This paper aims to present the integrated design, development, and testing procedures for a state-of-the-art torsion-based series elastic actuator that could be reliably employed for long-term use in force-controlled robot applications. The main objective in designing the actuator was to meet weight and dimensional requirements whilst improving the long-term durability, ensuring high torque output, and containing its total weight. A four-fold design approach was implemented: (i) following recursive design-and-test procedures, an optimal torsional spring topology was unveiled with the help of SIMP (Solid Isotropic Material with Penalization) topology optimization method, (ii) the proposed spring was manufactured and multiple specimens were experimentally tested via a torsional test machine to validate linearity, loading rate response, and mechanical limits, (iii) the actuator’s thermal response was experimentally scrutinized to ensure that the generated heat was dissipated for long-term use, and (iv) the fatigue life of the spring was computed with the help of real-life experiment data. Having concluded the development and verification procedures, two different versions of the actuator were built, and preliminary torque control experiments were conducted. In conclusion, favorable torque tracking with a bandwidth of 19 Hz was achieved while peak-to-peak torque input was 20 Nm.

本文旨在介绍最先进的基于扭力的串联弹性执行器的集成设计、开发和测试程序，该执行器可以可靠地用于力控制机器人应用的长期使用。设计执行器的主要目标是满足重量和尺寸要求，同时提高长期耐用性，确保高扭矩输出，并控制其总重量。实施了四重设计方法：（i）遵循递归设计和测试程序，借助 SIMP（带惩罚的固体各向同性材料）拓扑优化方法，揭示了最佳扭转弹簧拓扑，（ii）提出的弹簧制造并通过扭转试验机对多个试样进行实验测试，以验证线性度、加载速率响应、和机械限制，(iii) 对执行器的热响应进行了实验检查，以确保产生的热量在长期使用中消散，以及 (iv) 弹簧的疲劳寿命是在实际实验数据的帮助下计算的。完成开发和验证程序后，构建了两个不同版本的执行器，并进行了初步的扭矩控制实验。总之，在峰值扭矩输入为 20 Nm 的情况下，实现了带宽为 19 Hz 的有利扭矩跟踪。构建了两种不同版本的执行器，并进行了初步的扭矩控制实验。总之，在峰值扭矩输入为 20 Nm 的情况下，实现了带宽为 19 Hz 的有利扭矩跟踪。构建了两种不同版本的执行器，并进行了初步的扭矩控制实验。总之，在峰值扭矩输入为 20 Nm 的情况下，实现了带宽为 19 Hz 的有利扭矩跟踪。