Pneumatic artificial muscles are a class of pneumatically driven actuators that are remarkable for their simplicity, lightweight, and excellent performance. These actuators are essentially a tubular bladder surrounded by a braided sleeve and sealed at both ends. Pressurization of the actuators generates contraction and tensile forces. Pneumatic artificial muscles have traditionally been used for robotics applications, but there has been recent interest in adapting them to a variety of aerospace actuation applications where their large stroke and force, which are realized at minimal weight penalty, create potential performance improvements over traditional technologies. However, an impediment to wide-spread acceptance of pneumatic artificial muscles is the relatively short fatigue lives of the actuators reported in the literature (typically, less than 18,000 actuation cycles before damage occurs). The purpose of this study is to develop a new construction method designed to greatly increase the number of fatigue cycles before damage occurs. The fabrication methodology employs a swaging process to provide smooth and distributed clamping of the bladder and braided sleeve components onto the end fittings. This approach minimizes stress concentrations and provides high mechanical strength, which can be experimentally validated via testing for the ultimate tensile failure load. Finite element analysis was used to refine the design of the swaged end fittings before extensive fatigue testing began. Long-term fatigue testing of the actuators under realistic operating conditions showed a substantial increase in actuator life, from a maximum of less than 18,000 cycles in previous research studies to more than 120,000,000 cycles in this study.

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Pneumatic artificial muscles (PAMs) provide numerous advantages for use as actuators in a wide variety of mechanical systems. Our study focused on determining the effects of braid angle on the performance of PAMs. This paper discusses how we constructed a set of PAMs with varying braid angle, predicted their performance using analytical models, gathered empirical data characterizing the PAMs, and compared the analytical predictions with the experimental results. We constructed six PAMs of different braid angles between 38° and 73°. To predict PAM performance, we used an analysis based on the force equilibrium equations for a pressurized actuator. We first quantified the performance limits of each actuator in a series of static characterization tests. Then we subjected each PAM to cyclical displacement testing. Finally, a series of cyclical tests were performed with a pre-strain applied to the PAMs, to better approximate their typical use. Our results showed variation of braid angle causes significant differences in performance among the six PAMs tested; PAMs with larger braid angle generated higher blocked force and exhibited greater contraction. The empirical data matched the model predictions based on our estimates for the braid angle of a given PAM.

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