How much does connector reliability actually contribute to field failures?

[timothy.roberts2]

One nitpick - 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. This whole thread is a good reminder how young this field still is.

[emily.walker2]

@timothy.roberts2 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.

[brenda52]

Agreed, and I'd add: 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. 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.

[shill]

@brenda52 Not sure I fully agree here. 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. 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.

[lbianchi]

Follow-up question though - 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. 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.

[pierregreen]

Yeah, this tracks with what I've read as well. 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. Backdrivability is the property that lets an external force move a joint without destroying the gearbox or the motor - it's central to both safe human-robot contact and to letting a leg comply naturally when the robot stumbles.

[joseph.robinson]

@pierregreen 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.

[emily45]

@joseph.robinson Slight correction, though the overall point stands: 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. Makes me wonder how this looks in another five years.

[mohammed.rossi]

@emily45 This matches what I've seen too. Backdrivability is the property that lets an external force move a joint without destroying the gearbox or the motor - it's central to both safe human-robot contact and to letting a leg comply naturally when the robot stumbles. 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.

[omar.farouk]

Appreciate the detailed 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. 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.