Design of a torsional stiffener for a cable-driven hyper-redundant robot composed of gear transmission joints

This work describes the advancement in developing a cable-driven gear transmission joint designed as a basic element for a long-reach hyper-redundant robot. Hyper-redundancy allows the robot to perform auxiliary tasks such as obstacle avoidance and joint limits satisfaction. This feature makes hyper-redundant robots particularly useful for performing tasks in confined and hazardous environments and areas that are not reachable by a human operator. The long-reach feature of the robot requires a detailed study of the overall structure and its components. The joint must be capable of transmitting forces and movements over a long distance without losing the precision and accuracy of the end-effector, so it is designed to optimise the robot’s performance in terms of stiffness, structural resistance, and functional characteristics. In light of the above considerations, the main focus of this work is to improve the structural performance of the entire robotic system. Consequently, since the most critical component of the robot in terms of torsional deformation is the gear transmission joint, this paper aims to design a torsional stiffener element to reduce its deformation and, thus, an increase of torsional stiffness of the overall robotic system. Tube-shaped and rectangular-shaped stiffener elements, which can fit the joint design satisfying its geometrical constraints, are proposed. A computer-aided engineering approach is implemented to improve the precision of positioning of the end-effector by adding stiffener elements in the joint. Two sensitivity analyses, varying the geometry of the proposed stiffener elements, are performed to evaluate their performance in terms of added mass and displacement reduction.