The optimal design of robotic actuators is a critical area of research, yet limited attention has been given to optimizing gearbox parameters and automating actuator CAD. This paper introduces COMPAct: Computational Optimization and Automated Modular Design of Planetary Actuators, a framework that systematically identifies optimal gearbox parameters for a given motor across four gearbox types, single-stage planetary gearbox (SSPG), compound planetary gearbox (CPG), Wolfrom planetary gearbox (WPG), and double-stage planetary gearbox (DSPG). The framework minimizes mass and actuator width while maximizing efficiency, and further automates actuator CAD generation to enable direct 3D printing without manual redesign. Using this framework, optimal gearbox designs are explored over a wide range of gear ratios, providing insights into the suitability of different gearbox types across various gear ratio ranges. In addition, the framework is used to generate CAD models of all four gearbox types with varying gear ratios and motors. Two actuator types are fabricated and experimentally evaluated through power efficiency, no-load backlash, and transmission stiffness tests. Experimental results indicate that the SSPG actuator achieves a mechanical efficiency of 60-80 %, a no-load backlash of 0.59 deg, and a transmission stiffness of 242.7 Nm/rad, while the CPG actuator demonstrates 60 % efficiency, 2.6 deg backlash, and a stiffness of 201.6 Nm/rad. Code available at: https://anonymous.4open.science/r/COMPAct-SubNum-3408 Video: https://youtu.be/99zOKgxsDho

A monoped's jump height and energy consumption depend on both, its mechanical design and control strategy. Existing co-design frameworks typically optimize for either maximum height or minimum energy, neglecting their trade-off. They also often omit gearbox parameter optimization and use oversimplified actuator mass models, producing designs difficult to replicate in practice. In this work, we introduce a novel three-stage co-design optimization framework that jointly maximizes jump height while minimizing mechanical energy consumption of a monoped. The proposed method explicitly incorporates realistic actuator mass models and optimizes mechanical design (including gearbox) and control parameters within a unified framework. The resulting design outputs are then used to automatically generate a parameterized CAD model suitable for direct fabrication, significantly reducing manual design iterations. Our experimental evaluations demonstrate a 50 percent reduction in mechanical energy consumption compared to the baseline design, while achieving a jump height of 0.8m. Video presentation is available at http://y2u.be/XW8IFRCcPgM

In robotics, structural design and behavior optimization have long been considered separate processes, resulting in the development of systems with limited capabilities. Recently, co-design methods have gained popularity, where bi-level formulations are used to simultaneously optimize the robot design and behavior for specific tasks. However, most implementations assume a serial or tree-type model of the robot, overlooking the fact that many robot platforms incorporate parallel mechanisms. In this paper, we present a novel co-design approach that explicitly incorporates parallel coupling constraints into the dynamic model of the robot. In this framework, an outer optimization loop focuses on the design parameters, in our case the transmission ratios of a parallel belt-driven manipulator, which map the desired torques from the joint space to the actuation space. An inner loop performs trajectory optimization in the actuation space, thus exploiting the entire dynamic range of the manipulator. We compare the proposed method with a conventional co-design approach based on a simplified tree-type model. By taking advantage of the actuation space representation, our approach leads to a significant increase in dynamic payload capacity compared to the conventional co-design implementation.

Legged robots, such as quadrupeds and humanoids, require high-performance actuators for efficient locomotion. Quasi-Direct-Drive (QDD) actuators with single-stage planetary gearboxes offer low inertia, high efficiency, and transparency. Among planetary gearbox architectures, Internal (ISSPG) and External Single-Stage Planetary Gearbox (ESSPG) are the two predominant designs. While ISSPG is often preferred for its compactness and high torque density at certain gear ratios, no objective comparison between the two architectures exists. Additionally, existing designs rely on heuristics rather than systematic optimization. This paper presents a design framework for optimally selecting actuator parameters based on given performance requirements and motor specifications. Using this framework, we generate and analyze various optimized gearbox designs for both architectures. Our results demonstrate that for the T-motor U12, ISSPG is the superior choice within the lower gear ratio range of 5:1 to 7:1, offering a lighter design. However, for gear ratios exceeding 7:1, ISSPG becomes infeasible, making ESSPG the better option in the 7:1 to 11:1 range. To validate our approach, we designed and optimized two actuators for manufacturing: an ISSPG with a 6.0:1 gear ratio and an ESSPG with a 7.2:1 gear ratio. Their respective masses closely align with our optimization model predictions, confirming the effectiveness of our methodology.

-- This paper presents a 3-DOF hopping robot with a human-like lower-limb joint configuration and a flat foot, capable of performing dynamic and repetitive jumping motions. T o achieve both high torque output and a large hollow shaft diameter for efficient cable routing, a compact 3K compound planetary gearbox was designed using mixed-integer nonlinear programming for gear tooth optimization. T o meet performance requirements within the constrained joint geometry, all major components--including the actuator, motor driver, and communication interface--were custom-designed. The robot weighs 12.45 kg, including a dummy mass, and measures 840 mm in length when the knee joint is fully extended. A reinforcement learning-based controller was employed, and the robot's performance was validated through hardware experiments, demonstrating stable and repetitive hopping motions in response to user inputs. These experimental results indicate that the platform serves as a solid foundation for future bipedal robot development. A supplementary video is available at: https://youtu.be/BZ2H0dQBcXc

Carbon emissions have long been attributed to the increase in climate change. With the effects of climate change escalating in the past few years, there has been an increased effort to find green alternatives to power generation, which has been a major contributor to carbon emissions. One prominent way that has arisen is biomechanical energy, or harvesting energy based on natural human movement. This study will evaluate the feasibility of electric generation using a gear and generator-based biomechanical energy harvester in the elbow joint. The joint was chosen using kinetic arm analysis through MediaPipe, in which the elbow joint showed much higher angular velocity during walking, thus showing more potential as a place to construct the harvester. Leg joints were excluded to not obstruct daily movement. The gear and generator type was decided to maximize energy production in the elbow joint. The device was constructed using a gearbox and a generator. The results show that it generated as much as 0.16 watts using the optimal resistance. This demonstrates the feasibility of electric generation with an elbow joint gear and generator-type biomechanical energy harvester.

We provide the mechanical and dynamical requirements for a robotic finger capable of performing thirty diverse everyday tasks. To match these requirements, we present a finger design based on series-elastic actuation that we call the everyday finger. Our focus is to make the fingers as compact as possible while achieving the desired performance. We evaluated everyday fingers by constructing a two-finger robotic hand that was tested on various performance parameters and tasks like picking and placing dishes in a rack, picking thin and flat objects like paper and delicate objects such as strawberries. Videos are available at the project website: https://sites.google.com/view/everydayfinger.

This paper present a novel dual-speed actuator adapted to robotics. In many applications, robots have to bear large loads while moving slowly and also have to move quickly through the air with almost no load. This lead to conflicting requirements for their actuators. Multiple gear ratios address this issue by allowing an effective use of power over a wide range of torque-speed load conditions. Furthermore, very different gear ratios also lead to drastic changes of the intrinsic impedance, enabling a non-back-drivable mode for stiff position control and a back-drivable mode for force control. The proposed actuator consists of two electric motors coupled to a differential; one has a large gear ratio while the other is almost direct-drive and equipped with a brake. During the high-force mode the brake is locked, only one motor is used, and the actuator behaves like a regular highly-geared servo-motor. During the high-speed mode the brake is open, both motor are used at the same time, and the actuator behaves like a direct drive motor. A dynamic model is developed and novel controllers are proposed for synergic use of both motors. The redundancy of motors is exploited for maintaining full control of the output during mode transitions, allowing for fast and seamless switching even when interacting with unknown environments. Results are demonstrated with a proof-of-concept linear actuator.

The process of robot design is a complex task and the majority of design decisions are still based on human intuition or tedious manual tuning. A more informed way of facing this task is computational design methods where design parameters are concurrently optimized with corresponding controllers. Existing approaches, however, are strongly influenced by predefined control rules or motion templates and cannot provide end-to-end solutions. In this paper, we present a design optimization framework using model-free meta reinforcement learning, and its application to the optimizing kinematics and actuator parameters of quadrupedal robots. We use meta reinforcement learning to train a locomotion policy that can quickly adapt to different designs. This policy is used to evaluate each design instance during the design optimization. We demonstrate that the policy can control robots of different designs to track random velocity commands over various rough terrains. With controlled experiments, we show that the meta policy achieves close-to-optimal performance for each design instance after adaptation. Lastly, we compare our results against a model-based baseline and show that our approach allows higher performance while not being constrained by predefined motions or gait patterns.

We present a versatile framework for the computational co-design of legged robots and dynamic maneuvers. Current state-of-the-art approaches are typically based on random sampling or concurrent optimization. We propose a novel bilevel optimization approach that exploits the derivatives of the motion planning sub-problem (i.e., the lower level). These motion-planning derivatives allow us to incorporate arbitrary design constraints and costs in an general-purpose nonlinear program (i.e., the upper level). Our approach allows for the use of any differentiable motion planner in the lower level and also allows for an upper level that captures arbitrary design constraints and costs. It efficiently optimizes the robot's morphology, payload distribution and actuator parameters while considering its full dynamics, joint limits and physical constraints such as friction cones. We demonstrate these capabilities by designing quadruped robots that jump and trot. We show that our method is able to design a more energy-efficient Solo robot for these tasks.