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Analysis of Bending Abilities of Soft Pneumatic ActuatorLecture Notes in Mechanical Engineering
Analysis of Bending Abilities of Soft Pneumatic ActuatorLecture Notes in Mechanical Engineering
Pneumatic Actuator
1 Introduction
Soft robotics is expected to achieve USD 4965.06 million in the year 2025 in market
value from USD 645.45 million in 2019, at compound annual growth rate (CARG) of
40.5% over the forecast period 2020–2025, and it has immense capabilities to offer in
the military and medical field. But conformability of the robots to the object of interest
having variation in size, shape, and orientation and new techniques for modeling and
simulating soft structures are required as the conventional solutions are inappropriate
for behavior of soft robots. In this context, many research works focused to develop
the response of SPAs with internal fluidic channels governed by its morphology and
the properties of the materials used in fabrication, but the analytical models were
created making assumptions which lead to inaccurate results. The objective of the
work was to create a model of the SPA with experimental testing of bending behavior
based on morphology and examine the results.
TPU due to its hyper elastic nature was selected for the fused deposition modeling
(FDM) of the actuator. Two prototypes were procured where the initial prototype
mimicked the human finger, and upon experimental testing, the second prototype
was procured with improved morphology for better bending. Solidworks and Abaqus
software were used, respectively, for modeling and simulation of pneumatic-based
soft actuator. The hyper elastic material was used for the analysis as it is best suited
for nearly incompressible and nonlinear elastic material such as in our case TPU.
The experimental and simulation models are executed for different range of pres-
sure. The safe loading range for pressure was found to be 0.01–0.05 MPa. The
bending angles of the gripper finger for each pressure from the safe loading range
were found to be 60°, 72°, 83°, 100°, and 121°, respectively. The bending angle of
the actuator with gravity load alone was found to be 43°. With the development of
various new manufacturing techniques and simulation software, the growth in field
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022 491
S. Kumar et al. (eds.), Recent Advances in Manufacturing Modelling and Optimization,
Lecture Notes in Mechanical Engineering,
https://doi.org/10.1007/978-981-16-9952-8_42
492 S. Chigurupati and J. Balaji
of soft robots is certainly bound to be exponential. This data can also be used to
create other types of end effectors for many other robotic applications. These next
generations soft robots are expected to replace and create jobs that traditional robots
in fields that they do not prevail in.
Bio-inspired design of soft structures has capability to match and exceed the extraor-
dinary multi-functioning of animals like starfish and octopus. Normally, conven-
tional robots are made up of material (i.e., metals, plastics) which has an elasticity
modulus more than the materials present in natural organisms (i.e., cartilage, muscle
tissue). Viscoelastic materials exhibit viscous and elastic property; hence, including
of viscoelastic materials will allow soft robotic structures to maintain stable and
steady motion during dynamic loading. While selecting materials to fabricate soft
actuators, it is crucial to identify fracture toughness, work energy density, and optimal
viscoelastic material features [1]. Ecoflex has a high elongation at break and low
young’s modulus. Hence, it is being used for fabricating soft, elastic, pressure actua-
tors, and medical applications due to its water repellency, low surface energy, thermal
stability, and chemical inertness [2].
SPAs are structures composed of a pneumatic chamber, a frame constraint struc-
ture, and a body made by compliant materials. The pneumatic chamber is used to
actuate the soft pneumatic actuator with deformation. The usage of SPA with its
compliance nature allows for less complex analytical modeling and material charac-
terization. Fabrics can be used in soft structures to improve stiffness, strength, and
durability [3].
The pneumatic actuator fabricated from elastomer (elastosil M4601) compared to
ecoflex 30 required 8× more pressure and 1.5× less change in volume [4]. Fabrics
which are strong increase durability and strength of the soft components, which is
valuable in soft structures, while fabrics which are elastic maintain elastic property
and enhance strength [5]. Bending soft actuators are made up of silicone rubber, and
a layer of strong fabric which is coated with silicone is attached to the underside
surface. This fabric layer helps actuators to not extend in horizontal direction and to
bend uniformly [6].
A wide range of multi-degree-of-freedom motions can be generated by using
different fabrics and their layered arrangements when a thin pneumatic actuator is
inserted between and inflated with pressurized air [7]. Dilibal et al. [8] compared
three different SPAs using additive manufacturing and observed the highest tensile
strength. Robinson et al. [9] used direct ink writing to 3D print the SPA model. Aliff
et al. [10] developed a flexible robotic arm and observed the square trajectory using a
compact control system. Elgeneidy et al. [11] have determined the bending abilities
of the SPA using regression and neural network modeling. Wang et al. [12] developed
a programmable pneumatic network actuator to perform complex operations. Dilibal
et al. [8] compared experimental models of three different pneumatic actuators with
Analysis of Bending Abilities of Soft Pneumatic Actuator 493
numerical models of the same. The numerical analysis was carried out in Marc
Mentat software tool. The analysis of the actuators (which are of TPU material) are
done based on three different mathematical models—(1) Neo-Hookean model, (2)
Mooney–Rivlin model, and (3) Ogden model (the formulae for the same are shown
below). Ogden model provides the best result that is like that of the experimental
analysis. Ogden model uses principal stretches to depict large deformations for hyper
elastic material models. The responses of both methods were equal when the applied
pressure is 0.1–0.5 MPa.
N
μk αk
WOgden model = . λ1 + λα2 k + λα3 k − 3
α
k=1 k
where
P is the relative differential air pressure,
θ is the braid angle,
b is the individual braid length,
n is the number of braids.
Polygerinos et al. [13] investigated the bending angle and the response force of
the actuators that are used in rehabilitation glove by finite element methods before
fabrication. The analytical model is compared to that of experimental model for veri-
fying the results obtained. The FEM analysis is carried out in Abaqus 6.11 Computer
494 S. Chigurupati and J. Balaji
Aided Engineering package. The stress on the actuator is observed as shown in Fig. 1.
The maximum bending angle was found to be 320 degrees which verifies the analyt-
ical value, and the maximum internal pressure was found to be 50 kPa. Robinson
et al. [9] have developed soft integrated sensors which respond to tactile sense. Elastic
moduli of silicone fabricated by different methods were analyzed. The value of elastic
modulus of casted silicone model at 100% strain is larger (nearly 109 kPa) than that
of 3D printed silicone (nearly 73 kPa) using direct ink writing (DIW). Aliff et al.
[10] developed a robotic arm having master–slave control and trajectory control. The
control system is processed by a PID controller. An analytical model confirms the
effectiveness of the system. Elgeneidy et al. [11] investigated a soft pneumatic actu-
ator at different values of input pressures, and the feedback is collected by the flex
sensors and pressure sensor that are inbuilt into the actuator. A high-speed camera is
used to capture the image of actuation and use it for video motion analysis in Kinovea
software. Later, this model was compared with a data-driven model resulting in same
output. Wang et al. [14] demonstrated a programmable pneu-net actuator, which was
analyzed for bending and twisting characteristics of the actuators by finite element
analysis and later verified experimental model. For geometric models, SolidWorks
2016 (Dassault Systems S.A) was used, and the thermo-models were meshed in
HyperMesh 13.0 (Altair) with C3D4H elements. The meshed models were then
imported into Abaqus 6.14-4 (Dassault Systems S.A) for FEA simulations. Design
of pneu-nets consists of two layers [15], top extensible layer and bottom inexten-
sible layer, and two types are designed, one is “slow pneu-net” (sPN) and another
“fast pneu-net” (fPN). The bending ability of soft actuator is undeniable, but the
stiffness of the soft actuator cannot be increased much; hence, this leads to limiting
the actuator to handle lighter objects [14]. The crawlers design [16] is bio-inspired
which has six legs and has symmetrical movement. This soft pneumatic actuator can
achieve two types of locomotion, one is locomotion by pushing the walls and another
locomotion on flat surface.
3 Fabrication
The ability to design and model soft actuators is particularly crucial because in soft
robotics the motion path is typically programmed in the design of the actuator. The
size and shape of the gripper for the SPA are decided by imitating the average size
of a human finger. In the process of deciding the final dimensions of the gripper, two
prototypes were fabricated. The gripper is attached to the robotic arm with the help
of the clamp and the base. The gripper is firmly attached to the clamp with the use
of adhesive.
Initially, the overall length of the gripper was decided to be 118 mm and the height
of the gripper to be 18 mm with width 10 mm. Besides the length and height of the
gripper, there are a number of other parameters such as chamber height, chamber
wall thickness, number of chambers, sidewalls, and the air hole. The first prototype
with the dimensions shown in the sectional view in Fig. 3 certain dimensions of the
parameters of the SPA such as chamber height, chamber wall thickness, number of
chambers, sidewalls, and the air hole after analysis is shown in Fig. 4 for the second
prototype.
As we are using FDM for fabrication of the SPA, research on the materials used in
FDM was done [1, 5, 6] and the commercial materials used in the FDM process
are poly lactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyethylene
terephthalate (PET), thermoplastic polyurethane (NYLON, TPU), and polycarbonate
(PC).
By comparing the properties of the materials listed above according to our appli-
cation, TPU is mostly used for flexible application, PLA is a rigid material as well
as ABS which is usually used for preparing mold for the resin, PET is heavier than
PLA and ABS, and comparing properties like elongation at break, impact resistance,
ease of printing, layer adhesion, and max stress. TPU material is selected based on
its higher impact resistance, higher elongation at break, heat resistance up to 80 °C,
high durability, decent max stress, and best flexibility compared to the rest.
ABS material is chosen as the material for the clamp and the base, as it is a very
rigid material and has a high load bearing capacity. Since the clamp and base undergo
less loads, this material was ideal solution. Also, fused deposition of ABS is very
common, and the parts manufactured using this are extremely precise.
498 S. Chigurupati and J. Balaji
4.2 Analysis
The hyper elastic soft materials such as TPU are sensitive to high loads. There is a
high possibility that the material fails in the process due to high loading. Hence, the
500 S. Chigurupati and J. Balaji
main objective of this present study is to find the safe loading range for the gripper
which is important, in our case the range of pressure. And from this range, we can
find the wrapping space in turn determines the size of the objects that the gripper can
hold from the bending angles of the individual fingers of the gripper. Therefore, with
the help of Abaqus CAE software, we ran simulations with different input pressures
to find out the safe loading range of pressure, bending angles, stress zones, and other
relevant parameters.
The results obtained about the parameters of the SPA which affects the perfor-
mance of the SPA in the process of selection of the gripper are explained in Table
1.
Due to the insufficient bending shown by the first Prototype, a new second Proto-
type is designed by altering certain dimensions of the parameters of the SPA such
as chamber height, chamber wall thickness, number of chambers, sidewalls, and the
air hole. By keeping the width and height of the gripper same, the overall length
was decreased to 87 mm to keep the number of chambers a whole number, and also
because in the experimental testing of the first prototype, it was observed that the
length of the first Prototype was more than required for the gripper holder. Thinner
walls lead to an increased force output and requires less pressure for the actuator to
reach max bending. The base of the SPA is made thick to facilitate one directional
bending.
The actuator fixed on the one end was applied with two loads, gravity load and
pressure load, where the gravity remains uniform throughout the testing of 9.81 N.
The pressure of 0.01 MPa was applied for case 1. We can observe the results in
Fig. 8, where Fig. 8a depicts the initial condition without any loads, Fig. 8b depicts
the deformation or bending of the actuator with gravity alone, and Fig. 8c depicts
the complete bending of the actuator for 0.01 MPa. The bending angle of an actuator
is defined as the angle between when the actuator is in initial position and the line
joining the ends of the actuator at complete bending. The bending angle for the Test
Case 1 with 0.01 MPa is 60 degrees.
The color-coding of the stress in the actuator is shown in Fig. 9, where Fig. 9a
depicts the color-coding of stress in the actuator for gravity alone and Fig. 9b depicts
Fig. 8 Abaqus view of SPA a at initial condition; b at only gravity loading; c at 0.01 MPa
502 S. Chigurupati and J. Balaji
Fig. 9 Color-coding of stress in the actuator a only gravity load b at 0.01 MPa
the color-coding of the stress for 0.01 MPa pressure. Observing Fig. 9b, we can
conclude that the load of 0.01 MPa pressure is under safe condition for working of
the actuator. Hence, we conclude the Test Case 1 with positive results.
The pressure of 0.02 MPa was applied for Test Case 2. We can observe the results
in Fig. 10, which depicts the complete bending of the actuator for 0.02 MPa. The
bending angle for the Test Case 2 with 0.02 MPa was found to be 72°, where a little
increase in the angle can be seen compared to the first case.
The color-coding of the stress in the actuator for 0.02 MPa pressure is shown
in Fig. 11. Observing Fig. 11, we can conclude that the load of 0.02 MPa pressure
is also under safe condition for working of the actuator and also the sides of the
air chambers are seen to turn into light blue indicating the increase in stress which
is very little; that is, the material of the actuator (TPU) can withstand the load of
0.02 MPa pressure as well. Hence, we conclude the Test Case 2 with positive results
and increase the pressure to 0.03 MPa pressure in the next Test Case.
The pressure of 0.03 MPa was applied for Test Case 3. We can observe the results
in Fig. 12, which depicts the complete bending of the actuator for 0.03 MPa. The
bending angle for the Test Case 3 with 0.03 MPa was found to be 83°, where a curve
shape can easily be visible.
The color-coding of the stress in the actuator is shown in Fig. 13, which depicts
the color-coding of the stress for 0.03 MPa pressure. Observing Fig. 13, we can
conclude that the load of 0.03 MPa pressure is also under safe condition for working
of the actuator and also the sides of the air chambers are seen to turn into light green
indicating the increase in stress which is little; that is, the material of the actuator
(TPU) can withstand the load of 0.03 MPa pressure as well. Hence, we conclude the
504 S. Chigurupati and J. Balaji
Test Case 3 with positive results and increase the pressure to 0.04 MPa pressure in
the next Test Case.
The pressure of 0.04 MPa was applied for Test Case 4. We can observe the results in
Fig. 14 which depicts the complete bending of the actuator for 0.04 MPa. The bending
angle for the Test Case 4 with 0.04 MPa was found to be 100°, where a curve shape
can easily be visible. We can observe that the air chambers touch each other in turn
pushing to create a force which makes the bending possible. The color-coding of the
stress in the actuator for 0.04 MPa pressure is shown in Fig. 15. Observing Fig. 15,
we can conclude that the load of 0.04 MPa pressure is also under safe condition for
working of the actuator and also the sides of the air chambers are seen to turn into
green evidently indicating the increase in stress; that is, the material of the actuator
(TPU) can withstand the load of 0.04 MPa pressure as well. Hence, we conclude the
Test Case 4 with positive results and increase the pressure to 0.05 MPa pressure in
the next Test Case.
The pressure of 0.05 MPa was applied for Test Case 5. We can observe the results
in Fig. 16, which depicts the complete bending of the actuator for 0.05 MPa. The
bending angle for the Test Case 5 with 0.05 MPa was found to be 121°.
The color-coding of the stress in the actuator for 0.05 MPa pressure is shown
in Fig. 17. Observing Fig. 17c which is cross-sectional view, we can conclude that
the load of 0.05 MPa pressure is under safe condition for working of the actuator
Fig. 17 Color-coding of stress in the actuator a at 0.05 MPa; b at 0.05 MPa with cross-sectional
view perpendicular to Z axis
considering the factor of safety and also the air chambers are seen to turn into green
at the middle and turn yellow and then orange toward the end evidently indicating
the increase in stress. Hence, we conclude the Test Case 5 with positive results.
As mentioned earlier, the pressure exerted by the air on to the inner cavity of the
SPA makes the hollow chambers to bulge, and in turn, the adjacent walls pushing
each other cause the actuator actuate in the uni-direction when one end of the SPA is
fixed. This phenomenon can be observed in Fig. 18, where with the help of view cut
manager, the cavity of the SPA is cut in Z-plane for better visualization. The applied
pressure, that is, 0.05 MPa for the soft pneumatic actuator, was observed to be under
the material’s limit.
The stress concentration is more at the center along the axis than at the ends.
The stress concentration is highest between the walls of the air chambers due to the
contact; hence, design of these chambers should be important. In Fig. 19, the color-
coding of the spatial displacements at nodes is shown. The displacements according
to Fig. 19 are less at the fixed end of the actuator and observed to increase along the
actuator length uniformly to reach the peak at the other end.
Hence, we conclude the results with range of safe pressure, bending angles of
the gripper finger for each pressure values applied from Test Case 1 to Test Case 5,
which in turn provides the wrap space of the gripper for working. The loading range
was found to be 0.01–0.05 MPa pressure as when we tried with 0.06 MPa pressure,
the material failed, hence 0.01–0.05 MPa being the safe loading range. The bending
angles of the gripper finger for each pressure loading are tabulated in Table 2. The
bending angle of the actuator with gravity load alone was found to be 43°.
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