Best actuator failure story you've personally witnessed or caused?

[chenperez]

Not sure if this has been discussed before, but here goes. 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. 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. Interested to see if this matches what others are seeing.

[deborahperez]

Sorry if this is a basic question, but 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.

[scott.andersson5]

I see it a little differently. It's common for a single humanoid to mix actuator types by joint - harmonic drives or hybrid geared actuators at the hips and shoulders where sustained torque matters most, and lower-ratio QDD-style actuators at ankles and knees where backdrivability and impact tolerance matter more. Field-oriented control (FOC) tuning directly affects how smooth torque output feels - poorly tuned current loops show up as audible whine and jerky low-speed motion, while well-tuned FOC can make even a geared actuator feel fairly fluid.

[emilyperez]

@scott.andersson5 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. 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.

[jhansen]

New to this, so forgive me if this is obvious - 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. 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.

[scott21]

To answer this directly: 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.

[scott21]

@scott21 Minor factual note: 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. Kind of makes me think about how different this all looked even three years ago.

[scott.andersson5]

This matches what I've seen too. Motor cogging torque (the 'notchy' feel from magnet-to-slot interactions) shows up as small periodic torque ripple that can translate into visible joint jitter at low speeds - it's usually mitigated with skewed magnets, better current control, or software compensation tables.

[kwilliams]

@scott.andersson5 I see it a little differently. 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. A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist. Makes me wonder how this looks in another five years.

[sharonschmidt]

@kwilliams This is a great summary, thanks. 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. 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.