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Design and Fabrication of an Elastomeric Unit for Soft Modular Robots in Minimally Invasive Surgery
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A compact variable stiffness joint for compliant robotics enabled by torsion-spring mean-diameter variation.

Xiangxu Qu1, Zhengkai Feng2, Kang Ju3

  • 1College of Mechanical and Electrical Engineering, Qingdao Binhai University, Qingdao, 266555, China.

Scientific Reports
|May 5, 2026
PubMed
Summary

This study introduces a novel variable-stiffness joint (TSDV) for robots, utilizing a torsion spring mechanism. The TSDV joint offers tunable stiffness for safer human-robot interaction and compliant actuation in various applications.

Keywords:
Compliant actuationHuman-robot interactionTorsion springVariable stiffness joint

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Area of Science:

  • Robotics
  • Mechanical Engineering
  • Control Systems

Background:

  • Robotic applications in rehabilitation, human-robot collaboration, and unstructured environments necessitate compliant and safe joint designs.
  • Existing variable-stiffness joints often face limitations in compactness, range of regulation, or control complexity.

Purpose of the Study:

  • To propose and validate a novel variable-stiffness joint design method (TSDV) based on torsion spring mechanics.
  • To achieve a compact, wide-range, and controllable variable-stiffness joint for robotic systems.

Main Methods:

  • Analysis of torsion spring mean coil diameter variation with joint deflection.
  • Development of a structural scheme constraining spring inner diameter for stiffness modulation.
  • Establishment of a nonlinear stiffness model using an energy-based method.
  • Verification through numerical simulations, finite-element analysis, and experimental testing of a TSDV prototype.

Main Results:

  • The TSDV joint exhibits tunable nonlinear stiffness and output torque characteristics.
  • Experimental results confirm passive and active stiffness regulation capabilities.
  • Demonstrated output torque range increase from 0-3.8 Nm to 0-9.2 Nm at 1.2 rad deflection.
  • Achieved a locking function, transitioning to a rigid joint when spring diameter variation is fully suppressed.

Conclusions:

  • The proposed TSDV variable-stiffness joint offers a compact structure and a large stiffness regulation range.
  • It provides a new approach for safe interaction and compliant actuation in robotic systems.
  • The joint features high control resolution and tunable stiffness for diverse robotic applications.