Design, modeling and evaluation of a millimeter-scale SMA bending actuator with variable length

Millimeter-scale continuum bending actuators are useful in minimally invasive surgery to allow distal visualization and manipulation outside the line of sight. This paper presents a new continuum bending actuator based on shape memory alloy (SMA) with variable bending length. It consists of two SMA wires antagonistically configured to produce bidirectional bending under Joule heating. A linearly actuated rigid tube along the longitudinal axis enables continuous bending length adjustment, thus enhancing its workspace and force range. The proposed fabrication method tackles the challenging assembly tasks of maintaining the antagonistic configuration of long SMA wires, and robust electrical and mechanical connection during actuation. A quasi-static model of the actuator based on beam model and SMA constitutive model is presented and verified. The bending actuator was evaluated comprehensively for its workspace, blocked force, and trajectory tracking capability at different bending lengths and under different cooling conditions. It is the first work that demonstrates real-time continuous bending length adjustment in SMA-based bending actuator, leading to the potential development of compact and compliant robotic end effectors with improved distal workspace and force.