Coordinated Optimization of Actuation and Component Structures in Lightweight Dynamic Arm‐Like Systems

ABSTRACT The interaction between actuation and structure in robot arms and similar arm‐like systems offers potential for lightweight design, leading to improved energy efficiency and dynamics. However, this interaction introduces complexity into the design and optimization process. This work presents an approach to optimize the actuation and structural components in a coordinated manner using nested loops to manage this complexity. The procedure allows for the simultaneous variation of the actuation principle (e.g., joint motors or belt drives) and associated actuator variables (e.g., motor masses or belt drive positions). Within this framework, the individual arm segments are structurally designed using density‐based topology optimization. The topology optimization uses linear static load cases, which are derived from a multi‐body simulation at specific time points with a predefined motion. The presented approach systematically explores the design space, leading to holistically optimized lightweight structures for arm‐like systems. An example demonstrates how the interaction between actuation and structure is taken into account.