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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.

In this paper, we discuss the procedure for finding nominal trajectories of the planar five-link bipedal robot with point contact. To this end we use a virtual constraints method that transforms robot’s dynamics to a lowdimensional zero manifold; we also use a nonlinear optimization algorithms to find virtual constraints parameters that minimize robot’s cost of transportation. We analyzed the effect of the degree of Bezier polynomials that approximate the virtual constraints and continuity of the torques on the cost of transportation. Based on numerical results we found that it is sufficient to consider polynomials with degrees between five and six, as further increase in the degree of polynomial results in increased computation time while it does not guarantee reduction of the cost of transportation. Moreover, it was shown that introduction of torque continuity constraints does not lead to significant increase of the objective function and makes the gait more implementable on a real robot.

We propose a two step procedure for finding minimum of the considered optimization problem with objective function in the form of cost of transportation and with high number of constraints. During the first step we solve a feasibility problem: remove cost function (set it to zero) and search for feasible solution in the parameter space. During the second step we introduce the objective function and use the solution found in the first step as initial guess. For the first step we put forward an algorithm for finding initial guess that considerably reduced optimization time of the first step (down to 3–4 seconds) compared to random initialization. Comparison of the objective function of the solutions found during the first and second steps showed that on average during the second step objective function was reduced twofold, even though overall computation time increased significantly.