The safety of human-robot interaction is an essential requirement for designing collaborative robotics. Thus, this paper aims to design a novel variable stiffness actuator (VSA) that can provide safer physical human-robot interaction for collaborative robotics. VSA follows the idea of modular design, mainly including a variable stiffness module and a drive module. The variable stiffness module transmits the motion from the drive module in a roundabout manner, making the modularization of VSA possible. As the key component of the variable stiffness module, a stiffness adjustment mechanism with a symmetrical structure is applied to change the positions of a pair of pivots in two levers linearly and simultaneously, which can eliminate the additional bending moment caused by the asymmetric structure. The design of the double-deck grooves in the lever allows the pivot to move freely in the groove, avoiding the geometric constraint between the parts. Consequently, the VSA stiffness can change from zero to infinity as the pivot moves from one end of the groove to the other. To facilitate building a manipulator in the future, an expandable electrical system with a distributed structure is also proposed. Stiffness calibration and control experiments are performed to evaluate the physical performance of the designed VSA. Experiment results show that the VSA stiffness is close to the theoretical design stiffness. Furthermore, the VSA with a proportional-derivative feedback plus feedforward controller exhibits a fast response for stiffness regulation and a good performance for position tracking.

In this paper, a novel mechatronic design philosophy is introduced to develop a compact modular rotary elastic joint for a humanoid manipulator. The designed elastic joint is mainly composed of a brushless direct current (DC) motor, harmonic reducer, customized torsional spring, and fail-safe brake. The customized spring considerably reduces the volume of the elastic joint and facilitates the construction of a humanoid manipulator which employs this joint. The large central hole along the joint axis brings convenience for cabling and the fail-safe brake can guarantee safety when the power is off. In order to reduce the computational burden on the central controller and simplify system maintenance, an expandable electrical system, which has a double-layer control structure, is introduced. Furthermore, a robust position controller for the elastic joint is proposed and interpreted in detail. Vibration of the elastic joint is suppressed by means of resonance ratio control (RRC). In this method, the ratio between the resonant and anti-resonant frequency can be arbitrarily designated according to the feedback of the nominal spring torsion. Instead of using an expensive torque sensor, the spring torque can be obtained by calculating the product of spring stiffness and deformation, due to the high linearity of the customized spring. In addition, to improve the system robustness, a motor-side disturbance observer (DOb) and an arm-side DOb are employed to estimate and compensate for external disturbances and system uncertainties, such as model variation, friction, and unknown external load. Validity of the DOb-based RRC is demonstrated in the simulation results. Experimental results show the performance of the modular elastic joint and the viability of the proposed controller further.

High-frequency injection (HFI) is widely adopted for the sensorless control of permanent magnet synchronous motors (PMSMs) at low speeds. However, conventional HFI strategies relying on fixed-frequency carrier modulation and square-wave injection concentrate current harmonic energy within narrow spectral bands, thereby inducing pronounced high-frequency motor vibrations and noise. To mitigate this issue, this paper proposes a noise suppression strategy based on synchronized periodic frequency modulation (PFM) of both the carrier and high-frequency square-wave signals. By innovatively synchronizing the periodic modulation of the triangular carrier in space vector pulse width modulation (SVPWM) with the injected high-frequency square wave, harmonic energy dispersion and noise reduction are achieved, substantially lowering peak acoustic emissions. First, the harmonic characteristics of the voltage-source inverter output under symmetric triangular carrier SVPWM are analyzed within a sawtooth-wave PFM framework. Concurrently, a harmonic current model is developed for the high-frequency square-wave injection method, enabling the precise derivation of harmonic components. A frequency-synchronized modulation strategy between the carrier and injection signals is proposed, with a rigorous analysis of its harmonic suppression mechanism. The rotor position is then estimated via high-frequency signal extraction and a normalized phase-locked loop (PLL). Comparative simulations and experiments confirm significant noise peak attenuation compared to conventional methods, while position estimation accuracy remains unaffected. This work provides both theoretical and practical advancements for noise-sensitive sensorless motor control applications.

In this paper, a new controller for an operating manipulator work in the space microgravity environment is proposed. First, on the basis of the load variation caused by microgravity, a sliding mode control method is used to model the gravity term, and the logistic function is introduced as the approaching function. An improved sliding mode reaching law is proposed to control the manipulator effectively, and Lyapunov theory is used to deduce its closed-loop stability. A friction compensation scheme, which regards friction as disturbance, is introduced to the microgravity environment, and a space disturbance observer (SDO) is designed from the viewpoint of disturbance suppression to identify the friction characteristics of the control system accurately. To model the lagging friction phenomenon caused by velocity inversion during operation tasks, an adaptive compensation scheme based on the LuGre model is proposed. Finally, the design of a manipulator system, which consists of a robot arm, dexterous hand, teleoperation system, central controller, and visual system, is presented. On-orbit maintenance and capture experiments are carried out successively. The effectiveness and reliability of the controller are verified, and the on-orbit operation tasks are completed successfully.

This paper proposes the virtual reconfiguration method (VRM) to construct the unified framework for closed-form solutions of a special class of serial manipulators. Central to the research is the inverse kinematics problem (KP) of 6- and 7-DOF serial manipulators, which contain either the Pieper's geometry or the Duffy's geometry. Given the desired end-effector pose of the manipulator, a virtual single chain (SLC) is developed by connecting the base and the end-effector with a hypothetical link. The equivalent single open chain (SOC) with different configurations can be obtained by cutting open the virtual SLC at one link between adjacent joints. Kinematic equivalence between the original manipulator and the new SOC is proven. Closed-form solutions of the original manipulator can be determined by solving the KP of the equivalent SOC. The VRM is further developed on the basis of the relationship between the manipulator and its equivalent SOC. In this paper, the KPs of 6-DOF manipulators with the spherical wrist and manipulators with the three-axis parallel shoulder joint are analysed. Principles and applications of the VRM are proposed. Finally, the validity and efficiency of the VRM are demonstrated by kinematics simulations of four different manipulators. Unlike traditional approaches, the VRM simplifies the computation of KPs and establishes a unified framework for closed-form solutions of the special class of 6- and 7-DOF serial manipulators, irrespective of the allocation of either the Pieper's geometry or the Duffy's geometry.