Reconfigurable Modular Soft Robots for Flat-to-Spherical Exploration

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Solution Overview

Problem

Existing exploratory robots made of standard manufacturing materials like metal or hard plastic are limited in size and shape adaptability, making them unsuitable for exploring various environments and prone to damage, and spherical projection onto a flat plane results in distortion.

Innovation Solution

A modular soft robot design featuring a base, arm, and actuator with deformable channels, allowing transformation between flat and curved configurations, utilizing actuators like motor tendon, spring, or memory alloy to minimize distortion and enable reconfiguration into 2D or 3D shapes such as a sphere.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If standard manufacturing materials (metal or hard plastic) are used for exploratory robots, then structural strength is improved, but adaptability to various environments and shapes deteriorates

Engineering Contradiction:
Improvestructural strengthVSAvoidenvironmental adaptability
Core Design Contradiction:
StrengthVSAdaptability or versatility

Solution Approach 1:

The patent employs soft materials with variable mechanical properties that can change their shape and configuration parameters. The robotic system uses materials that allow continuous deformation between different geometric states (flat, curved, spherical), enabling adaptation to various environments while maintaining sufficient structural integrity through material selection and design

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The invention implements a dynamic robotic structure that can actively change its configuration from flat to curved to spherical forms. This dynamic reconfigurability allows the robot to adapt its shape to match different environmental requirements, transitioning between states as needed for exploration tasks

Inventive Principle:
Principle #15Dynamics

2Ease of manufacture

If spherical configuration is projected onto flat plane, then manufacturing ease is improved, but distortion increases

Engineering Contradiction:
Improvemanufacturing easeVSAvoidshape accuracy
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent incorporates curved and spherical geometric features directly into the robotic structure's design. By integrating curvature into the base configuration rather than attempting to flatten spherical forms, the system achieves accurate spherical morphology without the distortions that would result from projection, while maintaining manufacturability through appropriate material selection and fabrication methods

Inventive Principle:
Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If robot size is increased to improve exploration capability, then exploration coverage is improved, but risk of damage from impacts or falls increases

Engineering Contradiction:
Improveexploration capabilityVSAvoiddamage resistance
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent utilizes soft materials with compliant mechanical properties that allow the robotic structure to deform under impact loads. This compliance enables the robot to absorb impact energy through controlled deformation rather than rigid fracture, maintaining reliability during exploration activities while preserving the ability to perform exploration functions

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

The modular soft robot system effectively navigates diverse terrains and environments with minimal distortion, enhancing adaptability and reducing damage risk through its deformable materials and reconfigurable structure.

Implementation Method 1

a modular soft robot including a base, an arm coupled to the base, and an actuator. The arm includes a first surface and a second surface opposite and spaced apart from the first surface. The actuator is configured to deform the arm between a flat configuration and a curved configuration

Methodology Applied
Scientific EffectElasticity: Elasticity

Implementation Method 2

In some implementations, the actuator is a motor tendon actuator at least partially disposed within the arm adjacent the base

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 3

In other implementations, the actuator is a spring or a memory alloy

Methodology Applied
Scientific EffectSpring energy storage: Spring

Implementation Method 4

In other implementations, the actuator is a spring or a memory alloy

Methodology Applied
Scientific EffectShape memory effect: Shape Memory Alloy

Data Source

PatentUS12384023B2Reconfigurable modular soft robots and methods of designing the same
Publication Date: 2025.08.12 UNIVERSITY OF ALABAMA
  • US12384023B2 patent drawing
  • US12384023B2 patent drawing
  • US12384023B2 patent drawing

AI summary

Various implementations include a modular soft robot including a base, an arm coupled to the base, and an actuator. The arm includes a first surface and a second surface opposite and spaced apart from the first surface. The first surface defines a plurality of channels, each channel comprising a proximal end at the first surface and a distal end spaced apart from the proximal end. Each channel has a longitudinal axis extending therethrough. The actuator is configured to deform the arm.