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Leeds Thesis Template Phase Change Materials for Controllable Stiffness of Robotic Joints Bingyin Ma Submitted in accordance with the requirements for the degree of Doctor of Philosophy The University of Leeds Institute of Design, Robotics and Optimisation School of Mechanical Engineering September 2018 - ii - The candidate confirms that the work submitted is his own and appropriate credit has been given within the thesis where reference has been made to the work of others. This copy has been supplied on the understanding that it is copyright material and that no quotation from the thesis may be published without proper acknowledgement. © 2018 The University of Leeds and Bingyin Ma - iii - Acknowledgements Undertaking this PhD has been a life-changing experience for me and it would not be possible to do without the guidance and support I received from many people. I would like to thank my mom and dad for believing in me and always being there for me. I am forever indebted to my parents for giving me the opportunities and support that have made me who I am. Thank you to my mother, Zhang Li-Jun, for raising me, guiding me and encouraging me to explore new directions in life. This journey would not have been possible if not for you, and I dedicate this milestone to you, mom. I owe my deepest gratitude to my supervisor Professor Robert Richardson, you have been a tremendous mentor for me. Your guidance helped me in all the time of research and writing of this thesis. Without your enthusiasm, encouragement, support and continuous optimism this thesis could hardly have been completed. I could not have imagined having a better boss for my PhD study. To my friends, thank you for supporting me through this entire process. Special thanks to Jason Liu, Wang Qiang, Hongkai Ye and Farhan Maqbool for your friendship and generous help. Thank you, Marcy. Merci. - iv - Abstract Snake-like manipulators are well suited for operation in restricted and confined environments where the manipulator body can bend around obstacles to place an end effector at a difficult to access location. They require high stiffness when self-supporting weight against gravity and undertake precision manipulation task, but also require soft properties when operating in complex and delicate environments. A controllable stiffness manipulator has the potential to meet the application demands as it can switch between rigid and soft state. This thesis experimentally investigates the properties of four materials, (low melting point solder, hot-melt adhesive, low melting point alloy and granular material) as candidates for mechanically altering the stiffness of the joints/modules in snake-like manipulators. These materials were evaluated for bonding strength, repeatability, and activation time. Modules for a snake-like manipulator were fabricated using 3D printing and silicone casting techniques including, for the first time, variable stiffness joints that use hot-melt adhesive and low melting point alloy. These modules were evaluated for stiffness properties and low melting point solder based module was found to achieve a stiffness change 150X greater than the state of the art granular material approach. In addition, the proposed modules were able to support 25X of their own weight. - v - Table of Contents Acknowledgements .................................................................................... iii Abstract ....................................................................................................... iv Table of Contents ........................................................................................ v List of Tables ............................................................................................... x List of Figures ........................................................................................... xii List of Abbreviations ................................................................................ xxi Chapter 1 Introduction ................................................................................ 1 1.1 Introduction .................................................................................... 1 1.1.1 Snake-like Manipulator ........................................................ 1 1.1.2 Stiffness Modulation ............................................................ 3 1.2 Motivation for Research ................................................................. 4 1.3 Aims and Objectives....................................................................... 4 1.4 Statement of Contribution ............................................................... 4 1.5 Structure of Thesis ......................................................................... 5 Chapter 2 Literature Review ....................................................................... 7 2.1 Introduction .................................................................................... 7 2.2 Hard Manipulators .......................................................................... 8 2.2.1 Discrete Hyper-Redundant Manipulators ............................ 8 2.2.2 Continuum Manipulators ................................................... 11 2.3 Soft Manipulators ......................................................................... 20 2.4 Controllable Stiffness Robots ....................................................... 27 2.4.1 Antagonistic Principle-based Controllable Stiffness Robots ................................................................................. 28 2.4.2 Friction-based Controllable Stiffness Robots .................... 29 2.4.3 Electro- and Magneto- rheological Materials-based Controllable Stiffness Robots .............................................. 31 2.4.4 Thermorheological Materials-based Controllable Stiffness Robot .................................................................... 32 2.4.5 Granular Materials-based Controllable Stiffness Robot..... 34 2.5 Summary ...................................................................................... 36 Chapter 3 Material Selection and erterization ......................................... 38 3.1 Introduction .................................................................................. 38 3.2 Low Melting Point Solder (LMPS) ................................................ 41 3.2.1 Material Selection .............................................................. 41 3.2.2 Experimental Characterisation .......................................... 42 - vi - 3.2.2.1 Solidus Temperature .............................................. 42 3.2.2.2 Temperature-dependent of Bonding Strength ........ 43 3.2.2.3 Repeatability .......................................................... 45 3.3 Hot-Melt Adhesive (HMA) ............................................................. 47 3.3.1 Material Selection .............................................................. 47 3.3.2 Experimental Characterisation .......................................... 48 3.3.2.1 Solidus Temperature .............................................. 48 3.3.2.2 Temperature-dependent of Bonding Strength ........ 48 3.3.2.3 Adherend-dependent of Bonding Strength ............. 49 3.3.2.4 Repeatability .......................................................... 50 3.4 Low Melting Point Alloy (LMPA) ................................................... 51 3.4.1 Material Selection .............................................................. 51 3.4.2 Experimental Characterisation .......................................... 52 3.4.2.1 Solidus Temperature .............................................. 52 3.4.2.2 Elastic Modulus ...................................................... 52 3.5 Granular Materials (GM) ............................................................... 54 3.5.1 Material Selection .............................................................. 54 3.5.2 Elastic Modulus ................................................................. 55 3.6 Silicone Materials ......................................................................... 57 3.6.1 Strain Range of the Silicone Materials .............................. 57 3.6.2 Mechanical Properties Testing .......................................... 58 3.6.3 Hyperelastic Material Models ............................................ 61 3.6.4 Test Results ...................................................................... 63 3.7 Summary ...................................................................................... 66 Chapter 4 Design and Analysis of Single Module .................................. 67 4.1 Introduction .................................................................................. 67 4.2 Design and Analysis of Surface Bonding Modules ....................... 68 4.2.1 Mechanical Design of Single Modules............................... 68 4.2.1.1 Revolute Joint ........................................................ 68 4.2.1.2 Spherical Joint ........................................................ 71 4.2.2 Analysis of Surface Bonding Single Modules .................... 72 4.2.2.1 Bonding Torque ...................................................... 72 4.2.2.2 FEA Simulation on Strain Range ............................ 75 4.2.2.3 FEA Simulation on Bending Stiffness ..................... 77 4.3 Design and Analysis of Phase Change Modules .......................... 81 - vii - 4.3.1 Mechanical Design of Single Module ................................ 81 4.3.2 Design Optimization of the Bellows-like Structure ............. 84 4.3.3 Analysis of
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