Modern industry benefits from the automation capabilities and flexibility of robots. Consequently, the performance depends on the individual task, robot and trajectory, while application periods of several years lead to a significant impact of the use phase on the resource efficiency. In this work, simulation models predicting a robot’s energy consumption are extended by an estimation of the reliability, enabling the consideration of maintenance to enhance the assessment of the application’s life cycle costs. Furthermore, a life cycle assessment yields the greenhouse gas emissions for the individual application. Potential benefits of the combination of motion simulation and cost analysis are highlighted by the application to an exemplary system. For the selected application, the consumed energy has a distinct impact on greenhouse gas emissions, while acquisition costs govern life cycle costs. Low cycle times result in reduced costs per workpiece, however, for short cycle times and higher payloads, the probability of required spare parts distinctly increases for two critical robotic joints. Hence, the analysis of energy consumption and reliability, in combination with maintenance, life cycle costing and life cycle assessment, can provide additional information to improve the resource efficiency.

Variable elastic actuators are very promising for applications in physical human–robot interaction. Besides enabling human safety, such actuators can support energy efficiency, especially if the natural behavior of the system is exploited. In this paper, the power and energy consumption of variable stiffness actuators with serial elasticity is investigated analytically and experimentally. Besides the fundamental mechanics, the influence of friction and electrical losses is discussed. A simple but effective stiffness control method is used to exploit the corresponding knowledge of natural dynamics by tuning the system to antiresonance operation. Despite nonlinear friction effects and additional electrical dynamics, the consideration of the ideal mechanical dynamics is completely sufficient for stiffness control. Simulations and experiments show that this yields a distinct reduction in power and energy consumption, which underlines the suitability of the control strategy.

For people with lower limb amputation, a user-specific human-machine interaction with their prostheses is required to ensure safe and comfortable assistance. Especially during dynamic turning manoeuvres, users experience high loads at the stump, which decreases comfort and may lead to long-term tissue damage. Preliminary experiments with users wearing a configurable, passive torsional adaptor indicate increased comfort and safety achieved by adaptation of torsional stiffness and foot alignment. Moreover, the results show that the individual preference regarding both parameters depend on gait situation and individual preference. Hence, measured loads in the structure of the prosthesis and subjective feedback regarding comfort and safety during different turning motions are considered in a user-specific human-machine interaction strategy for a prosthetic shank adaptor. Therefore, the interrelations of gait parameters with optimal configuration are stored in an individual preference-setting matrix. Stiffness and foot alignment are actively adjusted to the optimal parameters by a parallel elastic actuator. Two subjects reported that they experienced appropriate variation of stiffness and foot alignment, a noticeable reduction of load at the stump and that they could turn with less effort.

This paper proposes a probabilistic approach for the design of elastic elements to be used in structure-controlled variable stiffness actuators (VSA) for robotic applications. Considering the natural dynamics of the elastic actuation system, requirements are defined and material selection as well as geometry calculation are performed using lumped parameter models. Monte Carlo simulations are integrated in the design procedure to ensure a robust implementation of the required dynamical characteristics. Thereby, effects of uncertainties that might be caused by manufacturing or deviations of material properties are taken into account. To validate the suitability of the overall approach and the particular methods, a torsional elastic element is implemented and experimentally evaluated. The evaluation shows a fulfillment of the key requirements, i.e., specific natural dynamic behavior, that is only achieved due to considering uncertainties. Further, the transferability of the approach to other structure-controlled elastic actuators is discussed and implications are given. Only the governing equations of stiffness properties in certain load situation need to be adapted, e.g., from torsion to bending. Due to the simple transfer, the proposed probabilistic and model-based approach is promising for application to various actuator concepts with structure-controlled variable stiffness.