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The Underactuated Lightweight Tensegrity Robotic Assistive Spine (ULTRA Spine) project is an ongoing effort to create a compliant, cable-driven, 3-degree-of-freedom, underactuated tensegrity core for quadruped robots. This work presents simulations and preliminary mechanism designs of that robot. Design goals and the iterative design process for an ULTRA Spine prototype are discussed. Inverse kinematics simulations are used to develop engineering characteristics for the robot, and forward kinematics simulations are used to verify these parameters. Then, multiple novel mechanism designs are presented that address challenges for this structure, in the context of design for prototyping and assembly. These include the spine robot’s multiple-gear-ratio actuators, spine link structure, spine link assembly locks, and the multiple-spring cable compliance system.

Abstract-Tensegrity robots are a class of compliant robots that have many desirable traits when designing mass efficient systems that must interact with uncertain environments. Various promising control approaches have been proposed for tensegrity systems in simulation. Unfortunately, state estimation methods for tensegrity robots have not yet been thoroughly studied. In this paper, we present the design and evaluation of a state estimator for tensegrity robots. This state estimator will enable existing and future control algorithms to transfer from simulation to hardware. Our approach is based on the unscented Kalman filter (UKF) and combines inertial measurements, ultra wideband time-of-flight ranging measurements, and actuator state information. We evaluate the effectiveness of our method on the SUPERball, a tensegrity based planetary exploration robotic prototype. In particular, we conduct tests for evaluating both the robot's success in estimating global position in relation to fixed ranging base stations during rolling maneuvers as well as local behavior due to small-amplitude deformations induced by cable actuation.