Design, optimisation and testing of a compact, inexpensive elastic element for series elastic actuators

This paper presents the development of a compact torsion spring for use as an elastic element in a lightweight series elastic actuator for an active orthosis. This orthosis is going to be utilised as an assistive device for motorically impaired stroke-patients. In the design a two-step optimisation strategy was implemented to meet all requirements for the torsion spring. The first step was to identify a promising topology for the element. In the second step, the shape was optimised based on a finite element model using two different optimisation methods in order to minimise the von Mises equivalent stresses. Four promising variants of the identified topology were extracted from these calculations, one of which was then chosen as the final design. A prototype was manufactured by a laser cutting process, which is a new procedure in the context of elastic elements for series elastic actuators. The calculation results were validated successfully by measurement of the spring properties of this prototype.