Torque sensing integration - strain gauge placement tips?

[rossi30]

I dealt with almost this exact situation. For dynamic walking and recovery, joint control bandwidth in the tens of Hz range is typically necessary to react to a stumble before the center of mass gets too far outside the support polygon. Quasi-direct drive (QDD) actuators use lower gear ratios (roughly 6:1 to 10:1) paired with high-torque-density motors, trading some peak force density for backdrivability and low reflected inertia, which matters a lot for impact tolerance and fall recovery.

[pierregreen]

Just to be precise about one thing: Cycloidal drives are a less common but real alternative to harmonic drives - lower cost at high ratios, decent efficiency, but historically bulkier for the same torque density, which is part of why they haven't fully displaced harmonic drives in commercial hips and knees.

[jwang]

@pierregreen Not sure I fully agree here. Torque sensing is frequently integrated directly into the actuator housing via strain gauges near the output flange or spring element, rather than bolted on as an external sensor, to save weight and reduce noise from mechanical slop. Harmonic drives use high reduction ratios (often around 100:1), which gives excellent force density, stiffness, and thermal endurance for continuous-duty lifting - the tradeoff is low backdrivability and some backlash.

[karen.chen3]

Slightly off-topic, but related: For dynamic walking and recovery, joint control bandwidth in the tens of Hz range is typically necessary to react to a stumble before the center of mass gets too far outside the support polygon.

[deborah59]

@karen.chen3 Short answer: Series elastic actuators add a spring element in series with the drivetrain, which gives cheap, precise torque sensing (measure spring deflection) and passive shock absorption, at the cost of reduced control bandwidth and added complexity.

[gimbalmar65]

Here's the relevant bit as far as I understand it: Harmonic drives use high reduction ratios (often around 100:1), which gives excellent force density, stiffness, and thermal endurance for continuous-duty lifting - the tradeoff is low backdrivability and some backlash. Anti-backlash techniques in production actuators range from mechanical preloading (spring-loaded gear meshes) to purely software compensation that models and corrects for known backlash in the control loop. Reminds me a bit of the early drone hobbyist scene, honestly.

[sarah.santos3]

@gimbalmar65 Side note that might be relevant: Cycloidal drives are a less common but real alternative to harmonic drives - lower cost at high ratios, decent efficiency, but historically bulkier for the same torque density, which is part of why they haven't fully displaced harmonic drives in commercial hips and knees.

[jchen]

@sarah.santos3 Minor factual note: Boston Dynamics' commercial electric Atlas switched fully from hydraulic to QDD-style electric actuation, ending up quieter and lighter with comparable or better dynamic performance than the old hydraulic platform. Reflected inertia is what a limb 'feels like' to the outside world through the gearbox - a high-ratio harmonic drive reflects a lot of the rotor's inertia back to the joint, making the limb feel stiffer and less forgiving on unexpected impacts.

[young58]

@jchen Just to be precise about one thing: Anti-backlash techniques in production actuators range from mechanical preloading (spring-loaded gear meshes) to purely software compensation that models and corrects for known backlash in the control loop.

[shill]

Can I ask a dumb follow-up - Encoder resolution requirements scale with how tightly you need to control low-speed motion - coarse encoders are fine for open-loop swing phases but cause visible stutter during precise placement or fine force control.