Novel Lightweight Hydraulic Integration Methodology for Robotic Applications

Hydraulic integration is one of the novel technologies in the field of robotics and assistive devices. Researchers have applied recent technologies starting from non-conventional machining methodologies and ending with additive manufacturing of metals. However, those methodologies have several drawbacks related to the cost, time, and robot weight. This motivates the research of new methodologies toward developing compact, cost-effective, and lightweight hydraulic integrated robotics mechanisms. This paper presents a novel methodology for fabricating hydraulically integrated parts by using lightweight and high-strength materials. The proposed materials, fabrication steps and the obtained results are thoroughly discussed. Silicon pipes are used for building the network of internal passages. This network is built inside a 3D-printed mould which is designed accordingly. A theoretical study is conducted for the newly manufactured hydraulic parts to define the design parameters and the working pressure at which the manufactured parts can withstand in addition to stresses and deformations analysis. The theoretical results are validated using finite element modelling (FEM) and experimental testing. The simulation results were consistent with the FEM results and the experimental results by 95% and 90% respectively. The proposed methodology is cheap and simple to implement in fabrication. Hence, this methodology can be used to fabricate hydraulic integrated components in hydraulically actuated humanoid robots successfully.