Tendon Driven Continuum Robots (TDCR)
Project overview: I was brought in to upgrade a custom, tendon-driven robotic arm used for the automated testing of medical devices. The arm worked, but it operated entirely open-loop. My job was to design and integrate a closed-loop control system by embedding custom IMUs all the way along the arm's central core to provide real-time positional feedback.
Mechanical redesign: Adding sensors meant a total CAD overhaul. I redesigned the core links to include precise mounting pockets for the tiny IMU boards and designed internal routing channels for the delicate power and data cables. I worked closely with the electronics team to source boards that were lightweight enough to avoid disrupting the arm's dynamics while still fitting inside the tight spatial constraints.
Robustness testing: Tendon-driven arms endure massive internal compressive forces. To ensure the new hollowed-out sensor links wouldn't crush themselves during operation, I modeled the maximum expected forces mathematically and then took those estimates into the lab. I used a Mecmesin force tester to destructively test multiple 3D-printed material choices, fastener types, and surface coatings. This empirical data let us optimize the design before final assembly, saving us from endless iterative rebuilds.
The final result: The combination of the reinforced mechanical structure and the new closed-loop electronic feedback resulted in an incredibly resilient and precise arm. I wrapped up the project by producing a demonstration video showing off the arm's impressive dexterity, which was later presented at a technical medical robotics conference.