Physically compliant actuator brings significant benefits to robots in terms of environmental adaptability, human–robot interaction, and energy efficiency as the introduction of the inherent compliance. However, this inherent compliance also limits the force and position control performance of the actuator system due to the induced oscillations and decreased mechanical bandwidth. To solve this problem, we first investigate the dynamic effects of implementing variable physical damping into a compliant actuator. Following this, we propose a structural scheme that integrates a variable damping element in parallel to a conventional series elastic actuator. A damping regulation algorithm is then developed for the parallel spring-damping actuator (PSDA) to tune the dynamic performance of the system while remaining sufficient compliance. Experimental results show that the PSDA offers better stability and dynamic capability in the force and position control by generating appropriate damping levels.

Owing to inherent flexibility, compliant actuator with physical elastic elements can implement compliant interactions between robot and environment. Nonlinear stiffness elastic actuators (NSEAs) use one motor to adjust position and stiffness, which improve compactness of variable stiffness actuators, and consider high torque/force resolution and high bandwidth. The primary challenge of designing a NSEA is designing a reliable compliant mechanism with a given torque-deflection profile. In this study, a general design method of torsional compliant mechanism through given discrete torque-deflection points was proposed, where a chain algorithm based on 2R pseudo-rigid-body model was used to describe the large deformation in elastic elements. Moreover, the theoretical model of stiffness of a compliant mechanism based on series flexible beams was developed. Based on the proposed model, the dimensional parameters of proposed compliant mechanism were designed satisfying the condition of the given torque-deflection points. Finally, simulation and physical experiment of the designed compliant mechanism through three given torque-deflection points are conducted to show the effectiveness of the proposed method. The designed compliant mechanism was tested and evaluated in the self-developed NSEA.

GH3536 alloy is one of the high-temperature nickel-based alloys and widely applied in aviation and aerospace industries. In this study, a combination of experiment and simulation is proposed to study the effect of processing parameters on the selective laser melting (SLM) of GH3536 powder. It is concluded that the relationship between density and laser input energy during SLM complies with a quadratic function and presents an inverted U-shaped distribution. By fitting density and input power to a quadratic polynomial, the optimal laser input energy during SLM of GH3536 alloy can be obtained. The result shows that using 275 W laser power and 960 mm/s scanning speed, the SLM GH3536 specimens can reach the maximum density. This experimental result is consistent with the simulation result obtained by analyzing molten pool dimension. Furthermore, a full process energy prediction diagram for SLM GH3536 alloy based on the simulated molten pool depth and width is proposed. The result shows that it provides an innovative and efficient method for the selection of processing parameters during SLM of GH3536 powder.