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The article focuses on the problem of mechanisms’ co-design for robotic systems to perform adaptive physical interaction with an unstructured environment, including physical human robot interaction. The co-design means simultaneous optimization of mechanics and control system, ensuring optimal behavior and performance of the system. Mechanics optimization refers to the search for optimal structure, geometric parameters, mass distribution among the links and their compliance; control refers to the search for motion trajectories for mechanism’s joints. The paper presents a generalized method of structural-parametric synthesis of underactuated mechanisms with closed kinematics for robotic systems for various purposes, e. g., it was previously used for the co-design of fingers’ mechanisms for anthropomorphic gripper and legs’ mechanisms for galloping robots. The method implements the concept of morphological computation of control laws due to the features of mechanical design, minimizing the control effort from the algorithmic component of the control system, which reduces the requirements for the level of technical equipment and reduces energy consumption. In this paper, the proposed method is used to optimize the structure and geometric parameters of the passive mechanism of the back support module of an industrial exosuit. Human movements are diverse and non-deterministic when compared with the movements of autonomous robots, which complicates the design of wearable robotic devices. To reduce injuries, fatigue and increase the productivity of workers, the synthesized industrial exosuit should not only compensate for loads, but also not interfere with the natural human motions. To test the developed exosuit, kinematic datasets from motion capture of an entire human body during industrial operations were used. The proposed method of structural-parametric synthesis was used to improve the ergonomics of a wearable robotic device. Verification of the synthesized mechanism was carried out using simulation: the passive module of the back is attached to two geometric primitives that move the chest and pelvis of the exosuit operator in accordance with the motion capture data. The ergonomics of the back module is quantified by the distance between the joints connecting the upper and bottom parts of the exosuit; minimizing deviation from the average value corresponds to a lesser limitation of the operator’s movement, i. e. greater ergonomics. The article provides a detailed description of the method of structural-parametric synthesis, an example of synthesis of an exosuit module and the results of simulation.

The paper is a study of the mathematical model and kinematics of a parallel spherical manipulator. This type of manipulator was proposed back in the 80s of the last century and has since found application in exoskeletons and rehabilitation robots due to its structure, which allows imitating natural joint movements of the human body.

The Parallel Spherical Manipulator is a robot with three legs and two platforms, a base platform and a mobile platform. Its legs consist of two support links that are arc-shaped. Mathematically, the manipulator can be described using two virtual pyramids that are placed on top of each other.

The paper considers two types of manipulator configurations: classical and asymmetric, and solves basic kinematic problems for each. The study shows that the asymmetric design of the manipulator has the maximum workspace, especially when the motors are mounted at the joints of the manipulator’s links inside legs.

To optimize the parameters of the parallel spherical manipulator, we introduced a metric of usable workspace volume. This metric represents the volume of the sector of the sphere in which the robot does not experience internal collisions or singular states. There are three types of singular states possible within a parallel spherical manipulator — serial, parallel, and mixed singularity. We used all three types of singularities to calculate the useful volume. In our research work, we solved the problem related to maximizing the usable volume of the workspace.

Through our research work, we found that the asymmetric configuration of the spherical manipulator maximizes the workspace when the motors are located at the articulation point of the robot leg support arms. At the same time, the parameter $\beta_1$ must be zero degrees to maximize the workspace. This allowed us to create a prototype robot in which we eliminated the use of lower links in legs in favor of a radiused rail along which the motors run. This allowed us to reduce the linear dimensions of the robot itself and gain on the stiffness of the structure.

The results obtained can be used to optimize the parameters of the parallel spherical manipulator in various industrial and scientific applications, as well as for further research of other types of parallel robots and manipulators.

This paper demonstrates the advantages of using artificial intelligence algorithms for the design of experiment theory, which makes possible to improve the accuracy of parameter identification for an elastostatic robot model. Design of experiment for a robot consists of the optimal configuration-external force pairs for the identification algorithms and can be described by several main stages. At the first stage, an elastostatic model of the robot is created, taking into account all possible mechanical compliances. The second stage selects the objective function, which can be represented by both classical optimality criteria and criteria defined by the desired application of the robot. At the third stage the optimal measurement configurations are found using numerical optimization. The fourth stage measures the position of the robot body in the obtained configurations under the influence of an external force. At the last, fifth stage, the elastostatic parameters of the manipulator are identified based on the measured data.

The objective function required to finding the optimal configurations for industrial robot calibration is constrained by mechanical limits both on the part of the possible angles of rotation of the robot’s joints and on the part of the possible applied forces. The solution of this multidimensional and constrained problem is not simple, therefore it is proposed to use approaches based on artificial intelligence. To find the minimum of the objective function, the following methods, also sometimes called heuristics, were used: genetic algorithms, particle swarm optimization, simulated annealing algorithm, etc. The obtained results were analyzed in terms of the time required to obtain the configurations, the optimal value, as well as the final accuracy after applying the calibration. The comparison showed the advantages of the considered optimization techniques based on artificial intelligence over the classical methods of finding the optimal value. The results of this work allow us to reduce the time spent on calibration and increase the positioning accuracy of the robot’s end-effector after calibration for contact operations with high loads, such as machining and incremental forming.

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.