Highly integrated sensor-actuator-controller units for modular robot design

We present highly integrated sensor-actuator-controller units (SAC units), addressing the increasing need for easy to use components in the design of modern high-performance robotic systems. Following strict design principles and an electro-mechanical co-design from the beginning on, our development resulted in highly integrated SAC units. Each SAC unit includes a motor, a gear unit, an IMU, sensors for torque, position and temperature as well as all necessary embedded electronics for control and communication over a high-speed EtherCAT bus. Key design considerations were easy to use interfaces and a robust cabling system. Using slip rings to electrically connect the input and output side, the units allow continuous rotation even when chained along a robotic arm. The experimental validation shows the potential of the new SAC units regarding the design of humanoid robots.