Integrated Analytical Modeling and Numerical Simulation Framework for Design Optimization of Electromagnetic Soft Actuators

The growing interest in soft robotics arises from their unique ability to perform tasks beyond the capabilities of rigid robots, with soft actuators playing a central role in this innovation. Among these, electromagnetic soft actuators (ESAs) stand out for their fast response, simple control mechanisms, and compact design. Analytical and experimental studies indicate that smaller ESAs enhance the force per unit cross-sectional area (F/CSA) without compromising force efficiency. This work uses the magnetic vector potential (MVP) to calculate the magnetic field of an ESA, which is then used to derive the actuator’s generated force. A mixed integer non-linear programming (MINLP) optimization framework is introduced to maximize the ESA’s F/CSA. Unlike prior methods that independently optimized parameters, such as ESA length and permanent magnet diameter, this study jointly optimizes these parameters to achieve a more efficient and effective design. To validate the proposed framework, finite element-based COMSOL 5.4 is used to simulate the magnetic field and generated force, ensuring consistency between MVP-based calculations and the physical model. Additionally, simulation results demonstrate the effectiveness of MINLP optimization in identifying the optimal design parameters for maximizing the F/CSA of the ESA. The data and code are available at GitHub Repository.