Design of a Compact Actuated Compliant Elbow Joint

Compactness is a valuable property in designs of assistive devices and exoskeletons. Current devices are large and stigmatizing in the eyes of the users. The cosmetic appearance will increase by reducing the size. The users want a device that is small enough to be worn underneath the clothes, so it becomes unnoticeable. The goals of this paper are (1) to provide an overview of the shape-changing-material-actuated large-deflection compliant rotational joints, (2) provide new introduced performance indicators that evaluate the designs on performance with respect to volume or weight and (3) design a compact active assistive elbow device as a case study. In order to reach these goals, two evolving fields of study are brought together that have great potential to reduce the size of exoskeletons: smart materials and compliant rotational joints. Smart materials have the ability to change their shape, which make them suitable as actuators. Compliant joints can be compact, since they are made out of one piece of material. An overview of shape-changing-material-actuated large-deflection compliant rotational joints is presented. Performance indicators are proposed to evaluate the existing designs and the prototype. As a case study a compact actuated rotational elbow joint is presented. An antagonistic actuator made from shape memory alloy wires is able to carry an external load and to actuate to move the arm to different positions. The compliant joint is optimized to balance the weight of the arm and to auto-align with the rotational axis of the human elbow joint. A prototype is able to generate a volume specific stall torque of 5.77 ⋅ 10³ Nm/m³, produces a work density of 7.27 ⋅ 10³ J/m³ based on volumes including isolation covers and the half-cycle efficiency of the device is 3.6%. The prototype is able to balance and actuate a torque of 1.1 Nm.