Differential Linear Actuation for Compact Humanoid Body Joints

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Solution Overview

Problem

Humanoid robots face a tradeoff between shape and performance due to the limited volume available for actuators within the human envelope, with larger actuators providing better performance but requiring a larger space.

Innovation Solution

The use of quasi-direct drive (QDD) linear actuators with low gear ratios (10:1 to 50:1) and differential linear actuation in pairs to adjust body joints in two degrees of freedom, allowing for a more compact and efficient humanoid robot design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If larger actuators are used to improve performance, then the robot's actuation performance is improved, but the robot's volume increases and it can no longer fit within the human envelope

Engineering Contradiction:
Improveactuator performanceVSAvoidrobot volume
Core Design Contradiction:
PowerVSVolume of moving object

Solution Approach 1:

The actuation system is segmented into multiple smaller linear actuators arranged in pairs or groups, where each actuator handles a portion of the total actuation load. This segmentation allows the robot to achieve high performance through coordinated action of multiple compact units rather than relying on single large actuators, thereby maintaining a compact form factor within the human envelope.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The linear actuators are nested within the robot's limb structures, with actuators positioned inside or along the length of limbs. This nesting approach maximizes the use of available internal volume, allowing high-performance actuation systems to be integrated without increasing the external dimensions of the robot beyond the human envelope.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Ease of operation

If traditional actuators are used in humanoid robots, then the robot can achieve human-like movement, but the friction and energy consumption increase, reducing runtime

Engineering Contradiction:
Improvehuman-like gaitVSAvoidenergy consumption
Core Design Contradiction:
Ease of operationVSLoss of energy

Solution Approach 1:

Traditional rotary actuators with complex gear trains and mechanical transmission systems are replaced with linear actuators that provide quasi-direct drive to the joints. This substitution eliminates or minimizes mechanical friction sources associated with gears and transmission mechanisms, significantly reducing energy loss while maintaining the ability to produce human-like movement patterns.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The actuation approach changes from indirect mechanical transmission to direct linear actuation, fundamentally altering the mechanical parameters of the system. This parameter change reduces friction coefficients and energy dissipation, enabling extended runtime while preserving human-like gait capabilities.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enables improved balance, human-like gait, efficient actuation, and a sleek form factor, enabling the robot to operate in human environments and perform tasks that traditional robots struggle with, while minimizing friction and enhancing runtime.

Implementation Method 1

at least one pair of joint linear actuators configured to operate in combination to adjust the at least one body joint assembly in two degrees of freedom through differential linear actuation

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS20250360978A1Humanoid robot
Publication Date: 2025.11.27 APPTRONIK INC
  • US20250360978A1 patent drawing
  • US20250360978A1 patent drawing
  • US20250360978A1 patent drawing

AI summary

A method of operating a robot includes operating a robot that includes a body assembly that includes a frame formed of at least one body joint assembly, and at least one pair of joint linear actuators that form the at least one body joint. The method further includes controlling the at least one pair of joint linear actuators to operate in combination to adjust the at least one body joint assembly in two degrees of freedom through differential linear actuation.