WAVE: Worm Gear-based Adaptive Variable Elasticity for Decoupling Actuators from External Forces

Robotic manipulators capable of regulating both compliance and stiffness offer enhanced operational safety and versatility. Here, we introduce Worm Gear-based Adaptive Variable Elasticity (WAVE), a variable stiffness actuator (VSA) that integrates a non-backdrivable worm gear. By decoupling the driving motor from external forces using this gear, WAVE enables precise force transmission to the joint, while absorbing positional discrepancies through compliance. WAVE is protected from excessive loads by converting impact forces into elastic energy stored in a spring. In addition, the actuator achieves continuous joint stiffness modulation by changing the spring's precompression length. We demonstrate these capabilities, experimentally validate the proposed stiffness model, show that motor loads approach zero at rest--even under external loading--and present applications using a manipulator with WAVE. This outcome showcases the successful decoupling of external forces. The protective attributes of this actuator allow for extended operation in contact-intensive tasks, and for robust robotic applications in challenging environments.