Proceedings of 2017 IEEE
International Conference on Mechatronics and Automation
August 6 - 9, Takamatsu, Japan
Mechanical Design of a Compact and Dexterous
Quadruped Robot
Jiang Yang, Wenchuan Jia*, Yi Sun, Huayan Pu,
Shugen Ma, Li Chen
Shanghai Key Laboratory of Intelligent Manufacturing and
Robotics
School of Mechatronic Engineering and Automation
Shanghai University
Shanghai, China
*Corresponding author: lovvchris@shu.edu.cn
Abstract –This manuscript introduced the modularized
structural design of a medium sized quadruped robot with desired
compact and dexterous mobility. In detail, the ball screw
transmission and the four-bar linkages mechanism were adopted
to construct the quadruped robot, and then the relationship
between the torque of the knee joint and the torque of the motor
was modelled and analyzed. Moreover, the mechanical
performance of transmission is analyzed, then the practical result
indicates that the shank should be configurated to get close as
much as possible to the limited position of extension while
walking. The loading analysis further showed that the structural
strength of each leg is still enough, when adding 200N external
force that similar to the whole weight of the robot to one foot.
Based on the optimized design, the mechanical prototype was
accomplished, and the corresponding control strategy were briefly
illustrated. Finally, locomotory planning in typical walking and
when the robot falls down were discussed preliminarily.
Index Terms – quadruped robot, structural design, dynamic
analysis, strength analysis, locomotion analysis.
I. INTRODUCTION
The legged robot has a very high performance to adapt to
varied terrains as compared to wheeled and tracked vehicles. It
will be an excellent movement platform for exploring the outer
planets, which motivates some teams to manage to develop the
robots that can work beyond laboratory products. The early
quadruped movement platform is GE Walking Truck made by
Mosher [1], which is car-sized and operated manually by using
the hydraulic actuator switches to control the machine. It is well
known that Hirose et al. developed TITAN series quadruped
robots [2-4], which can walk stably and has the excellent
robustness. Their configurations are mostly all sprawling type
different with the biomimetic principles. There are some well-
known biped robots, such as the NASA’s Valkyrie [5], the
Boston Dynamic’s Atlas [6], Honda’s ASIMO [7] and the
Toyota humanoid robot [8]. Their appearances are similar to
human, and they are all made by metals worked as the skeleton
and plastics worked as the shell, which has the excellent
structural reliability. And they all can walk and complete the
978-1-5090-6759-6/17/$31.00 ©2017 IEEE
Bin Han
the State Key Laboratory of Digital Manufacturing
Equipment and Technology
Huazhong University of Science and Technology
Wuhan, Hubei Province, China
binhan@hust.edu.cn
missions like opening doors or picking up some objects. The
Boston Dynamic’s BigDog [9][10], which is abandoned by the
US army owing to the loud noise, weighs about 109 kg, is about
1 meter tall, 1.1 meters long, 0.3 m wide, is driven hydraulically.
Compared with electricity, it has a larger power to weight ratio,
and the disadvantages are that it has a small movement of joint,
joint angular velocity is low, movement accuracy is not well,
and it is hard to control. Therefore the main solution for robot
power is electricity for the time being. To improve joint torque
driven by electricity, some teams have developed the actuator
of high torque density to be applied to their robots, such as
MIT’s cheetah 1[11] and cheetah 2 [12]. And the MIT teams
also came up with four design principles [13] for highly
efficient quadrupeds such as low impedance transmission and
low inertia leg. The Cheetah 1 weighs 33kg, and the Cheetah 2
is heavier. They both have better cost of transport (COT). Also,
Macro Hutter et al. developed scarlETH [14] and the follower
ANYmal [15]. ANYmal with series elastic actuation can move
more than 2 hours, the link length of ANYmal is 0.25m for
thigh and shank, a total weight is less than 30 kg, the main body
and the leg segments are built from aluminum and carbon fiber
to achieve this lightweight design. All these robots mentioned
above have demonstrated structural reliability and excellent
dynamic running on different grounds.
II. ROBOT SYSTEM DESIGN
A. Overview
The design of a sample mechanical topology with 12 DOF
for this robot that are linked by rigid mechanical components
is depicted in Fig. 1. With an approximate link length of 0.3m
for thigh and shank, and a total weight of about 22 kg, while
standing in the posture of the initial design, its length, width
and height are about 0.98m, 0.53m and 0.58m respectively, it
can be considered as a medium sized dog. It is constructed
modularly from a carbon fiber main body and four legs with
same structural and different layout. And the overall layout of
knee can be called backward bending type (BBT) while moving
left or forward bending type (FBT) while moving right. The
other two kinds of layouts are inward bending type (IBT),
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which is similar to “X” and conforms to one of the biomimetic
principles, and outward bending type (OBT) that knee joint is
away from the center of the body at the same time. The merits
of the layout for knee are that it is easier to step over obstacles
and its structure is more suitable.
1) Main body
In order to ensure the structural strength and reduce the
weight of the robot, carbon fiber is applied to the main body as
a skeleton. Control system, driving system, perception system,
communication system and power supporting system, which
will learn from the previous version of quadruped robot XDog
[16], will be configured in the main body. And detailed layout
of these hardware will be adjusted to suit the present version.
A real-time operating system is assembled in the middle carbon
fiber plate with hole-array. Twelve motor driving boards are
divided into two sets, and the two sets will be placed in carbon
fiber plate respectively which is closing to the motor. Three-
axis gyroscope module and three-axis accelerometer module
will be fixed in the place of robot center of mass (COM). WiFi
module is put on the surface of the main body so as to make
robot communicate with control handle easily. There are four
power supplies providing power for control system, driving
system, cooling system and trip breaker module separately.
Those power supplies are fixed in the bottom of the main body
so as to bring down the center of gravity (COG).
2) Leg structure.
As is depicted in Fig. 2, the joint arrangement of every leg
with three DOF is chosen mammalian with successive hip
abduction/adduction (HAA), hip flexion/extension (HFE), and
knee flexion/extension (KFE). The limitations of rotation angle
are the same in the same joint of different legs. The ranges of a
rotation angle of the KFE joint, the HFE joint and HAA joint
are respectively -49.42°～62.11°, -180°～180°and -147.92°～
147.92°. In order to guarantee the rotating torque of hip joint
as small as possible to make locomotion easier, we
appropriately optimize shapes and sizes of the elements. For
this robot, aluminum alloy parts are featured in the thigh to
Fig. 1 Structural overview of the robot in the posture of designing this robot.
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make the leg has enough the strength. The outer frame of a
shank with 3D printed ABS material shows nice appearance
and carbon fiber tube is embedded in the shank to ensure the
strength. The impact between foot and ground can be absorbed
by the rubber fixed at the end of the foot. Force sensor protected
by rubber and buckles in the ankle can perceive whether the
foot is on the ground. The weight of one leg is 4kg, and a total
weight of shank is 0.44kg. The merits of the mass ratio are that
the low weight of shank has a small moment of inertia so that
the knee joint can move easily and the rotating torque of the
HFE joint can be reduced since the COM of leg is closed to the
axis of the HFE joint. Three motors of per leg are all installed
in the hip, which is convenient to manage the circuits. And the
one end of the HAA motor is fixed at the HAA port. The HAA
port is fixed at the HAA cover. The other end of the HAA motor
is fixed with a clutch that can transmit the movement to the
reducer or ball screw. The installations of the HFE motor and
the KFE motor are the same as the installation of the HAA
motor. Cooling fans can take away the redundant heat from the
actuators by the vents of the ports and the covers around the
motors and will be fixed at one end of the ports. The planetary
gearbox with a reduction ratio of 10:1 is placed in the HAA
joint and the HFE joint to convert speed to torque. Noiseless
and high-speed ball screw is used as a transmission mechanism,
which is strikingly different from many quadruped robots. The
length of thigh can be easily changed by modifying the length
of the ball screw to create different size of the robot. And when
the robot is assembled, the sufficient preload is added in case
of bouncing up and down. Also, due to the nice encapsulation,
the robot can effectively prevent the sundries from getting into
the internal structure to affect transmission.
Fig. 2 Structural description of the leg. The part transparencies of the HAA
cover, the HFE cover and the KFE cover, including the outer frame of a shank,
are changed to see internal structures in the 3D model of this leg.
 Regarding the leg transmission system, friction is one of
the main reason of energy loss. Therefore, bearings and
lubricating oil are both put in the revolute joint to guarantee
locomotory efficiently. Collisions are the reason of energy loss
as well. The solution is to use an elastic material in the position
of inevitable impact and select high precision parts.
B. Transmission system of the leg
The transmission method of the HAA joint and the HFE
joint is relatively simple. It is driven directly by the motor and
reducer. A key to designing the transmission system is the
transmission of the KFE joint. As shown in Fig. 3, the
transmission method is that the rotational movement of motor
is converted to the rectilinear movement of a screw by ball
screw mechanism and the rectilinear movement propels the
movement of the four-bar linkages mechanism. The shank is
just a link of the four-bar linkages mechanism. Eventually, the
movement of the KFE joint can be attained.
In the process of the KFE joint transmission, its torque can
be obtained:
2 solution will be carried out to control the motors.
T=
T1 represents the torque of the KFE joint motor. L1
represents the distance between two revolute joints in the end
of the linkage3. θ2 represents the angle of the revolute joint
between linkage1 and linkage2. θ1 represents the angle of the
revolute joint between linkage2 and linkage3. η1 and η2 express
the transmission efficiency of the ball screw mechanism and
the four-bar linkages mechanism respectively. And L
represents the lead of the ball screw.
C. Foot sensor setup
Fig. 3 The simplified model of the KFE joint transmission.
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All the parts of foot and ankle apart from bolts and nuts
are shown in Fig. 4. The foot sensor is a strain gauge. It is in
the ankle. The angle between the shank axis and its axis is
30°.The peak force of its measurement is about 200N. The two
ends of the sensor are separately fixed on the part C and the
part G. And the two parts are both made by 3D printed ABS.
Two protective measures are designed for the sensor, which can
expand the measured value, one is that the part E made by
rubber shares some of the loads. Another one is that the buckles
connected by the bolts can resist most of the loads. And the
buckles are designed in the junction between the part C and the
part G. The part E and the part F are made by ABS. They are
used as the shell of the ankle and can restrict the movement of
the sensor and the part E. The part B made by rubber can cut
down the collision force while touching the ground. It packages
the part A which is made by ABS.
D. Joint actuator control
The twelve actuators of the robot are all the permanent
magnet synchronous motors (PMSM). And the following
Fixed point processor of TI C2000 Piccolo 60MHz is used
as microcontroller unit (MCU). It contains power management
module, three phase, full-bridge driving chip, three phase
current sampling module and communication ports. The
classical direct torque control of PMSM with feed forward is
applied to get the torque control, speed control and other
additional control methods. All the process of driving can be
depicted in Fig. 5. The motor driving board mainly consists of
the MCU, Three-phase inverter and communication ports. DSP
can communicate with MCU by the bus of RS485. The motor
can be protected by a temperature sensor.
E. Control system of the robot
The main hardware devices of the robot control system
are mentioned above. The core device of the robot control
system is the motion controller that consists of computer
using Windows 10 and the DSP running C program. The
motion controller can communicate with twelve motor
driving boards by multiple sets of the high speed serial bus
(HSSB) such as RS485. At the same time, the motion controller
can collect data signals from the force sensors, three-axis
gyroscope module and three-axis accelerometer module. The
foot sensors is used to detect whether the foot contacts the
ground. Three-axis gyroscope module is used to detect the
Fig. 4 The setup of the foot sensor.
 Fig. 5 The frame of motor driving.
body posture of the robot. Three-axis accelerometer module is
used to know the acceleration or the velocity of the robot. The
remote control module is used to transfer the user’s movement
instructions. And the remote control module consists of the
gamepad, the tablet and the WIFI module. Different gaits of the
robot's motion control algorithm are programed into the motion
controller. The desired gaits, such as trotting, jumping and
climbing, can be realized by that the remote control module
launches signals to the motion controller, the motion controller
can communicate with twelve motor driving boards, which
makes the twelve motors work together by multiple sets of high
speed serial bus (HSSB) after the motion controller collects the
signal of all the sensors.
III. MECHANICAL SYSTEM PERFORMANCE ANALYSIS
A. The analysis of body height adjustment
Body height adjustment of the robot is an essential process
when the robot walks into the short channel. This process needs
cooperative movement between the HFE joint and the KFE
joint so that the body can move up and down. And the change
of the height can be seemed as a uniform movement, which
leads to the torque constant in the HFE joint. Therefore, the
only KFE joint is analyzed in the process of the height
adjustment.
The layout method of the knee leads to the COM of the
robot different from the geometric center of the four foot ends
while standing in the posture of designing this robot. The load
of one foot is not a quarter of the robot gravity but a variant
while standing. Therefore the load of foot is set as 200N similar
to the limited value of the sensor and gravity of the robot
system when the mechanical performance is analyzed in
ADAMS software (see Fig. 6). And the force vector is both
perpendicular to the ground and the axis of the HFE joint. Also,
the plane formed by the center of the foot and the HFE joint
axis is also perpendicular to the ground. And all the constraints,
structures and materials of this model in a simulation are the
same as the prototype. The simulation time is the 40s.
During the simulation, the robot’s thigh axis is originally
perpendicular to the shank axis in the initial state. Then, the
shank extends to the limited position. Finally, the shank flexes
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Fig. 6 The movement of the KFE joint in a simulation.
to the limited position. As shown in Fig. 7, the angular velocity
of the motor is constantly 286.5 deg/s. The position of the
trough in the curve represents the limited position of the knee
extension. The safe distance value of the limited position is
0.004m. From the limited position of the stretch to that of the
flexion, the torque of the motor firstly increases to a certain
peak value which is 0.756 Nm, then falls. When it reaches the
peak, the distance value between the screw nut end and the
bearing end is about 0.08m. By the way, the range of the
distance value from the limited position of extension to flexion
of the shank is 0.004m-0.107m. However, the resultant force of
knee joint has been increasing from the limited position of
extension to the limited position of flexion. Those results show
that when the distance value between the screw nut end and the
bearing end is lower than 0.08m, the greater the degree of the
leg stretch is, the smaller the driving force of a motor is, the
smaller the force of knee is, and easier the robot walks.
B. Structural strength analysis.
For this robot, the shank and the below of the shank are
the relatively weak in strength because those constructions are
mainly made by ABS. As depicted in Fig. 7, the requirement
of structural strength is highest when the shank is at the limited
position of flexion under the same load. Therefore we use
Fig. 7 The change of motor angular velocity, the output torque of the motor,
the distance between the screw nut end cover and the bearing end cover, and
resultant force of knee in a period of motion.
 (a) (b)
Fig. 8 structural stress and strain analysis of the leg under a load of 200 N. (a) shows the structure of the leg, (b) shows the total deformation of the leg, (c)
shows the equivalent stress of the leg, (d) shows the equivalent stress of the foot sensor.
ANSYS software to analyze the static structure strength of the
shank and the below when the shank is at the limited position
of flexion as shown in Fig. 7. The load is the same as the
analysis of body height adjustment. And all the constraints,
structures and materials of this model in a simulation are the
same as the prototype.
As shown in Fig. 8(a) and Fig. 8(b), three carbon fiber
tubes are embedded in the cyan transparent parts as the skeleton
to ensure the structural strength of shank. The cyan transparent
parts and the two parts at the two ends of the cyan transparent
parts are connected by three carbon fiber tubes with bolts. It
can cause gaps at the two ends of the cyan transparent parts
when given a load. The maximum deformation appears at the
end of the foot. The value is 0.022m. Such a large deformation
is up to the gaps and the properties of the material. The purpose
of the shank design is to bring spring elements to reduce the
collision while given a big load in case of the motor broken.
As shown in Fig. 8(c), the maximum stress value is
1.86GPa in the carbon fiber tubes, which is less than the yield
strength of this material. The stress value of the other parts is
less than strength of their material. The stresses in the carbon
fiber tubes, knee joint and three rods are similar as the
expectation. Therefore the number of rod is three rather than
one or two, and the material is structural steel. The construction
of the shank is made by the 3D printed ABS and the carbon
fiber with high strength, which is the weak position. Those
position of parts can be replaced by the material of higher
strength to adapt the greater load.
The stress of the foot sensor is shown in Fig. 8(d), we
found that the buckles can share partial load for the sensor,
which proves that structural design is workable. And the load
is changed in 10N, 50N and 100N. We found that the foot
(a) (b)
Fig. 9 The posture planning of standing up after the robot falls. (a) is the arbitrary posture (AP). (b) is the prostrating posture (PP). (c) is the half-squat posture
(HP). (d) is the standing posture (SP).
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(c) (d)
sensor is always the place of having largest stress in the ankle.
The buckles do not work, and the load is afforded by the rubber
and the sensor under the lower pressure. When the load get
higher, the buckles can share load for sensor. As a result, the
contact between foot and ground can be effectively detected by
the sensor. When the load is about 200N, the maximum stress
of the sensor is about 49MPa, which is less than the yield
strength of steel.
IV. LOCOMOTION ANALYSIS
A. Posture planning of the standing up after falling
Owing to the sudden trip of the robot or the slippery
ground, the robot may tumble. When it tumbles, the large
concussion will trigger the motor protection device to make the
whole driving system cut off, which means the joint is in a state
of free rotation. Consequently, the robot will have a lot of
postures after it tumbles. In order to reduce the difficulty of the
design of the standing algorithm when the robot falls, we will
change the structure of the body, so that it will not be lying on
the ground and the legs will not be completely suppressed by
the body. It is only a possible case, which is called arbitrary
posture (AP) as is shown in Fig. 9(a). It is prostrating posture
(PP) as shown in Fig. 9(b), which means the abdomen is in
closed contact with the ground. Fig. 9(c) shows a half-squat
posture (HP) which the four shanks are in full contact with the
ground and the abdomen just touches the ground. Fig. 9(d)
shows a normal standing posture (SP). No matter what the
posture of the fall is, the robot will stand by the AP to the PP,
then to the HP and finally to the SP.
The biggest problem during the process of standing is that
the turning torque is limited, which is the main reason that the
robot can’t directly rotate from any falling posture to the
(c) (d)
 (a) (b)
Fig. 10 The typical locomotory scenarios for the robot. (a) is opening the door. (b) is stepping over the obstacles. (c) is moving in the factory. (d) is climbing
stairs.
standing posture. The solutions we adopt here are the vibration
rotation (VR) and exploratory vibration rotation (EVR). VR is
when the robot joint rotates to the desired pose, if it has
encountered some obstacles, the driving torque will reach a
specific value, which will trigger the vibration rotation. A small
amplitude vibration signal will be given to the motor to make
the joint vibrate while turning to the target posture. EVR is
when the torque of the vibration joint of the robot is close to
the limited safety torque of the motor, the joint of the robot
can’t move towards the planning posture, then the robot can try
to make the joints of other legs or different joints of one leg
move to adjust the posture to make the blocked joints rotate
easily so as to make the robot turn to the planning posture.
Then, how the robot stands from falling would be
discussed. In the AP, four KFE joints are driven firstly to the
limit position of the flexion, then the HAA joint and the HFE
joint of each leg cooperate to drive simultaneously to turn the
robot posture into the PP. Four legs move in turn. If the torque
isn’t enough or the joint is stuck, then the above solutions
should be implemented. It also should be noted that when the
robot is lying on the ground, the structure of the HFE joint will
not interfere with the ground when the HAA joint rotates in a
rotatable angle. And the robot abdomen is a frame which will
be improved into an elliptic cylinder which just touches the
ground during the HP. This structure can simplify the control
difficulty. From the PP to the HP, it is enough that the HFE joint
and the HAA joint drive simultaneous to the squat type. The
above process is relatively easy. It is also not difficult for the
robot to stand from the HP. We just need to make the KFE joint
and HFE joint driven simultaneous. Above all, we have
completed the whole process of the robot from falling to
standing.
B. Typical locomotory scenarios
The desired gaits of the robot are walking, trotting,
jumping and climbing in the interaction with the environment.
Due to its large range of motion, the robot can be supported by
its three legs, the rest of one leg can be used a mechanical arm
to complete a task, for example opening the door as shown in
Fig. 10(a). And the big size can make it step over small
obstructions as shown in Fig. 10(b).If the robot can be
controlled to move smoothly, it is no problem to put a cup of
tea on its main body, and the tea would not fall down. Therefore
the robot can be worked as a good movement platform to carry
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(c) (d)
the objects in the factory as shown in Fig. 10(c). As a proof of
high mobility, the robot can climb the stairs while crawling gait
is implemented as shown in Fig. 10(d).
V. CONCLUSION
In this paper, mechanical system of a medium sized
quadruped robot with desired compact and dexterous mobility
is designed. Several verified skills are adopted to accomplish
the structure design. The carbon fiber is applied to construct the
skeleton of the robot to reduce the weight and ensure the
structural strength. The shank with 3D printed ABS and carbon
fiber is designed to achieve low inertia to make the KFE joint
move smoothly. Aluminum alloy is used in the thigh to make
the leg has enough strength. Two kinds of protective
mechanism of the force sensor fixed in the ankle is designed to
keep the measurement range and safety, and the force detection
is sensitive owing to this design. The ball screw mechanism and
the four-bar linkages mechanism are adopted to realize the joint
movement. And the relationship between the knee joint torque
and the motor torque is analyzed. More stretch of the leg means
that the quadruped walking could be accomplished easier. And
the leg structure is rigid when suffering heavy load on the foot.
Also, the methods of vibration rotation and exploratory
vibration rotation are discussed. These methods would solve
the problems, such as lack of joint torque or block, which
occurred when the robot stands up from falling down. The
robot has the locomotion ability to accomplish some actual
tasks, for instance, open the door, climb stairs, step over the
obstacles and carry objects.
ACKNOWLEDGMENT
This work is partially supported by the National Natural
Science Foundation of China under Grant 51575329 and
51575332; Shanghai Science and Technology Development
Funds under Grant 17QA1401500 and 17ZR1410200.
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