Design and Experiment Evaluation of Load Distribution on the Dual Motors in Cam-Based Variable Stiffness Actuator with Helping Mode

This paper presents a novel cam-based variable stiffness actuator (VSA). It significantly differs from its counterparts in that the external load distributes on its two motors with a small difference. It is a feasible method to improve VSA’s output power, especially in compact joints, such as rehabilitation devices. The stiffness adjustment involves a spring-balanced crank-slider mechanism with a variable-length base frame. Its tunable node is the common node for force decomposition, synthesis, stiffness adjustment, and position control by setting it at the common groove of two differential variable-pitch cams. The paper establishes analytical expressions among the pressure angle of the cam pitch curve, load distribution, and its crucial design indexes and constraints. Based on this, the pitch curve synthesis method is put forward to optimize the load distribution. In addition, a reasonable tradeoff can be easily made by locally adjusting the cam pressure angle. So, the dual motors can work against the output load together in the same direction with a close amount. In the fabricated prototype, current stratification caused by the unstable friction direction has been observed. The estimation results of motor frictionless current matched the designed load distribution behavior