Kevin Y. Ma

Controlled Flight of a Biologically Inspired, Insect-Scale Robot

Lord of the Robotic Flies While small-scale flying objects are ubiquitous in nature, they are quite hard to engineer. As sizes get smaller, fixed-winged flight becomes less efficient because of increased drag resistance. Ma et al. (p. 603) developed a tethered robotic fly with wings that flap through the use of piezo-electric materials. Control of the flight motion involved a feedback process, which allowed the tethered robotic fly to hover and make controlled flight maneuvers. A fly-scale, flapping-wing robot has been fabricated and can be controlled to perform unconstrained flight maneuvers. Flies are among the most agile flying creatures on Earth. To mimic this aerial prowess in a similarly sized robot requires tiny, high-efficiency mechanical components that pose miniaturization challenges governed by force-scaling laws, suggesting unconventional solutions for propulsion, actuation, and manufacturing. To this end, we developed high-power-density piezoelectric flight muscles and a manufacturing methodology capable of rapidly prototyping articulated, flexure-based sub-millimeter mechanisms. We built an 80-milligram, insect-scale, flapping-wing robot modeled loosely on the morphology of flies. Using a modular approach to flight control that relies on limited information about the robot’s dynamics, we demonstrated tethered but unconstrained stable hovering and basic controlled flight maneuvers. The result validates a sufficient suite of innovations for achieving artificial, insect-like flight.

Pop-up book MEMS

We present a design methodology and manufacturing process for the construction of articulated three-dimensional microstructures with features on the micron to centimeter scale. Flexure mechanisms and assembly folds result from the bulk machining and lamination of alternating rigid and compliant layers, similar to rigid-flex printed circuit board construction. Pop-up books and other forms of paper engineering inspire designs consisting of one complex part with a single assembly degree of freedom. Like an unopened pop-up book, mechanism links reside on multiple interconnected layers, reducing interference and allowing folding mechanisms of greater complexity than achievable with a single folding layer. Machined layers are aligned using dowel pins and bonded in parallel. Using mechanical alignment that persists during bonding allows device layers to be anisotropically pre-strained, a feature we exploit to create self-assembling structures. These methods and three example devices are presented.

Progress on 'pico' air vehicles

As the characteristic size of a flying robot decreases, the challenges for successful flight revert to basic questions of fabrication, actuation, fluid mechanics, stabilization, and power, whereas such questions have in general been answered for larger aircraft. When developing a flying robot on the scale of a common housefly, all hardware must be developed from scratch as there is nothing ‘off-the-shelf’ which can be used for mechanisms, sensors, or computation that would satisfy the extreme mass and power limitations. This technology void also applies to techniques available for fabrication and assembly of the aeromechanical components: the scale and complexity of the mechanical features requires new ways to design and prototype at scales between macro and microeletromechanical systems, but with rich topologies and material choices one would expect when designing human-scale vehicles. With these challenges in mind, we present progress in the essential technologies for insect-scale robots, or ‘pico’ air vehicles.

First controlled vertical flight of a biologically inspired microrobot

In this paper, we present experimental results on altitude control of a flying microrobot. The problem is approached in two stages. In the first stage, system identification of two relevant subsystems composing the microrobot is performed, using a static flapping experimental setup. In the second stage, the information gathered through the static flapping experiments is employed to design the controller used in vertical flight. The design of the proposed controller relies on the idea of treating an exciting signal as a subsystem of the microrobot. The methods and results presented here are a key step toward achieving total autonomy of bio-inspired flying microrobots.

Perching and takeoff of a robotic insect on overhangs using switchable electrostatic adhesion

Making small robots stick Aerial views offer the chance to observe a wide range of terrain at once, but they come at the cost of needing to stay aloft. Graule et al. found that electrostatic forces could keep their insect-sized flying robot stuck to the underside of a range of surfaces (see the Perspective by Kovac). They mounted an electrostatically charged pad to the top of their robot, which could then reversibly stick to existing elevated perches—including a leaf—using less power than would be needed for sustained flight. Science, this issue p. 978; see also p. 895 Electrostatic adhesion enables a robotic insect to efficiently perch on and take off from natural and artificial structures. For aerial robots, maintaining a high vantage point for an extended time is crucial in many applications. However, available on-board power and mechanical fatigue constrain their flight time, especially for smaller, battery-powered aircraft. Perching on elevated structures is a biologically inspired approach to overcome these limitations. Previous perching robots have required specific material properties for the landing sites, such as surface asperities for spines, or ferromagnetism. We describe a switchable electroadhesive that enables controlled perching and detachment on nearly any material while requiring approximately three orders of magnitude less power than required to sustain flight. These electroadhesives are designed, characterized, and used to demonstrate a flying robotic insect able to robustly perch on a wide range of materials, including glass, wood, and a natural leaf.

Efficient resonant drive of flapping-wing robots

Flapping-wing air vehicles can improve efficiency by running at resonance to reduce inertial costs of accelerating and decelerating the wings. For battery-powered, DC motor-driven systems with gears and cranks, the drive torque and velocity is a complicated function of battery voltage. Hence, resonant behavior is not as well defined as for flapping-wing systems with elastic actuators. In this paper, we analyze a resonant drive to reduce average battery power consumption for DC motor-driven flapping-wing robots. We derive a nondimensionalized analysis of the generic class of a motor-driven slider crank, considering motor and battery resistance. This analysis is used to demonstrate the benefits of efficient resonant drive on a 5.8g flapping-wing robot and experiments showed a 30% average power reduction by integrating a tuned compliant element.

Controlling free flight of a robotic fly using an onboard vision sensor inspired by insect ocelli

Scaling a flying robot down to the size of a fly or bee requires advances in manufacturing, sensing and control, and will provide insights into mechanisms used by their biological counterparts. Controlled flight at this scale has previously required external cameras to provide the feedback to regulate the continuous corrective manoeuvres necessary to keep the unstable robot from tumbling. One stabilization mechanism used by flying insects may be to sense the horizon or Sun using the ocelli, a set of three light sensors distinct from the compound eyes. Here, we present an ocelli-inspired visual sensor and use it to stabilize a fly-sized robot. We propose a feedback controller that applies torque in proportion to the angular velocity of the source of light estimated by the ocelli. We demonstrate theoretically and empirically that this is sufficient to stabilize the robots upright orientation. This constitutes the first known use of onboard sensors at this scale. Dipteran flies use halteres to provide gyroscopic velocity feedback, but it is unknown how other insects such as honeybees stabilize flight without these sensory organs. Our results, using a vehicle of similar size and dynamics to the honeybee, suggest how the ocelli could serve this role.

Design, fabrication, and modeling of the split actuator microrobotic bee

The split actuator microrobotic bee is the first flight-capable, insect-scale flapping-wing micro air vehicle that uses “split-cycle” constant-period frequency modulation to control body forces and torques. Building this vehicle is an intricate challenge, but by leveraging a maturing fabrication technology for microscale devices, we have developed a solution to tackle the design and fabrication difficulties. We show that the design is able to independently modulate the motions of both wings and produce roll, pitch, and yaw torques, as well as a peak lift force of 1.3 mN, in a 70mg package.

Adaptive control of a millimeter-scale flapping-wing robot.

Challenges for the controlled flight of a robotic insect are due to the inherent instability of the system, complex fluid-structure interactions, and the general lack of a complete system model. In this paper, we propose theoretical models of the system based on the limited information available from previous work and a comprehensive flight controller. The modular flight controller is derived from Lyapunov function candidates with proven stability over a large region of attraction. Moreover, it comprises adaptive components that are capable of coping with uncertainties in the system that arise from manufacturing imperfections. We have demonstrated that the proposed methods enable the robot to achieve sustained hovering flights with relatively small errors compared to a non-adaptive approach. Simple lateral maneuvers and vertical takeoff and landing flights are also shown to illustrate the fidelity of the flight controller. The analysis suggests that the adaptive scheme is crucial in order to achieve millimeter-scale precision in flight control as observed in natural insect flight.

MEDIC: A legged millirobot utilizing novel obstacle traversal

This work presents the design, fabrication, capabilities, and obstacle traversal mechanics of MEDIC (Millirobot Enabled Diagnostic of Integrated Circuits), a small legged robot able to overcome a varied array of obstacles. MEDIC features a hull that keeps its body in contact with the ground at all times, and uses only four actuators to move forward, turn, mount obstacles, and move in reverse. The chassis is fabricated using a Smart Composite Microstructures (SCM) approach and the robot is actuated by coiled Shape Memory Alloy (SMA). MEDIC also features a camera which will be useful for navigation in the future.