Humanoid robot having common actuator components

Abstract

The present disclosure provides a humanoid robot having at least 28 actuators. The humanoid robot comprises a torso, a torso twist actuator coupled to the torso and configured to allow the torso to twist around a torso twist axis, and a knee actuator with a knee axis. An upper portion of the humanoid robot is positioned above the torso twist axis and includes a first actuator with a first momentary peak torque rating and a second actuator with a momentary peak torque rating, wherein one momentary peak torque rating of the two momentary peak torque ratings is below 10 Nm. A lower portion of the humanoid robot is positioned below the knee axis and includes a third actuator having at least one momentary peak torque rating that is above 35 Nm. A central portion extends between the upper portion and the lower portion and includes a fourth actuator having at least one momentary peak torque rating that is above 300 Nm.

Description

HUMANOID ROBOT HAVING COMMON ACTUATOR COMPONENTSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application Nos. 63 / 632,683, filed April 11, 2024, 63 / 633,113, filed Apnl 12, 2024, 63 / 633,405, filed April 12, 2024, 63 / 633,920, filed April 15, 2024, each of which is expressly incorporated by reference herein in its entirety.

[0002] Reference is hereby made to: (i) U.S. Patent Application Nos. 18 / 919,263,18 / 919,274, 19 / 000,626, 19 / 006,191, 19 / 038,657, 19 / 064,596, 19 / 066,122, (ii) U.S.Provisional Patent Application Nos. 63 / 556,102, 63 / 557,874, 63 / 561,307, 63 / 561,31563 / 561,295, 63 / 561,317, 63 / 561,318, 63 / 564,741, 63 / 564,534, 63 / 565,077, 63 / 573,22663 / 573,543, 63 / 574,349, 63 / 614,499, 63 / 615,766, 63 / 617,762, 63 / 620,633, 63 / 625,36263 / 625,370, 63 / 625,381, 63 / 625,384, 63 / 625,389, 63 / 625,405, 63 / 625,423, 63 / 625,43163 / 626,028, 63 / 626,030, 63 / 626,034, 63 / 626,035, 63 / 626,037, 63 / 626,039, 63 / 626,04063 / 626,105, 63 / 632,630, 63 / 633,931, 63 / 633,941, 63 / 634,599, 63 / 634,697, 63 / 635,15263 / 685,856, 63 / 696,507, 63 / 696,533, 63 / 700,749, 63 / 706,768, 63 / 707,547, 63 / 708,003,63 / 722 / 057, and (iii) PCT Patent Application Nos. PCT / US25 / 10425, PCT / US25 / 11450,PCT / US25 / 12544, PCT / US25 / 16930, each of which is expressly incorporated by reference herein in its entirety.TECHNICAL FIELD

[0003] The present disclosure relates to humanoid robots, and more particularly to a humanoid robot with an optimized actuator configuration for enhanced performance and versatility in human-centric environments.BACKGROUND

[0004] The labor market in the United States is currently experiencing a severe and sustained workforce shortage, with over 10 million unfilled positions across various industries. Many of these vacancies involve occupations characterized by hazardous conditions, physical strain, or tasks generally considered undesirable. This persistent labor gap has intensified the demand for advanced robotic systems capable of performing functions traditionally carried out by human workers. To effectively address these challenges, it is critical to develop humanoidrobots that can operate efficiently and reliably within human-centric environments. These robots must possess advanced capabilities such as dexterous manipulation, endurance, and precise navigation in workspaces designed for human use.

[0005] Despite their promise, conventional humanoid robots face limitations in range of motion, power efficiency, and overall functionality. Addressing these deficiencies requires advancements in several key areas. First, actuator systems should be improved to provide precise control, sufficient force output, and energy efficiency within a compact form factor, enabling robots to execute complex, human-like movements. Second, the integration of advanced sensor arrays and control systems is helpful for real-time environmental perception, proprioception, and adaptive decision-making. Enhanced data collection, proprioceptive feedback, and machine learning-driven control algorithms will enable more responsive and autonomous operation in complex environments. Third, power management and energy efficiency remain challenging, necessitating innovations in battery technology, power distribution, and energy-efficient actuation to ensure long-term operation in practical settings.

[0006] A key limitation of conventional humanoid robots is the reliance on highly specialized, proprietary, or custom-designed components, which increases production complexity, cost, and maintenance challenges. The lack of standardized or widely available components restricts scalability and manufacturability, making it difficult to deploy these robots at a large scale in commercial and industrial applications. Therefore, there is a need for a humanoid robot that incorporates common components — such as standardized actuators, sensors, motors, gearboxes, power systems, and linkages — humanoid robots can benefit from economies of scale, reduced lead times, and simplified supply chains. An advanced humaoid that includes these common components can simplify manufacturing, increase assembly speed, reduce cost, and minimize the number of unique parts required. This standardization also reduces the need for excessive part SKUs, streamlining inventory management and reducing engineering complexities.SUMMARY

[0007] The presently disclosed subject matter is directed to a humanoid robot having at least 28 actuators. The humanoid robot comprises a torso, a torso twist actuator coupled to the torso and configured to allow the torso to twist around a torso twist axis, and a knee actuator with a knee axis. An upper portion of the humanoid robot is positioned above the torso twist axis and includes a first actuator with a first momentary peak torque rating and a second actuator witha momentary peak torque rating, wherein one momentary peak torque rating of the two momentary peak torque ratings is below 10 Nm. A lower portion of the humanoid robot is positioned below the knee axis and includes a third actuator having at least one momentary peak torque rating that is above 35 Nm. A central portion extends between the upper portion of the humanoid robot and the lower portion of the humanoid robot and includes a fourth actuator having at least one momentary peak torque rating that is above 300 Nm.

[0008] The presently disclosed subject matter is directed to a humanoid robot having at least 28 actuators. The humanoid robot comprises a torso, a waist coupled to the torso, and a knee actuator positioned below the waist, when the robot is in a neutral position. An upper portion of the humanoid robot is positioned above the waist and includes at least four rotatory actuators, wherein: (i) two actuators of the at least four rotatory actuators have the same type of gearbox, and (ii) a first rotatory actuator of the four rotatory actuators has a first gear reduction ratio, and a second rotatory7actuator of the four rotatory7actuators has a second gear reduction ratio that is different from the first gear reduction ratio. A lower portion of the humanoid robot is positioned below the knee actuator and includes at least two actuators. A central portion extends between the upper portion of the humanoid robot and the lower portion of the humanoid robot and includes at least six rotatory7actuators, wherein: (i) three actuators at least six rotatory actuators have the same type of gearbox, and (ii) a first rotatory actuator of the six rotatory actuators has the first gear reduction ratio.

[0009] The presently disclosed subject matter is directed to a humanoid robot having at least 28 actuators. The humanoid robot comprises an arm assembly having at least five electrical actuators, wherein a first electrical actuator of the five electrical actuators has a first motor with a speed rating that is above 2,500 RPMs, and a second electrical actuator of the five electrical actuators has a second motor that is different from the first motor and has a speed rating that is below 10,000 RPMs. The humanoid robot also comprises a leg assembly having at least four electrical actuators, wherein a first electrical actuator of the four electrical actuators has the first motor with the speed rating that is above 2,500 RPMs, and a second electrical actuator of the four electrical actuators has a third motor that is different from the first motor and the second motor.

[0010] The presently disclosed subject matter is directed to a humanoid robot comprising an upper portion of the humanoid robot including: (i) ten actuators having a first momentary^ peak torque rating, (ii) four actuators having a second momentary7peak torque rating that is different from the first momentary peak torque, and (iii) four actuators having a third momentary peaktorque rating that is different from both the first and second momentary peak torques. The humanoid robot also comprises a lower portion of the humanoid robot including two actuators having a fourth momentary peak torque rating that is different from each of the first, second, and third momentary peak torques. The humanoid robot further comprises a central portion extending between the upper portion of the humanoid robot and the lower portion of the humanoid robot and including three actuators having a fifth momentary peak torque rating that is different from each of the first, second, third, and fourth momentary peak torques.

[0011] The presently disclosed subject matter is directed to a humanoid robot comprising a first set of twelve actuators having a first reduction ratio, a second set of four actuators having a second reduction ratio that is different from the first reduction ratio, a third set of three actuators having a third reduction ratio that is different from both of the first and second reduction ratios, and a fourth set of two actuators having a fourth reduction ratio that is different from each of the first, second, and third reduction ratios. The first and second sets of actuators are positioned in an upper portion of the humanoid robot, the third set of actuators is positioned in a central portion of the humanoid robot, and the fourth set of actuators is positioned in a lower portion of the humanoid robot.

[0012] The presently disclosed subject matter is directed to a humanoid robot having at least 28 actuators. The humanoid robot comprises a first set of eighteen actuators having a first encoder type, and a second set of two actuators having a second encoder t pe that is different from the first encoder type. At least 5% of the first set of actuators is positioned in a lower portion of the humanoid robot, at least 35% of said first set of actuators is positioned in a central portion of the humanoid robot, and at least 50% of the first set of actuators is positioned in an upper portion of the humanoid robot. The second set of actuators is positioned in the lower portion of the humanoid robot.

[0013] The presently disclosed subject matter is directed to a humanoid robot having at least 28 actuators. The humanoid robot comprises an arm assembly and a leg assembly, and wherein: (i) the arm and leg assemblies include at least eleven electric actuators with less than eight different ty pes of electronic assemblies, and (ii) one actuator of the eleven electric actuators is a shoulder actuator with a momentary peak torque rating that is less than 200 Nm. The humanoid robot also comprises a torso having an electric arm actuator coupled to the shoulder actuator, and wherein the shoulder actuator and the arm actuator are of the same actuator ty pe.

[0014] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises an upper portion including a head, a torso, two arms, and two hands; acentral portion including a spine and a pelvis; and a lower portion including two legs and two feet. The robot includes 62 degrees of freedom distributed as follows: 48 degrees of freedom in the upper portion, 10 degrees of freedom in the central portion, and 4 degrees of freedom in the lower portion. The 62 degrees of freedom are provided by 42 electric actuators, of which over 95% are electric rotary actuators.

[0015] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises an upper portion, a central portion, and a lower portion. The robot includes 42 electric actuators distributed as follows: 28 actuators in the upper portion, 10 actuators in the central portion, and 4 actuators in the lower portion. The 42 electric actuators are classified into seven primary types, with five of the seven types having substantially similar structures, assembly methods, and common components.

[0016] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises a plurality' of electric actuators. The actuators include motors of at least five distinct types, each optimized for specific joint functionalities. The motor types are distributed across the robot such that different portions of the robot utilize different motor types.

[0017] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises a plurality of electric actuators. The actuators include electronic components of at least five distinct types. The electronic component types are distributed across the robot such that different portions of the robot utilize different electronic component types.

[0018] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises a plurality of electric actuators. The actuators include at least three types of gearboxes and encoders. The gearbox and encoder types are distributed across the robot such that different portions of the robot utilize different gearbox and encoder types. Additionally, a subset of the actuators include a cross-roller bearing. The actuators w ith cross-roller bearings are distributed across the robot such that different portions of the robot have different proportions of actuators with cross-roller bearings.

[0019] In some embodiments, the spine includes one actuator of the first type; the pelvis includes one actuator of the first type; each hip includes one actuator of the second ty pe; each upper thigh includes two actuators of the first type; and each lower thigh includes one actuator of the second type.

[0020] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises a plurality of electric actuators. The actuators are configured to generatemomentary' peak torque values selected from a predefined set of torque levels. The torque levels are distributed across the robot such that different portions of the robot utilize different torque levels.

[0021] The presently disclosed subject matter is directed to a humanoid robot. Particularly, the robot comprises a plurality7of electric actuators. Each actuator includes a printed circuit board (PCB) assembly. The PCB assemblies are configured to receive connections that facilitate the passing of electrical current and control signals from a wire harness.

[0022] The presently disclosed subject matter is directed to a method of assembling a humanoid robot. Particularly, the method comprises providing an upper portion, a central portion, and a lower portion. The method includes installing 28 actuators in the upper portion, 10 actuators in the central portion, and 4 actuators in the lower portion. The actuators are classified into seven primary types, with five of the seven types having substantially similar structures, assembly methods, and common components.

[0023] The presently disclosed subject matter is directed to a method of assembling a humanoid robot. Particularly, the method comprises providing a plurality of electric actuators. The method includes selecting motors of at least five distinct types, each optimized for specific joint functionalities. The method includes distributing the motor ty pes across the robot such that different portions of the robot utilize different motor types.

[0024] The presently disclosed subject matter is directed to a method of configuring a humanoid robot. Particularly, the method comprises providing a plurality7of electric actuators. The method includes selecting electronic components of at least five distinct ty pes. The method includes distributing the electronic component types across the robot such that different portions of the robot utilize different electronic component types.

[0025] The presently disclosed subject matter is directed to a method of assembling a humanoid robot. Particularly, the method comprises providing a plurality of electric actuators. The method includes selecting at least three types of gearboxes and encoders. The method includes distributing the gearbox and encoder types across the robot such that different portions of the robot utilize different gearbox and encoder ty pes.

[0026] The present disclosure relates to a humanoid robot incorporating a modular actuator system with an integrated wire harness assembly, predefined torque characteristics, and distributed gearbox configurations. The robot comprises upper, central, and lower portions, each containing actuators optimized for their respective functional requirements. The wire harness assembly facilitates electrical connectivity while ensuring modularity, including a firstconnector coupled to the printed circuit board (PCB) assembly of an adjacent actuator, a connecting portion positioned within the robot’s housing, a strain relief member to mitigate mechanical stress, a through-bore portion housed within an actuator bore receiver, and a second connector secured to the actuator’s PCB assembly via a transfer connector. The wire harness configuration prevents wiring from spanning multiple degrees of freedom or routing around actuator peripheries, thereby enabling individual actuators to be modularly integrated, replaced, or upgraded.

[0027] The actuators exhibit predefined torque levels categorized into seven ranges, with specific torque levels allocated to different portions of the robot. The upper portion, comprising the arms and torso, includes actuators generating momentary peak torque values of 17-30 N m, 72-109 N m. and 3-10 N m. incorporating gear reduction ratios of 40: 1-60: 1 and 80: 1-120: 1. The central portion, including the spine, pelvis, hips, and thighs, comprises actuators generating momentary' peak torque values of 101-200 N m and 265-398 N m, with gear reduction ratios of 40: 1-60: 1 or 60: 1-100: 1. The lower portion, comprising the legs and feet, includes shin actuators generating momentary peak torque values of 96-150 N m and ankle actuators generating 35-55 N m, both featuring gear reduction ratios of 40: 1-60: 1. Shin actuators incorporate through-bore wiring and cross-roller bearings, whereas ankle actuators include cross-roller bearings but lack through-bore wiring. The cross-roller bearings are fabricated from high-grade steel alloys, nickel-based superalloys, cobalt-based alloys, or advanced ceramics.

[0028] The robot’s actuators are distributed to provide precise control over movement while enabling efficient maintenance and upgrades. Each hand includes five digits and has 16 degrees of freedom, driven by six actuators of the same type, each with a momentary peak torque of 3- 10 N m and a gear reduction ratio of 12: 1-18: 1. Each arm includes six actuators providing six degrees of freedom, with a distribution of one actuator in the shoulder, two in the upper arm, two in the lower forearm, and one in the wrist. These actuators include at least three different ty pes: a first type generating 72-109 N m with a 40: 1-60: 1 gear reduction ratio, a second type generating 17-30 N m with an 80:1-120: 1 gear reduction ratio, and a third type generating 3- 10 N m with a 12: 1-18:1 gear reduction ratio. The central portion comprises ten actuators providing ten degrees of freedom, incorporating at least two different actuator types. The actuators in the spine and pelvis feature momentary peak torques of 101 -200 N m and 265-398 N m, respectively, with gear reduction ratios of 40: 1-60: 1 or 60: 1-100: 1.

[0029] Through-bore wiring is selectively implemented to optimize electrical connectivity. At least 90% of actuators in the central portion incorporate through-bore wiring, while less than 50% of actuators in the upper and lower portions combined include such wiring. The actuators also include distinct gearbox and encoder configurations, with the arms and torso utilizing a first type, the hands a second type, the head a third type, the spine, pelvis, and hips a fourth ty pe, and the legs and feet a fifth type. Corresponding electronic components follow a similar distribution. Additionally, the upper portion includes a higher proportion of actuators with cross-roller bearings, with at least 80% of actuators incorporating such bearings, while less than 50% of actuators in the central and lower portions combined feature cross-roller bearings.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements.

[0031] FIG. 1 is a perspective view of a robot in an upright, arms extended position and including: (i) an upper portion having the following parts: (a) a head / neck, (b) a torso, (c) left and right shoulders, (d) left and right upper arm assemblies that each include an upper humerus, lower humerus, upper forearms, and lower forearms, (e) left and right wrists, and (f) left and right hands, (ii) a central portion having the following parts: (a) a spine, (b) a pelvis, (c) left and right hips, (d) left and right upper thighs, and (f) left and right lower thighs, and (iii) a lower portion having the following parts: (a) a left and right shins, (b) left and right talus, and (c) left and right feet;

[0032] FIG. 2 is a front view' of the robot of FIG. 1 ;

[0033] FIG. 3 is a rear view of the robot of FIG. 1 ;

[0034] FIG. 4 is a side view of the robot of FIG. 1;

[0035] FIG. 5 is a perspective view of the kinematic chains of the robot of FIG. 1 , showing common actuator types throughout the robot;

[0036] FIG. 6 is a perspective view of the kinematic chains of the robot of FIG. 1, showing common peak actuator torques throughout the robot;

[0037] FIG. 7 is a perspective view of the kinematic chains of the robot of FIG. 1, showing common gearbox reduction ratios throughout the robot;

[0038] FIG. 8 is a perspective view of the kinematic chains of the robot of FIG. 1, showing common actuator motor types throughout the robot;

[0039] FIG. 9 is a perspective view of the kinematic chains of the robot of FIG. 1. showing common actuator electronics throughout the robot;

[0040] FIG. 10 is a perspective view of the kinematic chains of the robot of FIG. 1, showing common actuator encoders and gearbox types throughout the robot;

[0041] FIG. 11 is a perspective view of the kinematic chains of the robot of FIG. 1. showing inclusion or exclusion of a cross-roller bearing within the robot; and

[0042] FIG. 12 is a perspective view of the kinematic chains of the robot of FIG. 1, showing common use of actuator through-bore wires throughout the robot.DETAILED DESCRIPTION

[0043] In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well-known methods, procedures, components, and / or circuitry7have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present disclosure.

[0044] While this disclosure includes several embodiments in many different forms, the drawings contained herewith are considered exemplary. As such, said drawings are not intended to limit the broad aspects of the disclosed concepts. As will be realized, the disclosed methods and systems are capable of other and different configurations, and several details are capable of being modified without departing from the scope of the disclosed methods and systems. For example, one or more of the following embodiments, in-part or whole, may be combined consistent with the disclosed methods and systems. As such, one or more steps from the flow charts or components in the Figures may be selectively omitted and / or combined consistent with the disclosed methods and systems. Additionally, one or more steps from the flow charts or the method of assembling the shoulder and upper arm may be performed in a different order. In summary, the drawings, flow charts and detailed descriptions are to be regarded as illustrative in nature, not restrictive or limiting.1. Definitions

[0045] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly format sense unless expressly defined herein.

[0046] Although selected human medical terminology is used to describe features and / or relative positions related to the humanoid robot, it should be understood said medical terminology does not directly correspond to the exact same features of a human. It should be understood that names of various assemblies and components (e.g. including housings and assemblies contained within) may generally relate to a location of similar anatomy of a human body and do not have an exact correlation in dimension, function, or shape. The reference system including three orthogonal reference planes is defined with respect to the robot in a neutral standing position to describe relative positions of components of the robot. Although standard human medical terminology is used to describe the anatomical reference planes (i.e. sagittal, coronal, transverse) of the robot, the planes may be shifted from the typical location on a human to be meaningful for the kinematic layout and features of the robot.

[0047] Neutral Position: is a self-supporting position of the robot. In this position, the robot is standing upright on a horizonal support surface and facing forward with its torso vertically aligned over its pelvis and legs, where the legs are substantially straight with the knees aligned under the hips and above the ankles, such that the robot's weight is balanced over its feet. In the neutral position, the robot’s head is facing forward, the arms are located at the sides of the robot, the hands are oriented with the palms facing inward, and the fingers pointing in a substantially downward direction toward the horizontal support surface.

[0048] Extended position: a position of the robot with the arms extended outward laterally at the shoulder and oriented with the palms of the hands facing forward and the fingers pointing in a substantially outward direction, where the central and lower portions of the robot remain in a neutral position.

[0049] Sagittal plane: a vertical plane that aids in defining the left and right sides of the robot. Accordingly, the sagittal plane may: (i) divide the robot and / or the torso into equal left and right sections or halves, (ii) extend through the axis of rotation about which the torso twists or rotates relative to the pelvis and legs, (iii) contain the origin point of the robot, and / or (iv) bedirectly positioned between the left and right legs, and / or left and right arms. In the illustrative embodiment, the sagittal plane (Ps) is a vertical plane that contains the rotational axis A10 of torso twist actuator (J 10) located in the spine 60 of the robot 1 and divides the left and right sides of the robot 1, as indicated in at least FIGS. 1 1-13 and 49. In other words, the sagittal plane (PS) is a plane that is coplanar with the rotational axis A10 of torso twist actuator (J10).

[0050] Coronal plane: a vertical plane that aids in defining the front and back portions of the robot. Accordingly, the coronal plane may: (i) divide the robot and / or the torso into equal front and back sections or halves, (ii) extend through the axis of rotation about which the torso pitches forward or backward, (iii) extend through the axis of rotation about which the knees pitch forward and backward, and / or (iv) extend through the axis of rotation about which the elbow moves forward and backward, when the robot is in the extended position. In various embodiments, said axis of rotation for torso pitch may be bilateral colinear axes, a single centrally located axis, or an axis defined by a line connecting the center of the actuator bearings of two actuator that provide the torso pitch function. In the illustrative embodiment, the coronal plane (Pc) is a vertical plane that contains the rotational axes Al 1 of the hip flex actuators (JI 1) located in the hips 70 and rotational axis A10 of torso twist actuator (J10) located in the spine 60 of the robot 1, as indicated in at least FIG. 15, 16, and 52. In other words, the coronal plane (Pc) is a plane that is coplanar with the rotational axis Al 1 of the hip flex actuators (JI 1) and rotational axis A10 of torso twist actuator (JI 0). Also, as shown in these figures, the coronal plane (Pc) does not bisect the robot, or torso, into equal front and back halves, it is offset forward of a majority of the arm actuators in the extended position, and other positional relationships that can be understood from the figures.

[0051] Transverse plane: a horizontal plane aids in defining the upper and lower portions of the robot. Accordingly, the transverse plane may: (i) divide the robot into equal upper and low er sections or halves, (ii) extend through the axis of rotation about which the torso pitches forward or backward, as defined above, and / or (iii) extend through the widest part of the pelvis. In the illustrative embodiment, the transverse plane (PT) is a horizontal plane that contains the rotational axes Al l of the hip flex actuators (JI 1) located in the hips 70 of the robot 1, as indicated in at least FIGS. 11-13 and 49. Also, as shown in these figures, transverse plane (Pi) is positioned below both spine actuators (J9 and J10), in front of a majority of the arm actuators, and other positional relationships that can be understood from the figures..

[0052] Origin point: the orthogonal intersection point of the sagittal plane, coronal plane, and transverse plane, all of which extend through humanoid robot disclosed herein..

[0053] Reference Axes: consist of: (i) the Z-axis (vertical) is defined at the intersection of the sagittal plane and coronal plane, (ii) the Y-axis (horizontal) is defined at the intersection of the coronal plane and transverse plane: and (iii) the X-axis (depth) is defined at the intersection of the sagittal plane and transverse plane.

[0054] Kinematic chain: a representation of an assembly of rigid bodies connected by joints to provide constrained motion. Within this application, the kinematic chain is illustrated by cylindrical bodies, where the central axis of the individual cylindrical bodies represent the position and orientation of the axis of rotation for the individual actuators. For example, each of the rotary' actuators has a central rotational axis. Other ty pes of actuators may include linkages that provide rotational movement about one or more rotational axes via linkages or other means.

[0055] Range of motion: a range of rotational motion of an actuator about an axis of rotation, where a first and second angle defines a rotational limit in opposing rotational directions from a neutral position expressed in degrees of rotation.

[0056] Degrees of Freedom (DoF): the number of parameters that define the configuration of the kinematic chain and possible movements associated therewith.

[0057] Joint singularities: geometric configurations ofthe robot's joints in which one or more degrees of freedom are effectively lost due to the alignment or overlap of rotational or translational axes.

[0058] Actuator bearing: a specific component of the individual actuator assembly that is generally ring-shaped with parallel edge guides, wherein the rotational axis (An) of the actuator is centered within the actuator bearing and perpendicular to the parallel edge guides. Within this application, the actuator bearings of individual actuators are referenced to further define orientation of the rotational axes and / or relative size of the individual actuator.

[0059] Actuator bearing plane (Bn): a plane defined mid-width of actuator bearing between parallel edge guides and perpendicular to the rotational axis (An).2. Introduction

[0060] The current workplace landscape is characterized by an unprecedented labor shortage, particularly evident in over 10 million unsafe or undesirable jobs across the United States. To address this growing labor deficit, there is a need for advanced robots capable of performing unappealing and hazardous workplace tasks. However, conventional robots may have limitations in their ability' to operate effectively in human-centric environments. This creates aneed for: (i) advanced robots capable of handling undesirable and hazardous tasks, or (ii) advanced robots capable of generating data that can be utilized to develop cutting-edge artificial intelligence models (e.g.. LLMs, VLMs, VLAs, and / or BAMs) to enable these robots to operate autonomously in human-centric environments.

[0061] The following undesirable and hazardous tasks may include walking long distances and obtaining objects from bins, among other general or specific tasks defined to an operational environment. These robot tasks may include single robot task or multiple robot tasks in a generally human-centric environment and may be dangerous, routine, and / or repetitive tasks. Unlike traditional automation systems, the humanoid robot tasks may be dexterous, humanlike tasks that demand advanced motor skills, environmental adaptability, and decision-making processes. Examples of such robot tasks include, but are not limited to, assembling components (e.g., automotive parts) in a production line, welding, painting, precision machining, or operating heavy machinery. The task may also include gathering and packing items from storage bins, transporting items between storage and staging areas or in customer service roles by providing real-time assistance to human customers, such as giving directions, answering queries, and facilitating checkout processes. In other commercial or retail settings, the robots may perform tasks such as stocking shelves, unloading delivery vehicles, conducting inventory counts, rearranging displays, and sanitizing high-touch areas. In non-industrial settings, the robot tasks may include tidying up spaces, putting away groceries, cleaning, folding clothes, making beds, preparing meals, organizing closets, and / or setting tables.

[0062] These robots may include general-purpose humanoid robots specifically tailored for human-centric environments. General-purpose humanoid robots may emulate the human form and functionality, featuring two legs, two arms, and a screen. This emulation may necessitate the integration of various actuators within the robot to closely replicate human movements and capabilities. The requirement for actuators extends beyond cosmetic resemblance, as the actuators enable the robot to manipulate its arms, legs, and other assemblies to interact seamlessly with diverse objects in complex environments.

[0063] The challenge of enabling humanoid robots to execute human movements and capabilities may be compounded by the vast array of potential positions, locations, and states the robot could occupy in a dynamic operating environment. These permutations can be reduced through training methodologies, such as: (i) imitation learning or teleoperation, (ii) supervised learning, (iii) unsupervised learning, (iv) reinforcement learning, (v) inverse reinforcement learning, (vi) regression techniques, or (vii) other established methods. Whiletraining can help minimize these permutations, improper or non-optimal configurations of parts, assemblies, and components may negate the benefits of training and render specific tasks infeasible. Therefore, it may be beneficial to optimize the arrangements of parts, assemblies, and components, particularly in the robot's kinematic chains, to ensure that the humanoid robot can replicate human movements and perform a wide range of tasks. Without such optimized kinematic configurations, advanced robots may not meet the operational requirements. Thus, the inclusion of at least one optimized component or assembly, such as a single actuator, a hand, or an arm, may be desirable.

[0064] The optimized component or assemblies of the humanoid robot 1 may comprise multiple systems, assemblies, components and / or parts that may have anthropomorphic characteristics to enable said robot 1 to emulate the human form and perform a diverse set of tasks. These systems, assemblies, components and / or parts may include a head / neck 10, torso 16, left and right arms, which each include a shoulder 26, upper humerus 30, lower humerus 36, upper forearm 40, lower forearm 46, wrist 50, and hand 56. The robot 1 also includes a spine 60, pelvis 64, left and right hips 70, and left and right legs, which each include an upper thigh 76, lower thigh 80, shin 84, talus 88, and foot 92.

[0065] The positional relationship of the actuators within the robot 1 and their positional relationship to one another provides said robot 1 with a substantial advantage over conventional robots. As shown in at least FIGS. 1-4 and explained below, the humanoid robot 1 includes 62 degrees of freedom (DoF). In particular, the 62 degrees of freedom are distributed within the robot 1 as follows: (i) 48 degrees of freedom are contained in the upper portion 2 of the robot 1, (ii) 10 degrees of freedom are contained in the central portion 3 of the robot 1, and (iii) 4 degrees of freedom are contained in the lower portion 4 of the robot 1. Stated another way, the 62 degrees of freedom are distributed within the robot 1 as follows: (i) 16 degrees of freedom are contained in each hand 56, (ii) 6 degrees of freedom are contained in each arm assembly 5, and (iv) 2 degrees of freedom are contained in each of the upper torso, spine / pelvis, and neck 10, 16, 60, 64. The number and distribution of the degrees of freedom provide the robot 1 several significant advantages over conventional robots. For example, positioning 77% of the degrees of freedom in the upper portion 2 of said robot 1 allows it to perform complex, dexterous tasks that could not be performed without a substantial majority of the degrees of freedom being positioned in said upper portion. As another example, minimizing the number of degrees of freedom in the central portion 3 allows the robot 1 to have a larger torso 16, which allows for the inclusion of a larger battery pack and additional computing power; therebyimproving the performance and reliability of the robot 1. As a further example, including at least 5% of the degrees of freedom within the lower portion 4 of the robot 1 allows it to minimize the time and number of steps required for turning around, which allows the robot 1 to have more humanlike movements and increases the speed at which certain tasks can be accomplished.

[0066] As shown in FIGS. 1-4, the 62 degrees of freedom of the inventive robot 1 are provided by a combination of 42 electric rotary and linear actuators (JI -JI 6), wherein an overwhelming majority (e.g., over 95%) of the actuators are electric rotary actuators as compared to linear actuators. In other words, the robot 1 only includes 2 linear actuators out of the 42 actuators contained in said robot 1. Of the 42 electric actuators, a majority (e.g.. over 60%) are not configured to drive a linkage: instead, said actuators are designed to directly drive the next part(s) of the robot 1. In particular, linkages are coupled to: (i) 14 rotary actuators of said 40 rotary7actuators, and (ii) all of the linear actuators. In other words, 35% of the rotary actuators and 100% of the linear actuators are coupled to a linkage. These linkages allow: (i) the fingers and thumb to be under-actuated, or in other words, the fingers and thumb retain their abil ity to flex, curl, or rotate around an object while eliminating the need for an actuator to control each joint or degree of freedom, (ii) the wrist to have two degrees of freedom that not only interact with one another, but are also substantially perpendicular to one another, and (iii) the foot to pivot around an axis that is located well forward (e.g., more than 10% of the overall length of the foot) of the center of the drive linkage.

[0067] As shown in FIGS. 5-11, the 42 electric rotary and linear actuators can be classified into eight primary types, wherein the different types of actuators can be identified by the different types of stippling in each of these Figures. Five of the eight types have structures that are substantially similar, are assembled in a similar manner, and include a number of common components. These similarities and commonalities reduce the need for specialized parts, increase assembly speeds, minimize cost, and simplify debugging and documentation of the robot 1. As shown in these Figures and described in greater detail below, the eight types of actuators are not equally distributed within the robot 1. Instead, an unequal distribution is utilized throughout the robot 1. In particular, the upper portion of the robot 1 includes 12 actuators of a first type (F), 8 actuators of a second type (B). and 6 actuators of a third type (A). As such, over 60% of the actuators in the robot 1 are actuator types A, B, F, while under 40% of the actuators in the robot 1 are actuator types C, D, E, F, H. The similarities and commonalities of the various actuators and their unequal distribution provides substantialbenefits to the robot 1 over conventional robots that lack these features and configuration. Additionally, the robot 1 only uses electric actuators, whereby the robot 1 lacks manual, hydraulic or pneumatic actuators. The use of only electric actuators: (i) reduces assembly, maintenance, weight and cost, and (ii) increases durability and safety considerations related to operating the robot 1 within or around other humans.

[0068] In addition to optimized kinematic configurations, the robot may have high-precision actuators paired with real-time sensor feedback loops and a control system. The sensors may be designed to continuously monitor the robot’s orientation, speed, and force exerted on one or more robot components (e.g. arm assembly, leg assembly, etc.). The control system may comprise a computing device including a processor and memory, and instructions, when executed in the computing device, to receive data from a plurality of sensors and control the actuators to affect movement of one or more of the robot components. The computing device of the robot may reside in a networked environment and execute additional instructions and / or applications not disclosed herein. The data collected can be processed by an advanced computing architecture, residing in the networked environment, to further train the neural networks that enable the robot to perform its tasks (e.g., enabling it to walk more human-like, climb stairs, or traverse uneven terrain with fluidity and stability) or said data may be used to train other neural networks that are designed to control different robots. Additionally, the disclosed advanced robots may also address technical challenges related to dexterity and object manipulation. For example, the disclosed robots may include end effectors that feature multijointed designs with a high number of degrees of freedom, enabling complex and precise movements. Additionally, tactile sensors may be embedded in the said end effectors to provide detailed feedback on pressure, texture, and temperature, which again can be used to train local or remote neural networks to improve execution of the set of tasks and / or response to other sensor input.

[0069] The robot may further include a cutting-edge computer vision system, which may be equipped with depth perception and object recognition capabilities. By integrating sensory data with artificial intelligence algorithms, the robot may leam from experience, improving its ability to grasp and manipulate a wide variety of objects over time. Predictive algorithms may also enable the robot to anticipate the behavior of dynamic objects, such as catching a ball in mid-air or interacting with moving conveyor belts in industrial settings.

[0070] Also, the robot may be capable of enhanced by the incorporation of human-robot interaction (HRI) capabilities with the robot. Equipped with auditory sensors and advancednatural language processing (NLP) algorithms, the robot may engage in verbal communication, understanding and generating speech in multiple languages. It may process contextual information to generate appropriate responses and detect emotional nuances in human speech, enabling meaningful and context-aware interactions. Additionally, the robot may integrate nonverbal communication cues, such as gestures and block-based expressions displayed on its screen, to create intuitive and human-like interactions. These features may make the robot highly adaptable to social environments, including classrooms, eldercare facilities, and hospitality settings.

[0071] Finally, the robot may include redundant systems to help ensure continuous operation in the event of component failure. For example, critical systems such as balance control and power management may be supported by backup circuits and secondary control algorithms. Advanced diagnostic tools may continuously monitor the robot’s components, predicting potential failures before they occur and initiating self-repair routines or alerting users. These safely measures, combined with the robot’s robust energy management systems, may ensure reliable performance in diverse and demanding applications.3. Degrees of Freedom of the Robot

[0072] These positional relationships of the rotational axes (An) at least partially define the kinematic chains. Also, the arrangement of the individual actuators JI -JI 6 contained in the robot 1 may be defined positionally by the actuator bearings, where the actuator bearing plane (Bn) is centered on the rotational axis (An) of the individual actuator (Jn). The positions of the rotational axes (An) and / or actuator bearings may be defined positionally relative to one or more of the sagittal, coronal, or transverse planes (Ps, Pc, PT), when in the robot is in a static position (neutral or extended).

[0073] As show n in FIGs. 5-11, the high level configuration of a kinematic chain for each arm 5 includes seven rotational axes (A1-A7) from the torso 16 to the wrist 50 to providing seven DoF for the arm 5 to position the hand 56 of the robot 1 , where Ai is located in the torso and A2-A7 are in the arm 5. Each hand further has sixteen DoF to further grasp or manipulate objects. Additionally, the high level configuration of a kinematic chain for each leg 6 includes six rotational axes (An-Aie) from the hip 60 to the foot 92 providing six DoF to position the foot 92. Additionally, the central rotational axes (A9-A11) provide three DoF to position the torso 16 with respect to the legs 6, where the pair of hip rotational axes (An) serve a dual purpose of rotating individual legs at the hip 60 and flexion / extension of the torso 16. Lastly,the head 10 includes rotational axes (As.i, As.2) for 2 DoF. Further, shown in FIG. 8B, each hand 56 can have a plurality of rotational axes in each finger and thumb configured to grasp objects.

[0074] The high level configuration of the robot 1 includes a total number of DoF that is greater than 30, preferably more than 45, most preferably more than 55, and approximately 62. Specifically, the total number of DoF of said humanoid robot are distributed within the robot 1 as follows:■ Upper Portion 2: 48 degrees of freedom (77% of the robot’s total DoF) o Head / Neck 10: 2 degrees of freedom (3% of the robot’s total DoF) o Upper Portion of the Torso 16: 2 degrees of freedom (3% of the robot’s total DoF) o Each Arm Assembly 5: 6 degrees of freedom (10% of the robot’s total DoF)■ Each Shoulder 26: 1 degree of freedom (1% of the robot’s total DoF)■ Each Upper Arm Assembly 24: 2 degrees of freedom (3% of the robot’s total DoF)• Each Upper Humerus 30: 1 degree of freedom (1% of the robot’s total DoF)• Each Lower Humerus / Elbow 36: 1 degree offreedom (l% of the robot’s total DoF)■ Each Lower Forearm 46: 2 degrees of freedom (3% of the robot’s total DoF)■ Each Wrist 50: 1 degree of freedom (1% of the robot’s total DoF) o Each Hand 56: 16 degrees of freedom (26% of the robot’s total DoF)■ Each Finger: 3 degrees of freedom (5% of the robot’s total DoF)■ Thumb: 4 degrees of freedom (6% of the robot’s total DoF)■ Central Portion 3: 10 degrees of freedom (16% of the robot’s total DoF) o Spine 60: 1 degree of freedom (1% of the robot’s total DoF) o Pelvis 64: 1 degree of freedom (1% of the robot’s total DoF) o Each Hip 70: 1 degree of freedom (1% of the robot’s total DoF) o Each Upper Thigh 76: 2 degrees of freedom (3% of the robot’s total DoF) o Each Lower Thigh 80: 1 degree of freedom (1 % of the robot’s total DoF)■ Lower Portion 4: 4 degrees of freedom (6% of the robot’s total DoF) o Each Shin 84: 1 degree of freedom (1% of the robot’s total DoF)o Each Talus 88 / Foot 92: 1 degree of freedom (1% of the robot’s total DoF)

[0075] The distribution of degrees of freedom throughout the robot's structure may be designed to optimize its capabilities for performing human-like tasks. For example, positioning more than 65%, preferably more than 70%, most preferably more than 75%, and approximately 77% of the degrees of freedom in the upper portion 2 of said robot 1 may allow said robot 1 to perform dexterous tasks that could be challenging without a substantial majority of the degrees of freedom being positioned in said upper portion 2. Additionally, having a relatively small number of degrees of freedom within the central portion 3 may allow the robot 1 to have a larger torso volume. Furthermore, including less than 15%, preferably less than 10%, and approximately only 6% of the degrees of freedom within the low er portion 4 of the robot 1 may help minimize torque placed on the knees and hips.

[0076] It should be understood that additional actuators, actuator bearings, and / or rotational axes may be added within the belly of the robot or in the hands. In other embodiments, said robot 1 may include fewer actuators, actuator bearings, and / or rotational axes. For example, the torso lean actuator (J9) 680, foot roll actuator (JI 6) 900, or an actuator located within the hand may be removed. However, it should be understood that the number / location of degrees of freedom associated with the disclosed humanoid robot materially and substantially differ from the number / location of degrees of freedom for a non-humanoid robot. As such, the number / location of degrees of freedom with non-humanoid robot cannot be simply adopted or implemented into a humanoid robot without careful analysis and verification of the complex realities of designing, testing, and manufacturing a general purpose humanoid robot. Theoretical designs that are an attempt to implement such modifications from anon-humanoid robot are insufficient (and in some instances, woefully insufficient) because they amount to mere design exercises that are not tethered to the complex realities of successfully of designing, testing, and manufacturing a general purpose humanoid robot.4. Actuators

[0077] Shown in at least FIGS. 5-11, the actuators contained within the physical robot 1 include actuators (JI -J 16) housed within components of the robot 1 to actuate movement of the components of said robot 1. Below is a summary table showing the actuators reference names and numbers, actuator names, and associated components from high level configuration of the robot 1. In particular, the actuator bearing of individual actuators may help define the motion of the component or structure attached to the output driven by the individual actuators.Table 1

[0078] Below is a high-level breakdown of the arrangement of the above actuators, which is shown in FIGs. 5-11. Specifically, the total number of actuator of said humanoid robot 1 are distributed within the robot 1 as follows:■ Upper Portion 2: 28 actuators (66% of the robot’s total actuators) o Head / Neck 10: 2 actuators (5% of the robot's total actuators) o Upper Portion of the Torso 16: 2 actuators (5% of the robot’s total actuators) o Each Arm Assembly 5: 6 actuators (14% of the robot’s total actuators)■ Each Shoulder 26: 1 actuator (2% of the robot’s total actuators)■ Each Upper Arm Assembly 24: 2 actuators (5% of the robot’s total actuators)• Each Upper Humerus 30: 1 actuator (2% of the robot’s total actuators)• Each Lower Humerus / Elbow 36: 1 actuator (2% of the robot’s total actuators)■ Each Lower Forearm 46: 2 actuator (5% of the robot’s total actuators)■ Each Wrist 50: 1 actuator (2% of the robot’s total actuators) o Each Hand 56: 12 actuator (28% of the robot’s total actuators)■ Each Finger: 1 actuator (2% of the robot’s total actuators)■ Thumb: 2 actuators (5% of the robot’s total actuators)■ Central Portion 3: 10 actuators (23% of the robot’s total actuators) o Spine 60: 1 actuator (2% of the robot’s total actuators) o Pelvis 64: 1 actuator (2% of the robot’s total actuators) o Each Hip 70: 1 actuator (2% of the robot’s total actuators) o Each Upper Thigh 76: 2 actuators (5% of the robot’s total actuators) o Each Lower Thigh 80: 1 actuator (2% of the robot’s total actuators)■ Lower Portion 4: 4 actuators (9% of the robot’s total actuators) o Each Shin 84: 1 actuator (2% of the robot’s total actuators) o Each Talus 88 / Foot 92: 1 actuator (2% of the robot’s total actuators) a. Commonalities of Actuator Components and Functions

[0079] To simplify manufacturing, increase assembly speed, reduce cost, minimize the number of unique components, reduce part SKUs, and reduce engineering complexities, the actuators include a number of common assemblies, components, parts, and / or functionality. The common assemblies, components, parts, and / or functionality include, but are not limited to,: (i) type, as shown in FIG. 5 and identified by A-H, (ii) torque, as shown in FIG. 6 and identified by I-O, (iii) gearbox reduction ratio, as shown in FIG. 7 and identified by P-T, (iv)motor type, as shown in FIG. 8 and identified by U-Y, (v) electronic PCBs, as shown in FIG. 9 and identified by Z-DD, (vi) encoder type and gearbox type, as shown in FIG. 10 and identified by EE-GG, (vii) inclusion or exclusion of a cross-roller bearing, as shown in FIG. 1 1 and identified by HH-II, and (viii) inclusion of a through-bore ware, as shown in FIG. 11 and identified by JJ-KK.

[0080] Similar to the statement set forth above in connection with the number / location of degrees of freedoms, it should be understood that the commonalities of the actuator assemblies, components, parts, and / or functionality associated with the disclosed humanoid robot materially and substantially differ from the assemblies, components, parts, and / or functionality for a non-humanoid robot. As such, the assemblies, components, parts, and / or functionality with non-humanoid robot cannot be simply adopted or implemented into a humanoid robot without careful analysis and verification of the complex realities of designing, testing, and manufacturing a general purpose humanoid robot. Theoretical designs that are an attempt to implement such modifications from a non-humanoid robot are insufficient (and in some instances, woefully insufficient) because they amount to mere design exercises that are not tethered to the complex realities of successfully of designing, testing, and manufacturing a general purpose humanoid robot. i. Types

[0081] All actuators (JI -JI 6) contained in the humanoid robot 1 fall within one ty pe of the eight types of actuators. The primary differences in the types of actuators are drive size and housing / mounting configuration. In particular, the primary difference between J1-J4 and J9- J16 is the drive size, while the difference between J5-J8.2 is the housing / mounting configuration. In other words, the differences betw een J1-J4, J9-J14, JI 6 directly relate to the size (z.e., 14, 17, 20, 25, NA) of the harmonic drive. And J8. 1-J8.2 are modified versions of J5- J7, wherein said modification relates to the mounting / housings of these actuators. Finally, J15 is the only linear actuator contained in the humanoid robot 1 . As shown in FIG. 5, the humanoid robot 1 includes the following types and total number of said types:Table 2

[0082] Based on these differences, the actuator types can be distributed within the humanoid robot 1, as shown in FIG. 5 and described below:Table 3

[0083] In addition to the above general arrangement, the following types are distributed as shown below:• Upper Portion 2: o Head / Neck 10: 2 type C’s (100% of the robot’s total type C’s) o Upper Portion of the Torso 16: 2 type B’s (25% of the robot’s total type B’s) o Each Arm Assembly 5: 6 actuators (14% of the robot’s total actuators)■ Each Shoulder 26: 1 type B (12% of the robot’s total type B’s)■ Each Upper Arm Assembly 24:• Each Upper Humerus 30: 1 type B (12% of the robot’s total type B's)• Each Lower Humerus / Elbow 36: 1 type B (12% of the robot’s total type B’s)■ Each Lower Forearm 46: 2 type A’s (33% of the robot’s total type A’s)■ Each Wrist 50: 1 type A (16% of the robot’s total type A’s) o Each Hand 56: 6 type F’s (50% of the robot’s total type F’s)■ Each Finger: 1 type F (8% of the robot’s ty pe F’s)■ Thumb: 2 type F (16% of the robot’s type F’s)Central Portion 3: o Spine 60: 1 type D (16% of the robot’s ty pe D’s) o Pelvis 64: 1 type D (16% of the robot’s type D’s) o Each Hip 70: 1 type E (25% of the robot’s type E’s) o Each Upper Thigh 76: 2 type Ds (33% of the robot’s t pe D’s) o Each Lower Thigh 80: 1 type E (25% of the robot's type E’s)• Lower Portion 4: o Each Shin 84: 1 type G (50% of the robot’s type G’s) o Each Talus 88 / Foot 92: 1 ty pe H (50% of the robot’s type H’s) ii. Peak Torque

[0084] All actuators (JI -JI 6) contained in the humanoid robot 1 are configured to generate momentary' peak torque values (N m) selected from a predefined set of torque levels. These momentary peak torques are determined based on the dynamic requirements of the humanoid robot 1, considering factors such as limb mass, joint positioning, degrees of freedom, and expected operational load conditions. The selection of specific torque values ensures optimized energy efficiency, structural integrity, and precise motion control under varying mechanical loads.

[0085] In particular, the humanoid robot 1 includes seven discrete momentary' peak torque values, strategically distributed among its joints to accommodate biomechanical constraints and enhance mobility', stability, and dexterity'. The torque distribution is designed to align with the expected force application at each joint, compensating for gravitational effects, inertial loads, and external perturbations during operation. FIG. 6 illustrates the seven predefined momentary' peak torque values implemented within the humanoid robot 1. These torque values correspond to actuators positioned at critical articulation points, such as the shoulder, elbow, wrist, hip, knee, and ankle joints, which require distinct torque capacities for controlled motion and force exertion. Additionally, the actuator selection accounts for peak torque demands during high-stress activities, including abrupt deceleration, lifting, and balancing tasks.

[0086] Each actuator comprises an integrated torque-sensing mechanism (i.e., torque cell) and closed-loop feedback control to regulate the applied torque in real time. This enables precise force modulation, reducing unnecessary power consumption while maintaining mechanical compliance with the humanoid robot's intended movement patterns. Moreover, the torque output is calibrated to prevent mechanical overload, ensuring long-term operationalreliability and minimizing wear on joint components. By incorporating these predefined torque values, the humanoid robot 1 achieves an optimal balance between power output and structural efficiency, facilitating precise motor coordination across all actuated joints. The strategic allocation of torque levels enhances overall robotic performance, enabling dynamic and adaptive movement control across various operational scenarios.Table 4

[0087] Based on these differences, the momentary peak torque ratings can be distributed within the humanoid robot 1, as shown in FIG. 6 and described below:Table 5

[0088] In addition to the above general arrangement, the following types are distributed as shown below :• Upper Portion 2: o Head / Neck 10: 2 type Ts (25% of the robot’s total type I’s) o Upper Portion of the Torso 16: 2 type J’s (25% of the robot’s total type J’s) o Each Arm Assembly 5:■ Each Shoulder 26: 1 type J (12% of the robot’s total type J’s)■ Each Upper Arm Assembly 24:• Each Upper Humerus 30: 1 type J (12% of the robot’s total type J’s)• Each Lower Humerus / Elbow 36: 1 type J (12% of the robot’s total type B’s)■ Each Lower Forearm 46: 2 type I’s (25% of the robot’s total type Ls)■ Each Wrist 50: 1 type I (12% of the robot’s total type I’s) o Each Hand 56: 6 type M’s (50% of the robot’s total type M’s)■ Each Finger: 1 type M (8% of the robot’s type M’s)■ Thumb: 2 type M (16% of the robot’s type M’s)• Central Portion 3: o Spine 60: 1 type K (16% of the robot’s ty pe K’s) o Pelvis 64: 1 type K (16% of the robot’s type K’s) o Each Hip 70: 1 type L (25% of the robot’s type L’s) o Each Upper Thigh 76: 2 type K’s (33% of the robot’s type K’s) o Each Lower Thigh 80: 1 type L (25% of the robot's type L’s)• Lower Portion 4: o Each Shin 84: 1 type N (50% of the robot’s type N’s) o Each Talus 88 / Foot 92: 1 type O (50% of the robot’s type O’s) iii. Gearbox Reduction Ratio

[0089] Each non-linear actuator (J1-J14 and J16) incorporated in the humanoid robot 1 is equipped with a gearbox that facilitates a gear reduction ratio, thereby optimizing torque output and motion precision. The selection of a specific gearbox ty pe is determined based on factors such as torque requirements, backlash minimization, efficiency, weight constraints, and durability considerations. The gear reduction ratio achieved by each gearbox can vary depending on the design and functional requirements of the humanoid robot 1. The reduction ratios may include, but are not limited to, 2:1. 3:1, 5: 1, 7: 1, 10: 1, 15: 1, 20: 1, 30: 1, 40: 1, 50: 1, 80: 1, 100: 1, 120: 1. 150: 1, 200: 1, 300: 1. 400: 1, and 500: 1. These ratios enable precise control over the robot’s kinematic chain by balancing speed and torque as required by different joints.

[0090] In particular, the humanoid robot 1 incorporates a structured selection of five distinct gear reduction values, strategically implemented to optimize mechanical performance acrossvarious actuation points. FIG. 7 illustrates the specific gear reduction values applied to different joints within the humanoid robot 1, ensuring a balance between power transmission efficiency, actuator responsiveness, and mechanical longevity. These values have been selected based on the dynamic and static load conditions of each joint, contributing to enhanced operational stability, accuracy, and energy efficiency of the humanoid system.

[0091] The utilization of multiple gear reduction ratios across the humanoid robot 1 allows for adaptive control strategies, enabling smooth and precise motion profiles tailored for different operational scenarios. By integrating diverse reduction ratios, the system can effectively manage vary ing torque and speed requirements, thereby enhancing the humanoid robot’s capability to perform complex movements while maintaining structural integrity and minimizing mechanical wear.Table 6

[0092] Based on these differences, the identified reduction ratios can be distributed within the humanoid robot 1, as shown in FIG. 7 and described below:Table 7

[0093] In addition to the above general arrangement, the following types are distributed as shown below:• Upper Portion 2: o Head / Neck 10: 2 type R’s (25% of the robot’s total type R’s) o Upper Portion of the Torso 16: 2 type P’s (12% of the robot’s total type P’s) o Each Arm Assembly 5:■ Each Shoulder 26: 1 type P (8% of the robot’s total type P’s)■ Each Upper Arm Assembly 24:• Each Upper Humerus 30: 1 type P (8% of the robot’s total type P’s)• Each Lower Humerus / Elbow 36: 1 type P (8% of the robot’s total type P's)■ Each Lower Forearm 46: 2 type R’s (25% of the robot’s total type R’s)■ Each Wrist 50: 1 type R (12% of the robot’s total type R’s) o Each Hand 56: 6 type T’s (50% of the robot's total type T’s)■ Each Finger: 1 type T (8% of the robot’s type T's)■ Thumb: 2 ty pe T (16% of the robot’s type T’s)• Central Portion 3: o Spine 60: 1 type P (8% of the robot’s type P’s) o Pelvis 64: 1 type P (8% of the robot’s type P’s) o Each Hip 70: 1 type Q (25% of the robot’s type Q’s) o Each Upper Thigh 76: 2 type P’s (12% of the robot’s type P’s) o Each Lower Thigh 80: 1 type Q (25% of the robot’s type Q's)• Lower Portion 4: o Each Shin 84: 1 type S (50% of the robot’s type S’s) o Each Talus 88 / Foot 92: 1 type P (6% of the robot’s type P’s)

[0094] In other alternative embodiments, the arm actuator (JI) 190 or the shoulder actuator (J2) 280 utilizing a synchronous reluctance motor (SynRM) coupled with a compound planetary gearbox. In contrast, the wrist pivot actuator (J7) 520 might employ a coreless DC motor paired with a strain wave gearbox. This system could achieve reduction ratios in the range of 1:50 to 1: 160, depending on the specific performance requirements. For actuators requiring a balance between speed and torque, such as the elbow actuator (J4) 374. a hybrid stepper motor combined with a cycloidal drive might be employed. This combination could achieve reduction ratios (1:30 to 1:87), offering a good compromise between speed and force.

[0095] In applications where back drivability is useful, such as in the knee actuator (JI 4) 820, a direct drive torque motor might be used in conjunction with a cable-driven differential mechanism. The cable system could be designed to achieve modest reduction ratios (e.g., 1:5 to 1 : 15) while maintaining high efficiency and low friction. For joints requiring extreme precision, like the head nod actuator (J8.2) 140, a closed-loop stepper motor system coupled with a micro-harmonic drive could be implemented. This configuration allows for microstepping capabilities and ultra-high reduction ratios (potentially exceeding 1 : 1000). enabling very fine angular adjustments. In scenarios where weight reduction is paramount, such as in distal joints like the wrist flex actuator (J ) 484, a flat or pancake-sty le brushless DC motor might be combined with a strain wave gearbox. This ultra-compact design could achieve reduction ratios from 1 :50 to 1 : 160 while minimizing the added mass at the end of the arm assembly. For actuators that experience widely varying loads, like the hip flex actuator (JI 1) 720, a variable transmission system could be employed. This might involve a continuously variable planetary (CVP) gearbox coupled with a high-torque AC servomotor. The CVP allows for dynamic adjustment of the reduction ratio (e.g, from 1: 1.5 to 1: 120) based on real-time load conditions, optimizing performance across different operating scenarios.

[0096] In applications requiring high power density and thermal management, such as the torso twist actuator (J10) 620, a liquid-cooled axial flux permanent magnet motor could be paired with a multi-stage epicyclic gearbox. This setup allows for high continuous torque output while achieving reduction ratios up to 1 :500 or more through the cascaded planetary stages. For joints that benefit from inherent compliance, like the foot roll actuator (JI 6) 900, a series elastic actuator (SEA) configuration might be used. This could involve a standard brushless DC motor coupled with a ball screw mechanism and a torsional spring element. The effective reduction ratio of this system can vary based on the spring stiffness and ball screw pitch, potentially ranging from 1:10 to 1: 100. In scenarios where extremely high reduction ratios are required, such as in a fine manipulation end-effector, a combination of different gearing types might be employed. For example, a worm gear (providing a reduction of 1 :50) could be coupled with a cycloid reducer (1 :87 reduction), resulting in a compound reduction ratio of 1:4350. iv. Motor Type

[0097] It should be noted that the actuators (JI) -(JI ) may incorporate a range and / or combination of advanced motor types, selected based on specific performance requirementssuch as torque density, response time, energy efficiency, and operational lifespan. These motor types may include, but are not limited to, brushless direct current (BLDC) motors, stepper motors, servo motors, coreless direct current (DC) motors, synchronous alternating current (AC) motors, asynchronous induction motors, linear motors, piezoelectric motors, direct-drive motors, switched reluctance motors, permanent magnet synchronous motors (PMSMs), axial flux motors, and hybrid stepper motors. The selection of motor types may depend on various operational constraints, including but not limited to, weight limitations, power consumption considerations, positional accuracy, feedback control mechanisms, and environmental conditions such as thermal dissipation and resistance to electromagnetic interference. For instance, piezoelectric motors may be preferred for high-precision applications requiring minimal backlash, whereas direct-drive motors eliminate the need for mechanical transmission components, thereby reducing system complexity and increasing reliability.

[0098] To enhance the performance of these actuators, the motors may employ rare-earth permanent magnet compositions such as neodymium-iron-boron (NdFeB) alloys and samarium-cobalt (SmCo) magnets, which offer high magnetic flux density and temperature stability. Alternative magnet ty pes, including ferrite magnets, aluminum-nickel-cobalt (alnico) magnets, flexible magnets, bonded rare-earth magnets, and high-temperature permanent magnets, may also be used depending on application-specific thermal and magnetic requirements. Additional alternatives include cobalt-platinum (CoPt) alloys, iron-nitride (FeN) magnets, strontium ferrite magnets, and amorphous metal-based magnets, which may provide enhanced performance characteristics such as higher coercivity', reduced eddy current losses, or improved manufacturability for specific actuator applications.

[0099] Furthermore, motor windings may be constructed using high-conductivity copper wire, with advanced insulation materials such as ceramic-based or polyimide coatings, to provide enhanced thermal stability, electrical insulation, and reduced power losses due to resistive heating. The use of high-performance winding topologies, including concentrated or distributed winding configurations, may further optimize motor efficiency, torque ripple reduction, and electromagnetic noise mitigation. Additionally, the incorporation of advanced cooling mechanisms, such as liquid cooling channels, phase-change materials, or forced air convection systems, can enhance thermal dissipation and prevent overheating under prolonged operational loads. Electromagnetic shielding materials and precision winding techniques may be implemented to minimize parasitic eddy currents and hysteresis losses, thereby improving overall energy efficiency. Furthermore, multi-stranded litz wire configurations can beemployed to reduce skin effect and optimize high-frequency current conduction, particularly in motors subjected to high-speed switching operation.

[0100] In particular, said humanoid robot 1 incorporates five distinct motor types, each optimized for specific joint functionalities to balance speed, torque, and precision. FIG. 8 illustrates that the humanoid robot 1 integrates the following five motor types:Table 8

[0101] Based on these differences, the motor ty pes can be distributed within the humanoid robot 1, as shown in FIG. 8 and described below:Table 9

[0102] In addition to the above general arrangement, the following types are distributed as shown below :• Upper Portion 2: o Head / Neck 10: 2 type W’s (25% of the robot’s total type W’s) o Upper Portion of the Torso 16: 2 type U’s (20% of the robot’s total type U’s) o Each Arm Assembly 5:■ Each Shoulder 26: 1 ty pe U (10% of the robot's total type U’s)■ Each Upper Arm Assembly 24:• Each Upper Humerus 30: 1 type U (10% of the robot’s total type U’s)• Each Lower Humerus / Elbow 36: 1 type U (10% of the robot’s total type U’s)■ Each Lower Forearm 46: 2 type W’s (25% of the robot’s total type W’s)■ Each Wrist 50: 1 type W (12% of the robot’s total type W’s) o Each Hand 56: 6 type X’s (50% of the robot’s total type X’s)■ Each Finger: 1 type X (8% of the robot’s type X’s)■ Thumb: 2 ty pe X (16% of the robot’s type X’s)• Central Portion 3: o Spine 60: 1 type V (10% of the robot’s type V’s) o Pelvis 64: 1 type V (10% of the robot’s type V’s) o Each Hip 70: 1 type V (10% of the robot’s type V’s) o Each Upper Thigh 76: 2 type V’s (20% of the robot’s type V’s) o Each Lower Thigh 80: 1 type V (25% of the robot’s type V’s)• Lower Portion 4: o Each Shin 84: 1 ty pe U (10% of the robot’s type U’s) o Each Talus 88 / Foot 92: 1 type Y (100% of the robot’s type U’s) v. Electronics

[0103] It should be noted that the actuators (J1)-(J16) may utilize common input printed circuit boards (PCBs) and / or output PCBs to facilitate efficient communication, control, and power distribution across the humanoid robot 1. These PCBs serve as important interfaces for the operation of various subsystems and may integrate multiple functionalities to optimize performance. In addition to other aspects, said PCBs incorporate components designed to obtain data from sensors, provide connectors for interlinking various modules or actuators, and transfer information between different electronic and mechanical elements. Such PCBs may also include microcontrollers, signal conditioning circuits, data buses, and power management systems to regulate and coordinate the function of actuators and other electromechanical components.

[0104] The five electronic types that are incorporated into the humanoid robot 1 can be grouped based on their structural layout. The sensor processing electronics and motor control electronics work together to manage perception and motion. The sensor processing electronicsacquire and interpret data from onboard sensors such as inertial measurement units (IMUs), force sensors, proximity sensors, and vision systems, providing real-time feedback for precise movement control. The motor control electronics, in turn, regulate and drive the actuators (JI)— (JI 6) using motor drivers, pulse-width modulation (PWM) controllers, and feedback loops that adjust torque, speed, and position, ensuring smooth and coordinated motion.

[0105] The power management electronics and communication and data transfer electronics enable the efficient distribution and exchange of energy and information. Power management electronics regulate electrical distribution, integrating voltage regulation, battery management, and thermal protection mechanisms to enhance energy7efficiency and prevent issues such as overcurrent or overheating. Meanwhile, communication and data transfer electronics ensure seamless connectivity between subsystems through wired and wireless interfaces such as CAN bus, I2C, SPI, Ethernet, Wi-Fi, or Bluetooth, facilitating real-time information exchange between sensors, actuators, and processing units. Finally, the processing and decision-making electronics form the central control unit of the humanoid robot 1. These electronics consist of embedded microcontrollers, field-programmable gate arrays (FPGAs), or other computational units responsible for executing control algorithms, machine learning models, and real-time decision-making processes essential for autonomous and semi-autonomous operation.Table 10

[0106] Based on these differences, the electronic types can be distributed within the humanoid robot 1, as shown in FIG. 9 and described below:Table 11

[0107] In addition to the above general arrangement, the following electronic types are distributed as shown below:• Upper Portion 2: o Head / Neck 10: 2 type Z’s (25% of the robot's total type Z’s) o Upper Portion of the Torso 16: 2 type AA’s (11% of the robot’s total type AA’s) o Each Arm Assembly 5:■ Each Shoulder 26: 1 type AA (5% of the robot’s total type AA’s)■ Each Upper Arm Assembly 24:• Each Upper Humerus 30: 1 type AA (5% of the robot’s total type AA’s)• Each Lower Humerus / Elbow 36: 1 t pe AA (5% of the robot’s total type AA’s)■ Each Lower Forearm 46: 2 type Z’s (25% of the robot’s total type Z’s)■ Each Wrist 50: 1 type Z (12% of the robot's total type Z’s) o Each Hand 56: 6 type DD’s (50% of the robot’s total type DD’s)■ Each Finger: 1 type DD (8% of the robot’s type DD’s)■ Thumb: 2 type DD (16% of the robot’s type DD’s)• Central Portion 3: o Spine 60: 1 type AA (5% of the robot’s type AA’s) o Pelvis 64: 1 type AA (5% of the robot’s type AA’s) o Each Hip 70: 1 type AA (5% of the robot’s type AA’s) o Each Upper Thigh 76: 2 type AA’s (5% of the robot’s type AA's) o Each Lower Thigh 80: 1 type AA (5% of the robot's type AA’s)• Lower Portion 4: o Each Shin 84: 1 type BB (5% of the robot’s type BB’s) o Each Talus 88 / Foot 92: 1 type CC (100% of the robot's type CC’s) vi. Gearbox Type and Encoder Type

[0108] FIG. 10 illustrates a schematic representation identifying commonalities between the actuator's gearbox type and encoder type. The motors may be coupled with various high-reduction gear mechanisms designed for precision, torque amplification, and load-handling capabilities. These may include, but are not limited to, strain wave gearboxes (e.g., Harmonic drives) known for their compact size and zero-backlash characteristics, cycloidal reducers offering high shock -load resistance and multi-tooth meshing for increased durability, planetary gearboxes providing high torque density and load distribution, bevel gear systems allowing directional power transmission through angular shafts, worm gears featuring inherent selflocking properties, parallel shaft helical gear mechanisms optimizing efficiency through helical teeth engagement, spur gear assemblies with simple, high-speed transmission capability, crossed helical gear systems with non-parallel, non-intersecting axes for torque redirection, double-enveloping worm gears increasing contact ratio for enhanced torque transmission, hernngbone gears minimizing axial thrust and vibration, hypoid gears offering increased torque transmission efficiency at non-intersecting angles, rack-and-pinion systems for linear motion conversion, bevel hypoid gears combining hypoid and bevel gear advantages, epicyclic gear trains facilitating compact high-ratio reductions, and differential gear systems enabling variable torque distribution across multiple output shafts.

[0109] Additionally, in some implementations, custom gear profiles may be engineered with non-standard tooth geometries, including asymmetric teeth, logarithmic spiral designs, or parabolic curvature, to optimize torque transfer efficiency, reduce backlash, improve wear resistance, and minimize noise. These profiles may be generated using advanced computational modeling techniques, such as finite element analysis (FEA) and topology optimization, to achieve optimal mechanical performance under varying loads. Advanced materials such as case-hardened alloy steels, ceramics, composite polymers, titanium alloys, or high- performance thermoplastics may be used to enhance durability, weight reduction, and efficiency. In some implementations, hybrid composite-metallic gears may be utilized to balance strength and flexibility, reducing overall system inertia. Surface treatments, including ion nitriding, carburizing, diamond-like carbon (DLC) coatings, boronizing, tungsten carbide coatings, and plasma-assisted chemical vapor deposition (PACVD), may further improve wear resistance, reduce friction losses, and enhance corrosion protection, particularly in high-load or high-speed applications. Additionally, low-friction coatings, such as molybdenum disulfide (M0S2) or polytetrafluoroethylene (PTFE)-based coatings, may be applied to improve energy efficiency and reduce mechanical wear over prolonged operation.

[0110] To achieve exceptional positional accuracy and ensure reliable operation, each motor may be equipped with advanced encoders. These encoders may employ various sensingmethodologies, such as optical encoders leveraging diffraction grating patterns for high- resolution feedback, magnetic encoders using Hall-effect sensors or magnetoresistive elements for robust performance in harsh environments, capacitive encoders detecting variations in capacitance for non-contact operation, inductive encoders utilizing coil-based electromagnetic field modulation, resistive encoders measuring positional changes via voltage division, piezoelectric encoders generating electrical signals proportional to mechanical displacement, Hall-effect encoders detecting magnetic flux variations for precise angular positioning, potentiometric encoders using resistive tracks for analog signal output, and ultrasonic encoders exploiting time-of-flight principles for non-contact distance measurement. These encoders may facilitate sub-millimeter-level accuracy, essential for applications requiring precise motion control, such as robotic surgical instruments, industrial automation, and high-fidelity humanoid articulation.[OHl] To complement positional data, the actuator assembly may further incorporate integrated torque sensors. These may include strain gauge sensors that detect minute deformations in mechanical components, piezoresistive sensors that leverage resistance changes under mechanical stress, magnetoelastic sensors that measure stress-induced magnetic field variations, capacitive torque sensors detecting variations in capacitance due to material strain, fiber-optic sensors utilizing Bragg grating or interferometric principles for high- sensitivity torque detection, and rotary transformers that convert mechanical torque into electrical signals without direct contact. Additionally, alternative sensor configurations may include ultrasonic torque sensors that measure strain through acoustic wave propagation, quartz-based piezoelectric torque sensors for high-frequency dynamic applications, and eddy current torque sensors that utilize magnetic field distortions for non-contact measurement. In some implementations, multi-axis torque sensors may be employed to detect torque components in multiple directions, enabling more comprehensive force feedback for advanced robotic applications. Moreover, advanced hybrid sensor designs may integrate multiple sensing modalities, such as combining strain gauges with fiber-optic sensors, to enhance sensitivity and redundancy. Smart self-calibrating torque sensors utilizing machine learning algorithms for drift compensation and real-time error correction may also be incorporated to improve longterm reliability and performance in highly dynamic environments.

[0112] Additionally, or alternatively, the actuators may include current sensors to monitor motor performance and optimize control strategies. These may comprise Hall-effect sensors measuring magnetic field variations in conductive elements, shunt resistors offering precisevoltage drop-based current sensing, fluxgate sensors enabling accurate low-noise current detection, Rogowski coils providing flexible, non-intrusive AC current sensing, and magnetoresistive sensors offering high-sensitivity current monitoring. Furthermore, for enhanced control and environmental adaptability, the system may integrate microelectromechanical systems (MEMS) gyroscopes and / or accelerometers. These sensors provide real-time feedback on orientation, angular velocity, and linear acceleration, enabling the humanoid robot to maintain balance, detect external disturbances, and execute smooth, adaptive movements. Sensor fusion algorithms may be employed to combine data from multiple sources, improving motion prediction accuracy and stability in dynamic environments.

[0113] In particular, said humanoid robot 1 includes three types of gearboxes and encoders. FIG. 10 shows the humanoid robot 1 includes the following three types of gearboxes and encoders:Table 12

[0114] Based on these differences, the gearbox and encoder types can be distributed within the humanoid robot 1, as shown in FIG. 10 and described below:Table 13

[0115] In addition to the above general arrangement, the following types are distributed as shown below-:• Upper Portion 2:o Head / Neck 10: 2 type EE’s (7% of the robot’s total type EE’s) o Upper Portion of the Torso 16: 2 type EE’s (7% of the robot’s total type EE’s) o Each Arm Assembly 5:■ Each Shoulder 26: 1 type EE (3% of the robot’s total type EE’s)■ Each Upper Arm Assembly 24:• Each Upper Humerus 30: 1 type EE (3% of the robot’s total type EE’s)• Each Lower Humerus / Elbow 36: 1 type EE (3% of the robot’s total ty pe EE’s)■ Each Lower Forearm 46: 2 type EE’s (7% of the robot's total type EE’s)■ Each Wrist 50: 1 type EE (7% of the robot’s total type EE’s) o Each Hand 56: 6 type GG’s (50% of the robot’s total type GG’s)■ Each Finger: 1 ty pe GG (8% of the robot’s ty pe GG's)■ Thumb: 2 ty pe GG (16% of the robot’s type GG's)• Central Portion 3: o Spine 60: 1 type EE (3% of the robot’s type EE’s) o Pelvis 64: 1 ty pe EE (3% of the robot’s ty pe EE's) o Each Hip 70: 1 type EE (3% of the robot’s type EE’s) o Each Upper Thigh 76: 2 type EE’s (7% of the robot’s type EE’s) o Each Lower Thigh 80: 1 type EE (3% of the robot’s ty pe EE’s)• Lower Portion 4: o Each Shin 84: 1 type FF (50% of the robot’s type FF’s) o Each Talus 88 / Foot 92: 1 type EE (3% of the robot’s type EE’s) vii. Inclusion of a Cross-Roller Bearing

[0116] The actuators or the output of the actuators may include bearing housings constructed using advanced materials like carbon-fiber-reinforced polymers (CFRPs), fiberglass-reinforced polymers (FRPs), metal alloys, polyetheretherketone (PEEK), thermoplastic composites, and ultra-high-molecular-weight polyethylene (UHMWPE). Additionally, the manufacturing processes for CFRPs, such as filament winding or automated fiber placement, allow for precise control over fiber orientation, further optimizing the mechanical performance of the housings. The bearings themselves can be fabricated from, include, or processed using highgrade steel alloys (e.g., AISI 52100, M50, or 440C stainless steel), high-performance nickel-based superalloys (e.g., Inconel 718 or Hastelloy), cobalt-based alloys (e.g., Stellite), advanced ceramics (e.g., alumina or zirconia-based composites), and polymer matrix composites reinforced with carbon or aramid fibers. These materials may also benefit from advanced heat treatments (e.g, vacuum hardening or cryogenic treatment), surface engineering processes (e.g, ion implantation or physical vapor deposition), or specialized coatings.

[0117] To further optimize performance, the rolling elements of the bearings may be composed of advanced ceramic materials (e.g.. silicon nitride, tungsten carbide, or zirconia), sapphire, or composite materials combining ceramic with metal or polymer matrices. In another embodiment, the assembly may incorporate cylindrical roller bearings, angular contact ball bearings, or hybrid bearings that combine steel races with ceramic rolling elements. Additionally, spherical roller bearings, tapered roller bearings, needle roller bearings, magnetic bearings, or hybrid or combinations thereof. Cutting-edge manufacturing techniques, including additive manufacturing methods like selective laser melting (SLM), could be employed to create complex bearing geometries. These geometries may integrate features such as internal cooling channels, lubrication reservoirs, or textured surfaces to enhance lubrication retention and minimize wear.

[0118] The incorporation of such features allows for improved thermal management, reduced friction, and consistent lubrication distribution, even under challenging operating conditions. Additive manufacturing also enables the production of customized bearing designs with minimal material waste, aligning with sustainable manufacturing practices. In addition to additive manufacturing, other advanced processes like precision machining, laser hardening, or chemical vapor deposition (CVD) coatings may be applied to enhance the surface properties of the bearings. These techniques can improve wear resistance, reduce friction, and provide protection against corrosion, further extending the operational life of the components. The integration of smart sensors within the bearing housing is another potential enhancement, allowing for real-time monitoring of parameters such as temperature, vibration, and load. This data can be used to predict maintenance needs and prevent unexpected failures, ensuring optimal performance and reliability in critical applications.

[0119] In particular, said humanoid robot 1 includes actuators that either include or do not include a cross-roller bearing. FIG. 11 shows the humanoid robot 1 that illustrates this binary configuration._ Table 14 _| Type | Inclusion or Exclusion of |

[0120] Based on these differences, the inclusion or exclusion of the cross-roller bearing can be distributed within the humanoid robot 1, as shown in FIG. 11 and described below:Table 15viii. Inclusion of Through-Bore Wire

[0121] A substantial majority of the electric actuators utilized in the robot include through- bore wiring, where wires or leads pass through a designated region, typically the center of the actuator. Each actuator includes a PCB assembly that receives connections that facilitate the passing of electrical current and control signals from a wire harness to said PCB. The wire harness extends from the PCB assembly, passes through a wire passage formed within the actuator, and exits at the bottom to connect to the PCB assembly of an adjacent actuator. This structured wiring configuration ensures efficient power distribution and control signal transmission while reducing mechanical complexity and potential points of failure.

[0122] The wire harness assembly consists of: (i) a first connector designed to couple with a PCB assembly of an adjacent actuator, (ii) a connecting portion positioned within the robot's housing or exoskeleton rather than inside an actuator, (iii) an optional strain relief member to minimize mechanical stress during wiring transitions, (iv) a through-bore portion housed within the actuator’s bore receiver, and (v) a second connector secured to the PCB assembly via a transfer connector. In other embodiments, the above described wire harness can be split into two harnesses, wherein: (i) one harness is coupled within the robot in a fixed manner, and (ii) the other harness is coupled between two PCBs (input and output) and is designed to rotate within the actuator through-bore.

[0123] Furthermore, the wire harness can incorporate additional protective layers such as braided shielding or dielectric coatings to enhance electrical insulation and minimize electromagnetic interference (EMI). In certain implementations, flexible printed circuit boards (FPCBs) or coiled wire configurations may be used to accommodate dynamic motion, reducing mechanical stress on the wiring system. The use of flexible conductors with reinforced sheathing enhances durability, especially in high-mobility robots requiring frequent articulation.

[0124] The structured design of the wire harness serves multiple functions: (i) it facilitates the seamless transfer of pow er and control signals between actuators, (ii) it ensures that no single wire extends across multiple degrees of freedom, (iii) it eliminates the need to route wires around the ends or periphenes of the actuators, and (iv) it allows for modular integration, making it easier to replace or upgrade individual actuator units. This arrangement reduces pinch points, enhances the mechanical reliability" of the wiring system, and simplifies actuator packaging within the robot.

[0125] Alternative embodiments may include different wire configurations, such as integrating electrical wiring and control wires within the robot’s shell or outer layers. In such embodiments, each actuator would interface with shell-based wiring using a single wire group. Additionally, variations in the number of wire groups (ranging from one to ten) can be implemented to accommodate different design requirements. For example, a dual-wire configuration may be used for redundant power supply or fail-safe mechanisms. Additionally, actuators may incorporate micro-connectors or magnetic coupling interfaces to further streamline the wiring architecture.

[0126] In particular, said humanoid robot 1 includes actuators that either include or do not include a cross-roller bearing. FIG. 12 show's the humanoid robot 1 that illustrates this binary configuration.Table 16

[0127] Based on these differences, the inclusion or exclusion of the through-bore wiring can be distributed within the humanoid robot 1, as shown in FIG. 12 and described below :Table 175. Industrial Application

[0128] While the disclosure shows illustrative embodiments of a robot (in particular, a humanoid robot), it should be understood that embodiments are designed to be examples of the principles of the disclosed assemblies, methods and systems, and are not intended to limit the broad aspects of the disclosed concepts to the embodiments illustrated. As will be realized, the disclosed robot, and its functionality and methods of operation, are capable of other and different configurations and several details are capable of being modified all without departing from the scope of the disclosed methods and systems. For example, one or more of the disclosed embodiments, in part or whole, may be combined with a disclosed assembly, method and system. As such, one or more steps from the diagrams or components in the Figures may be selectively omitted and / or combined consistent with the disclosed assemblies, methods and systems. Additionally, one or more steps from the arrangement of components may be omitted or performed in a different order. Accordingly, the drawings, diagrams, and detailed description are to be regarded as illustrative in nature, not restrictive or limiting, of said humanoid robot.

[0129] While the above-described methods and systems are designed for use with a general- purpose humanoid robot, it should be understood that the assemblies, components, learning capabilities, and / or kinematic capabilities may be used with other robots. Examples of other robots include: articulated robot (e.g., an arm having two, six. or ten degrees of freedom, etc.), a cartesian robot (e.g.. rectilinear or gantry robots, robots having three prismatic joints, etc.). Selective Compliance Assembly Robot Arm (SCARA) robots (e.g., with a donut shaped work envelope, with two parallel joints that provide compliance in one selected plane, with rotary shafts positioned vertically, with an end effector attached to an arm, etc.), delta robots (e.g., parallel link robots with parallel joint linkages connected with a common base, having directcontrol of each joint over the end effector, which may be used for pick-and-place or product transfer applications, etc ), polar robots (e.g., with a twisting joint connecting the arm with the base and a combination of two rotary joints and one linear joint connecting the links, having a centrally pivoting shaft and an extendable rotating arm, spherical robots, etc.), cylindrical robots (e.g., with at least one rotary joint at the base and at least one prismatic joint connecting the links, with a pivoting shaft and extendable arm that moves vertically and by sliding, with a cylindrical configuration that offers vertical and horizontal linear movement along with rotary movement about the vertical axis, etc.), self-driving car, a kitchen appliance, construction equipment, or a variety of other types of robot systems. The robot system may include one or more sensors (e.g., cameras, temperature, pressure, force, inductive or capacitive touch), motors (e.g., servo motors and stepper motors), actuators, biasing members, encoders, housing, or any other component known in the art that is used in connection with robot systems. Likewise, the robot system may omit one or more sensors (e.g., cameras, temperature, pressure, force, inductive or capacitive touch), motors (e.g., servo motors and stepper motors), actuators, biasing members, encoders, housing, or any other component known in the art that is used in connection with robot systems.

[0130] In other embodiments, other configurations and / or components may be utilized. As is known in the data processing and communications arts, a general-purpose computer typically comprises a central processor or other processing device, an internal communication bus, various types of memory or storage media (RAM, ROM, EEPROM, cache memory, disk drives etc.) for code and data storage, and one or more network interface cards or ports for communication purposes. The software functionalities involve programming, including executable code as well as associated stored data. The software code is executable by the general-purpose computer. In operation, the code is stored within the general-purpose computer platform. At other times, however, the software may be stored at other locations and / or transported for loading into the appropriate general-purpose computer system.

[0131] A server, for example, includes a data communication interface for packet data communication. The server also includes a central processing unit (CPU), in the form of one or more processors, for executing program instructions. The server platform typically includes an internal communication bus, program storage and data storage for various data files to be processed and / or communicated by the server, although the server often receives programming and data via network communications. The hardware elements, operating systems and programming languages of such servers are conventional in nature, and it is presumed thatthose skilled in the art are adequately familiar therewith. The server functions may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load.

[0132] Hence, aspects of the disclosed methods and systems outlined above may be embodied in programming. Program aspects of the technology may be thought of as “products” or “articles of manufacture” typically in the form of executable code and / or associated data that is carried on or embodied in a type of machine-readable medium. “Storage” type media includes any or all of the tangible memon of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide non-transitory storage at any time for the software programming. All or portions of the software may at times be communicated through the Internet or various other telecommunication netw orks. Thus, another type of media that may bear the softw are elements includes optical, electrical and electromagnetic w aves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links or the like, also may be considered as media bearing the software. As used herein, unless restricted to non-transitory, tangible “storage” media, terms such as computer or machine “readable medium” refer to any medium that participates in providing instructions to a processor for execution.

[0133] A machine-readable medium may take many forms, including but not limited to, a tangible storage medium, a carrier wave medium or physical transmission medium. Nonvolatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like, such as may be used to implement the disclosed methods and systems. Volatile storage media include dynamic memory, such as the main memory' of such a computer platform. Tangible transmission media include coaxial cables, copper wire and fiber optics, including the wires that comprise a bus within a computer system. Carrier-wave transmission media can take the form of electric or electromagnetic signals, or acoustic or light w aves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards, paper tape, any other physical storage medium with patterns of holes, a RAM, a PROM and EPROM, a FLASH- EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions,cables or links transporting such a carrier wave, or any other medium from which a computer can read programming code and / or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.

[0134] It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims. In the drawings, some structural or method features may be shown in specific arrangements and / or orderings. However, it should be appreciated that such specific arrangements and / or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and / or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, may not be included or may be combined with other features.

[0135] It should also be understood that substantially utilized herein means a deviation less than 15% and preferably less than 5%. It should also be understood that other configuration or arrangements of the above-described components is contemplated by this Application. Moreover, the description provided in the background section should not be assumed to be prior art merely because it is mentioned in or associated with the background section. The background section may include information that describes one or more aspects of the subject of the technology. Finally, the mere fact that something is described as conventional does not mean that the Applicant admits it is prior art.

[0136] In this Application, to the extent any U.S. patents, U.S. patent applications, or other materials (e.g.. articles) have been incorporated by reference, the text of such materials is only incorporated by reference to the extent that they do not conflict with materials, statements and drawings set forth herein. In the event of such conflict, the text of the present document controls, and terms in this document should not be given a narrow er reading in virtue of the way in which those terms are used in other materials incorporated by reference. It should also be understood that structures and / or features not directly associated with a robot cannot be adopted or implemented into the disclosed humanoid robot without careful analysis and verification of the complex realities of designing, testing, manufacturing, and certifying a robotfor completion of usable work nearby and / or around humans. Theoretical designs that attempt to implement such modifications from non-robotic structures and / or features are insufficient (and in some instances, woefully insufficient) because they amount to mere design exercises that are not tethered to the complex realities of successfully designing, manufacturing and testing a robot.

Claims

CLAIMS1. A humanoid robot having at least 28 actuators, the humanoid robot comprising: a torso; a torso twist actuator coupled to the torso and configured to allow the torso to move around a torso twist axis; a knee actuator with a knee axis; an upper portion of the humanoid robot positioned above the torso twist axis, the upper portion including a first actuator with a momentary peak torque rating and a second actuator with a momentary7peak torque rating, wherein one momentary peak torque rating of said momentary peak torque ratings is below 10 Nm; and a lower portion of the humanoid robot positioned below the knee axis, the low er portion including a third actuator having at least one momentary peak torque rating that is above 35 Nm; and a central portion extending between the upper portion of the humanoid robot and the lower portion of the humanoid robot, the central portion including a fourth actuator having at least one momentary peak torque rating that is above 300 Nm.

2. The humanoid robot of claim 1, wherein the first actuator is located in a shoulder of the humanoid robot, the first actuator having a momentary7peak torque rating betw een 70 Nm and 110 Nm, and wherein the second actuator is located in a wrist of the humanoid robot, the second actuator having a momentary peak torque rating between 15 Nm and 30 Nm.

3. The humanoid robot of claim 1, wherein the third actuator is located in a foot of the humanoid robot, the third actuator having a momentary peak torque rating betw een 40 Nm and 50 Nm, and the third actuator including a strain wave gearbox with a gear reduction ratio between 80: 1 and 100: 1.

4. The humanoid robot of claim 1, w herein the fourth actuator is located in a hip of the humanoid robot, the fourth actuator having a momentary7peak torque rating between 320 Nm and 380 Nm, and the fourth actuator including a cross-roller bearing and through-bore wiring for power and control signal transmission.

5. The humanoid robot of claim 1, wherein the third actuator has a momentary peak torque rating between 280 Nm and 360 Nm, the third actuator including both a crossroller bearing and a harmonic drive gearbox with a gear reduction ratio between 100:1 and 120: 1.

6. The humanoid robot of claim 1, further comprising a head assembly including two actuators utilizing optical encoders, wherein each of said two actuators has a momentary peak torque rating between 20 Nm and 25 Nm.

7. The humanoid robot of claim 1, wherein at least 22 of the at least 28 actuators include through-bore wiring for power and control signal transmission.

8. The humanoid robot of claim 1, wherein the central portion includes at least six rotary actuators, wherein three of the at least six rotary actuators have the same type of gearbox.

9. The humanoid robot of claim 9, wherein a first rotary actuator of the six rotary' actuators of the central portion has the same gear reduction ratio as one of the actuators in the upper portion.

10. The humanoid robot of claim 1, further comprising a leg assembly having at least four electrical actuators, wherein a first electrical actuator of the four electrical actuators has a first motor with a speed rating that is above 2,500 RPMs, and a second electrical actuator of the four electrical actuators has a second motor that is different from the first motor.

11. A humanoid robot having at least 28 actuators, the humanoid robot comprising: a torso; a waist coupled to the torso; a knee actuator positioned below the waist, when the robot is in a neutral position; an upper portion of the humanoid robot is positioned above the waist and includes at least four rotatory actuators, wherein: (i) two actuators of the at least four rotatory actuators have the same type of gearbox, and (ii) a first rotatory’ actuator of the four rotatory actuators has a first gear reduction ratio, and a second rotatory actuator of the four rotatory actuators has a second gear reduction ratio that is different from the first gear reduction ratio; a lower portion of the humanoid robot is positioned below the knee actuator, the lower portion including at least two actuators; and a central portion extending between the upper portion of the humanoid robot and the lower portion of the humanoid robot, the central portion including at least six rotatory actuators, wherein: (i) three actuators of the at least six rotatory' actuatorshave the same type of gearbox, and (ii) a first rotatory actuator of the six rotatory actuators has the first gear reduction ratio.

12. The humanoid robot of claim 11, wherein the first gear reduction ratio is between 40: 1 and 60: 1, and the first rotatory actuator of the upper portion is located in a shoulder of the humanoid robot.

13. The humanoid robot of claim 11, wherein the two actuators of the at least four rotatory actuators having the same t pe of gearbox utilize strain wave gearboxes that are located in a wrist assembly of the humanoid robot.

14. The humanoid robot of claim 11, wherein the three actuators of the at least six rotatory actuators having the same type of gearbox utilize harmonic drive gearboxes that are located in a hip assembly of the humanoid robot.

15. The humanoid robot of claim 11, wherein at least one of the at least four rotatory actuators in the upper portion both includes through-bore wiring for power and control signal transmission and utilizes a brushless DC motor.

16. The humanoid robot of claim 11, wherein at least one of the at least four rotatory actuators in the upper portion includes a cross-roller bearing with ceramic rolling elements.

17. The humanoid robot of claim 11, wherein the at least two actuators in the low er portion include a foot actuator with a momentary peak torque rating between 35 Nm and 55 Nm and a maximum rotational speed of 500 RPM.

18. The humanoid robot of claim 17, wherein the foot actuator includes a strain wave gearbox with a gear reduction ratio between 80: 1 and 100: 1 and a hollow^ shaft for cable routing.

19. The humanoid robot of claim 11, wherein the knee actuator has a momentary peak torque rating between 265 Nm and 398 Nm and incorporates a torque sensor for force feedback control.

20. A humanoid robot having at least 28 actuators, the humanoid robot comprising: an arm assembly having at least five electrical actuators, wherein a first electrical actuator of the five electrical actuators has a first motor with a speed rating greater than 2,500 RPMs, and a second electrical actuator of the five electrical actuators has a second motor that is different from the first motor and that has a speed rating less than 10,000 RPMs; anda leg assembly having at least four electrical actuators, wherein a first electrical actuator of the four electrical actuators has the first motor with the speed rating greater than 2,500 RPMs, and a second electrical actuator of the four electrical actuators has a third motor that is different from the first motor and the second motor.

21. The humanoid robot of claim 20, w herein the first electrical actuator of the arm assembly is located in a shoulder of the humanoid robot, the first electrical actuator having a momentary peak torque rating between 70 Nm and 110 Nm.

22. The humanoid robot of claim 20, wherein at least one of the electrical actuators in the arm assembly includes a strain wave gearbox with a gear reduction ratio between 40:1 and 60: 1.

23. The humanoid robot of claim 20, wherein at least three of the electrical actuators in the arm assembly include through-bore wiring for power and control signal transmission.

24. The humanoid robot of claim 20, further comprising a torso twist actuator coupled to a torso of the humanoid robot, the torso twist actuator configured to allow the torso to move around a torso twist axis.

25. The humanoid robot of claim 20, further comprising a foot actuator in the leg assembly, the foot actuator having a momentary' peak torque rating between 35 Nm and 55 Nm and a maximum rotational speed of 500 RPM.

26. The humanoid robot of claim 20, wherein at least one of the electrical actuators in the arm assembly utilizes a brushless DC motor and an optical encoder for position feedback.

27. The humanoid robot of claim 20, wherein at least one of the electrical actuators in the leg assembly incorporates a torque sensor for force feedback control.

28. The humanoid robot of claim 20, further comprising a head assembly including two actuators, each having a momentary peak torque rating between 20 Nm and 25 Nm.

29. The humanoid robot of claim 20, wherein the third motor in the leg assembly is a synchronous reluctance motor with a speed rating between 1,500 RPMs and 2,000 RPMs.

30. A humanoid robot having at least 28 actuators, the humanoid robot comprising: an arm assembly and a leg assembly, wherein: (i) the arm and leg assemblies collectively include at least eleven electric actuators with less than eight differenttypes of electronic assemblies, and (ii) one actuator of the eleven electric actuators is a shoulder actuator with a momentary peak torque rating that is less than 200 Nm; a torso having an electric arm actuator coupled to the shoulder actuator, and wherein the shoulder actuator and the arm actuator are of the same actuator type.

31. The humanoid robot of claim 30, wherein at least one of the electrical actuators in the arm assembly includes a strain wave gearbox with a gear reduction ratio between 50: 1 and 70: 1.

32. The humanoid robot of claim 30, wherein at least four of the electrical actuators in the arm assembly include through-bore wiring for power and control signal transmission.

33. The humanoid robot of any one of claims 30-32, further comprising a torso twist actuator coupled to a torso of the humanoid robot, the torso twist actuator configured to allow the torso to move around a torso twist axis, wherein the torso twist actuator has a momentary peak torque rating between 200 Nm and 300 Nm.

34. The humanoid robot of claim 30, further comprising a head assembly including two actuators, each having a momentary peak torque rating between 18 Nm and 22 Nm and utilizing magnetic encoders.

35. The humanoid robot of any one of claims 30-34, wherein a foot actuator in the leg assembly includes a strain wave gearbox with a gear reduction ratio between 85: 1 and 95 : 1 and a hollow shaft for cable routing.

36. The humanoid robot of claim 30, wherein at least three of the electrical actuators in the arm assembly and at least two of the electrical actuators in the leg assembly utilize the same type of electronic control board.

37. A humanoid robot comprising: an upper portion having a plurality of actuators that include: (i) ten electrical actuators, each having a first momentary peak torque rating, (ii) four electrical actuators, each having a second momentary peak torque rating that is different from the first momentary peak torque, and (iii) four electrical actuators having a third momentary peak torque rating that is different from both the first and second momentary peak torques; and a lower portion including two electrical actuators having a fourth momentary peak torque rating that is different than each of the first, second, and third momentary peak torques; anda central portion extending between the upper portion and the lower portion, the central portion including three electrical actuators having a fifth momentary peak torque rating that is different than each of the first, second, third, and fourth momentary peak torques.

38. The humanoid robot of claim 37, wherein the first electrical actuator of the **** arm assembly is located in a shoulder of the humanoid robot and has a momentary’ peak torque rating between 80 Nm and 100 Nm.

39. The humanoid robot of claim 37, further comprising a torso twist actuator coupled to a torso of the humanoid robot and configured to allow the torso to move around a torso twist axis, wherein the torso twist actuator has a momentary peak torque rating between 220 Nm and 280 Nm.

40. The humanoid robot of claim 37, further comprising a foot actuator in the lower assembly with a momentary peak torque rating between 40 Nm and 50 Nm and a maximum rotational speed between 450 RPM and 550 RPM.

41. The humanoid robot of claim 40, wherein the foot actuator includes a strain wave gearbox with a gear reduction ratio between 85: 1 and 95: 1 and a hollow shaft for cable routing.

42. The humanoid robot of claim 37, wherein at least one of the electrical actuators in the upper portion utilizes a brushless DC motor and an optical encoder with a resolution of at least 16 bits for position feedback.

43. The humanoid robot of claim 37, wherein at least one of the electrical actuators in the lower portion incorporates a torque sensor with a measurement range of at least 0-500 Nm for force feedback control.

44. The humanoid robot of any one of claims 37-43, wherein the lower portion includes a synchronous reluctance motor with a speed rating between 1,600 RPMs and 1,900 RPMs and a momentary peak torque rating between 150 Nm and 200 Nm.

45. The humanoid robot of claims 37-43, wherein at least three of the electrical actuators in the upper portion and at least two of the electrical actuators in the lower portion utilize the same type of electronic control board capable of processing signals from both optical encoders and torque sensors.

46. The humanoid robot of any one of claims 37-43, wherein the upper portion includes a first motor and a second motor, and wherein the first motor and the second motorhave different types of encoders for position feedback, with the first motor utilizing an optical encoder and the second motor utilizing a magnetic encoder.

47. A humanoid robot comprising: a first set of twelve actuators having a first reduction ratio; a second set of four actuators having a second reduction ratio that is different from the first reduction ratio; a third set of three actuators having a third reduction ratio that is different from both of the first and second reduction ratios; a fourth set of two actuators having a fourth reduction ratio that is different from each of the first, second, and third reduction ratios; and wherein: (i) the first and second sets of actuators are positioned in an upper portion of the humanoid robot, (ii) the third set of actuators is positioned in a central portion of the humanoid robot, and (iii) the fourth set of actuators is positioned in a lower portion of the humanoid robot.

48. The humanoid robot of claim 47, wherein the first set of twelve actuators comprises actuators located in the robot's fingers and thumbs, and wherein each actuator has a momentary peak torque rating between 3 Nm and 10 Nm.

49. The humanoid robot of claim 47, wherein the second set of four actuators comprises actuators located in the robot's wrists and elbows, and wherein each actuator has a momentary peak torque rating between 17 Nm and 30 Nm.

50. The humanoid robot of claim 47, wherein the third set of three actuators comprises actuators located in the robot's hip flexors and lumbar spine, and wherein each actuator has a momentary' peak torque rating between 265 Nm and 398 Nm.

51. The humanoid robot of claim 47, wherein the fourth set of two actuators comprises actuators located in an ankle region of the robot, and wherein each actuator has a momentary' peak torque rating between 96 Nm and 150 Nm.

52. The humanoid robot of any one of claims 47-51, w herein at least one actuator in each of the first through fourth sets includes through-bore wiring for power transmission and a separate through-bore wiring for control signal transmission, and wherein the power transmission wiring having a larger gauge than the control signal wiring.

53. The humanoid robot of any one of 47-51, further comprising a torso twist actuator coupled to a torso of the humanoid robot and configured to allow the torso to movearound a vertical torso twist axis, wherein the torso twist actuator utilizes a harmonic drive gearbox with a reduction ratio between 100: 1 and 120: 1.

54. The humanoid robot of claim 53, wherein the torso twist actuator has a momentary peak torque rating between 240 Nm and 260 Nm.

55. The humanoid robot of any one of claims 47-51, wherein at least one actuator in each of the first through fourth sets incorporates a strain gauge-based torque sensor with a measurement accuracy of ±0.5% full scale for closed-loop force feedback control.

56. A humanoid robot having at least 28 actuators, the humanoid robot comprising: a first set of eighteen actuators having a first encoder type; and a second set of two actuators positioned in the lower portion of the humanoid robot, said two actuators having a second encoder type that is different from the first encoder type; and wherein (i) at least 5% of the first set of actuators is positioned in a lower portion of the humanoid robot, (ii) at least 35% of said first set of actuators is positioned in a central portion of the humanoid robot, and (iii) at least 50% of the first set of actuators is positioned in an upper portion of the humanoid robot.

57. The humanoid robot of claim 56, wherein at least 90% of the first set of actuators include through-bore wiring for both power and control signal transmission.

58. The humanoid robot of claim 56, wherein: (i) at least 60% of the first set of actuators in the upper portion utilize strain wave gearboxes with gear reduction ratios between 50: 1 and 70: 1 , (ii) at least 70% of the first set of actuators in the central portion utilize harmonic drive gearboxes with gear reduction ratios between 100: 1 and 120: 1, and (iii) at least 80% of the first set of actuators in the lower portion utilize cycloidal reducers with gear reduction ratios between 80: 1 and 100: 1.

59. The humanoid robot of claim 56, wherein at least 75% of the first set of actuators utilize brushless DC motors with a power density of at least 1 kW / kg.

60. The humanoid robot of any one of claims 56-59, wherein at least 70% of the actuators in the upper portion include torque sensors with a measurement range of 0-100 Nm and an accuracy of ±0. 1% full scale.

61. The humanoid robot of claim 56, wherein at least 65% of the first set of actuators include custom-designed electronic control boards capable of closed-loop position, velocity, and torque control functionality.

62. The humanoid robot of claim 56, wherein: (i) at least 55% of the first set of actuators in the upper portion have a momentary peak torque rating between 15 Nm and 30 Nm, (ii) at least 65% of the first set of actuators in the central portion have a momentary peak torque rating between 200 Nm and 300 Nm, and (iii) at least 75% of the first set of actuators in the lower portion have a momentary peak torque rating between 350 Nm and 450 Nm.

63. The humanoid robot of claim 62, wherein the actuators with a momentary peak torque rating between 15 Nm and 30 Nm utilize a custom-wound stator with a copper fill factor of at least 65%.

64. The humanoid robot of claim 56, wherein at least 60% of the first set of actuators include a hollow shaft design with an inner diameter of at least 10 mm for cable routing.

65. The humanoid robot of claim 56, wherein the second set of actuators are located in an ankle region of the robot, wherein each of the second set of actuators (i) has a momentary peak torque rating between 100 Nm and 150 Nm, (ii) has a maximum rotational speed between 400 RPM and 500 RPM. and (iii) utilizes a strain wave gearbox with a gear reduction ratio between 80: 1 and 100: 1 .

Images