Convex Optimization for Spring Design in Series Elastic Actuators: From Theory to Practice

Natural dynamics, nonlinear optimization, and, more recently, convex optimization are available methods for stiffness design of energy-efficient series elastic actuators. Natural dynamics and general nonlinear optimization only work for a limited set of load kinetics and kinematics, cannot guarantee convergence to a global optimum, or depend on initial conditions to the numerical solver. Convex programs alleviate these limitations and allow a global solution in polynomial time, which is useful when the space of optimization variables grows (e.g., when designing optimal nonlinear springs or co-designing spring, controller, and reference trajectories). Our previous work introduced the stiffness design of series elastic actuators via convex optimization when the transmission dynamics are negligible, which is an assumption that applies mostly in theory or when the actuator uses a direct or quasi-direct drive. In this work, we extend our analysis to include friction at the transmission. Coulomb friction at the transmission results in a non-convex expression for the energy dissipated as heat, but we illustrate a convex approximation for stiffness design. We experimentally validated our framework using a series elastic actuator with specifications similar to the knee joint of the Open Source Leg, an open-source robotic knee-ankle prosthesis.