SHAFT: A Slack-Compensating, Helical-Buckling-Attenuating Flexible-Shaft Transmission for Lightweight Multi-DoF Manipulation

Abstract

Lightweight and slim manipulators enable safe operation in human living environments. Proximal actuation using remote transmission mechanisms, such as wire-driven or Bowden cables, effectively reduces inertia and arm size by relocating motors near the base and transmitting torque to distal joints. Existing approaches either increase mass through additional components, such as pulleys for direction changes, or suffer from reduced transmission efficiency due to friction losses. Flexible shaft transmission avoids both mass increase and excessive friction losses, but faces increasing angular transmission error due to helical buckling caused by slack generated at joint bending. To address this problem, we propose SHAFT: a Slack-compensating, Helical-buckling-Attenuating Flexible- shaft Transmission mechanism. This mechanism compensates for slack through a proximal tensioner, improving the angular transmission error and efficiency of flexible shaft transmission without increasing the moving mass of the arm section. In a transmission path containing four 90-degree bends, the proposed mechanism demonstrated approximately 30% higher efficiency and approximately 65% lower angular transmission error compared to a flexible shaft transmission without a tensioner. Using this mechanism, we fabricated a 6-Degree-of-Freedom (DoF) arm with a 1-DoF gripper manipulator consisting of a rotary module housing motors with a tensioner, and a 280 g weight for the arm module. The proposed manipulator represents a novel remote actuation system for achieving lightweight construction with high efficiency, contributing to the acceleration of safe robot deployment in human environments.