Design, modeling, and control of a variable stiffness joint based on a torsional magnetic spring

Industrial robots have made it possible for robotics to become a worldwide discipline both in economy and in science. However, their capabilities are limited, especially regarding contact tasks where it is required to regulate or at least limit contact forces. At one point, it was noticed that elasticity in the joint transmission, which was treated as a drawback previously, is actually helpful in this regard. This observation led to the introduction of elastic joint robots that are well-suited to contact tasks and cooperative behavior in particular, so they become more and more widespread nowadays. Many researchers try to implement such devices not with trivial series elastic actuators (SEA) but with more sophisticated variable stiffness actuators (VSA) that can regulate their own mechanical stiffness. All elastic actuators demonstrate shock robustness and safe interaction with external objects to some extent, but when stiffness may be varied, it provides additional benefits, e.g., in terms of energy efficiency and task adaptability. Here, we present a novel variable stiffness actuator with a magnetic coupler as an elastic element. Magnetic transmission is contactless and thus advantageous in terms of robustness to misalignment. In addition, the friction model of the transmission becomes less complex. It also has milder stiffness characteristic than typical mechanical nonlinear springs, moreover, the stiffness curve has a maximum after which it descends. Therefore, when this maximum torque is achieved, the coupler slips, and a new pair of poles defines the equilibrium position. As a result, the risk of damage is smaller for this design solution. The design of the joint is thoroughly described, along with its mathematical model. Finally, the control system is also proposed, and simulation tests confirm the design ideas.