application for underwater swimming, showing 2 cm/s (0.19 BL/s) speed. Inspired by biological neuromuscular systems’ sensory motion, which unifies the sensing and actuation in a single unit, we explore the hydrogel actuator’s self-sensing capacity utilizing strain-induced resistance change. The results show that the soft actuator’s proprioception can monitor the undulation in real-time with a sensitivity of 0.2%/degree. Furthermore, we take a finite-element method and first-order differential equations to model the actuator’s bending in response to pressure. We show that such a model can precisely predict the robot’s bending response over a range of pressures. With the self-sensing actuator and the proposed model, we expect the new approach can lead to future soft robots for underwater exploration with feedback control, and the underlying mechanism of the undulation control might offer significant insights for biomimetic research.

Modeling, design and control of normal-stressed electromagnetic actuated fast tool servos

The normal-stressed electromagnetic actuated fast tool servo (FTS) plays an important role in modern ultra-precision manufacturing due to its high actuation force density and fast dynamics response. In order to promote the design and control of the normal-stressed electromagnetic actuated FTS, this paper proposes a comprehensive dynamics model based on the principles of magnetic equivalent circuits, which can be described as a Hammerstein-like structure. The electromagnetic phenomena, including hysteresis, magnetic saturation, and eddy currents, as well as the coupling between electromagnetic and mechanical dynamics are explicitly represented in the model. Based on a simplified version of this model, an integrated optimal design method for simultaneously determining actuator and mechanism parameters of the FTS is developed with full consideration of various practical physical limitations, which is then systematically verified through the finite element analysis (FEA). Afterwards, the comprehensive model of the assembled FTS prototype is identified and experimentally verified with a two-step identification strategy. Finally, a dual-loop control scheme is employed to improve tracking accuracy while suppressing the hysteresis and lightly damped resonance. Both open-loop and closed-loop performance of the FTS prototype validate the feasibility and effectiveness of the proposed model and methods.

Macro-Mini Linear Actuator Using Electrorheological-Fluid Brake for Impedance Modulation in Physical Human–Robot Interaction

Robots designed to interact physically with humans are typically characterized by low impedance and low output force, but in many circumstances, high force is needed. Integrated to a high-torque velocity source, antagonistic designs of electrorheological (ER)-fluid or magnetorheological (MR)-fluid clutches enabled a range of achievable impedances for rotational uses. This letter presents an alternative novel concept of linear actuator which uses a rotary ER-fluid brake to engage the highly backdrivable unit to the high force unit. The end effector driven by a mini motor is connected to the brake rotor. Since the brake rotation allows the relative translation between the endpoint and the high-force actuator, the mechanical impedance can be modulated by controlling the brake friction through the applied voltage. The ER-fluid brake using multiple concentric cylinders for high torque-to-inertia ratio was characterized experimentally. The macro-mini linear actuator with an intrinsic failsafe can be applied for active body weight support systems requiring antigravity high force.

Modelling and mechanical design of a flexible tube-guided SMA actuator

Shape memory alloy (SMA) wires are excellent candidates for wearable actuators since they are thin, low weight and have a high actuation force. The main drawbacks are that the wire should be kept straight and needs to be relatively long to enable a large enough actuation stroke. Embedding the SMA wire in a flexible tube largely enhances its applicability since then the counter forces are transferred by the tube material and the tube can be rolled up or attached to flexible surfaces or clothing layers. The performance of such tube-guided SMA actuators is, however, more complicated since it not only depends on the SMA behaviour but also on the tube materials and the actuator construction.In this research, a simple end-state model for a tube-guided SMA actuator system is proposed. We measure and model both the SMA and tube material properties, including tube creep effects, and derive an approximate prediction for the actuator stroke. Validation experiments showed that the predicted stroke during the second heating and cooling experiments agreed well with the measurements and that the average deviation is 9.6%, even though the deviation is much larger (27.3%) for the maximum applied force.

Simultaneous damping and tracking control of a normal-stressed electromagnetic actuated nano-positioning stage

Normal-stressed electromagnetic actuated (NSEA) nano-positioning stage has become more and more promising in various fields due to its high actuation force density and large motion range. However, the intrinsic hysteresis of the actuator and the lightly-damped resonance of the mechanism hinder the stage for the high-accuracy and high-speed applications. To handle these two problems, the damping and tracking controllers are commonly adopted, as the inner and outer loops, respectively, to design a dual-loop controller. However, the existing sequential design approach limits the achievable performance of the controller. This paper proposes a simultaneous optimization approach for a dual-loop controller with the inner loop positive acceleration, velocity, and position feedback (PAVPF) damping controller and the outer loop proportional-integral (PI) tracking controller. The objective is to obtain a flat closed-loop frequency response with a large control bandwidth, and the parameters of the inner and outer loops are tuned simultaneously. Both the damping ratio and stiffness of the vibration mode are improved, and the obtained ± 3 dB control bandwidth exceeds the first resonant frequency of the open-loop system. Experiments are carried out on a custom designed NSEA nano-positioning stage. The tested bandwidth of the simultaneously optimized system agrees well with the theoretical one, and is 188.9% higher than that of the sequentially designed system. Step response tests, triangular wave tracking tests, and hysteresis reduction tests also demonstrate the effectiveness and advancement of the proposed approach.

Micro-Range Actuation by Pressure-Induced Elastic Deformation of 316L Steel Membranes Produced by Laser Powder Bed Fusion

In this paper, fundamental research is performed on membrane type actuators made out of 316L stainless steel, manufactured with Laser powder bed fusion (LPBF). A total of six membranes with membrane thicknesses ranging from 0.6 mm up to 1.2 mm were scanned using a high precision metrology system to measure the membrane for displacement at different actuating pressures. The membranes were furthermore investigated for roughness, porosity and thickness. This showed that the thinnest membranes skewed in the print direction when actuated. The remaining membranes achieved higher specific displacements than finite element simulations (FES) predicted, due to surface roughness and porosity. Membrane type actuators can be used for precise actuation within the micrometre range. LPBF allows the creation of internal pockets and membranes in a single metal piece. In opposition to the more commonly used polymers for membrane-type actuators, LPBF steel printed parts offer high stiffness and actuation force. However, due to limitations of the LPBF process on thin walls, large deviations from FES occur. In this paper, a CAD and FES compensation strategy is suggested, which makes future, more complex and effective, designs possible.

Piezoelectric Normally Open Microvalve with Multiple Valve Seat Trenches for Medical Applications

Microfluidic systems for medical applications necessitate reliable, wide flow range, and low leakage microvalves for flow path control. High design complexity of microvalves increases the risk of possible malfunction. We present a normally open microvalve based on energy-efficient piezoelectric actuation for high closing forces and micromachined valve seat trenches for reliable valve operation. A comprehensive investigation of influencing parameters is performed by extensive fluidic 3D finite element simulation, derivation of an analytical closed state leakage rate model, as well as fabrication and test of the microvalve. Additional valve seat coating and a high force actuator are introduced for further leakage reduction. The microvalve has a wide-open flow range as well as good sealing abilities in closed state. Extensive fatigue tests of 1 × 106 actuation cycles show that additional coating of the valve seat or increased actuator strength promote sealing performance stability. Analytical calculations of leakage are suitable to estimate experimentally obtained leakage rates and, along with computational fluidic dynamic (CFD) simulations, enable future microvalve design optimization. In conclusion, we demonstrate that the presented normally open microvalve is suitable for the design of safe and reliable microfluidic devices for medical applications.

T-Flex: A fully flexure-based large range of motion precision hexapod

Six degree of freedom manipulation provides full control over position and orientation, essential for many applications. However, six degree of freedom parallel kinematic manipulators (e.g. hexapods) either have a limited range of motion combined with a good repeatability when comprising flexure joints, or they have limited repeatability with a large workspace when using traditional rolling- or sliding-element bearings. In this paper, the design and optimization of a fully flexure-based large range of motion precision hexapod robot is presented. The flexure joints have been specifically developed for the purpose of large range of motion and high support stiffness for this manipulator. The obtained system allows for ±100 mm of translational and more than ±10° of rotational range of motion in each direction combined with a footprint of 0.6 m2 and a height of 0.4 m. Furthermore, a dedicated flexure-based design for the actuated joints combines high actuation forces with the absence of play and friction, allowing for accelerations exceeding 10 g. Experiments on a prototype validate the sub-micron repeatability, which is merely limited by the selected electronics.

Design and dynamic modeling of a continuum and compliant manipulator with large workspace

This paper focuses on the design and dynamic modeling of a novel multi-section continuum and compliant robotic manipulator with large workspace. In large scales, many of the design techniques and actuator types which have proved advantageous in creating continuum robots at smaller scales are not applicable. Fluidic muscles, a class of pneumatic muscle actuators (PMAs) with large scale movements, high actuation forces and compliant nature, are utilized in the design of the continuum manipulator. However, these actuators are capable of applying axial contracting forces and cannot produce bending movements. Moreover, their asymmetric hysteresis nonlinearity causes difficulties in the accurate control procedure. These drawbacks are addressed in the design and presented model of the manipulator. The presented model is based on constant curvature method and concentrated masses. The Bouc–Wen hysteretic function is modified to describe the asymmetric force/length hysteresis of the utilized PMAs in this model. Experimental results show that the proposed model has a proper performance to characterize the asymmetric hysteresis loop of the actuators. Finally, the design and dynamic model of the robot are validated experimentally on the implemented manipulator.

A Moisture‐Driven Actuator Based on Polydopamine‐Modified MXene/Bacterial Cellulose Nanofiber Composite Film

AbstractAs a new 2D material, MXene (Ti3C2Tx) shows great potential as a smart multifunctional humidity‐responsive actuator due to its high hydrophilicity and conductivity but suffers from ambient oxidation and mechanical brittleness. Inspired by the mussels, the authors overcome these weaknesses by designing and fabricating a nacre‐like and lamellar‐structured composite film that consists of polydopamine‐modified MXene and bacterial cellulose nanofibers, which shows improved properties as a moisture‐driven actuator. The actuator has high conductivity (2848 S cm–1), excellent tensile strength (406 MPa), and toughness (15.3 MJ m–3). Moreover, the actuator is highly sensitive to moisture with the advantages of fast response (1.6 s), large deformation (176°), and high actuation force output (6.5 N m–2). It is additionally demonstrated that the actuator works as the electrical switch, robotic arm, and motor in a moisture‐driven manner. Overall, it is believed that this work improves the drawbacks of current MXene‐based actuators, laying the groundwork for their wider applications as moisture‐driven devices.