Real-Time EtherCAT-Based Control Architecture for Electro-Hydraulic Humanoid

Electro-hydraulic actuators have witnessed significant development over recent years due to their remarkable abilities to perform complex and dynamic movements. Integrating such an actuator in humanoids is highly beneficial, leading to a humanoid capable of performing complex tasks requiring high force. This highlights the importance of safety, especially since high power output and safe interaction seem to be contradictory; the greater the robot’s ability to generate high dynamic movements, the more difficult it is to achieve safety, as this requires managing a large amount of motor energy before, during, and after the collision. No matter what technology or algorithm is used to achieve safety, none can be implemented without a stable control system. Hence, one of the main parameters remains the quality and reliability of the robot’s control architecture through handling a huge amount of data without system failure. This paper addresses the development of a stable control architecture that ensures, in later stages, that the safety algorithm is implemented correctly. The optimum control architecture to utilize and ensure the maximum benefit of electro-hydraulic actuators in humanoid robots is one of the important subjects in this field. For a stable and safe functioning of the humanoid, the development of the control architecture and the communication between the different components should adhere to some requirements such as stability, robustness, speed, and reduced complexity, ensuring the easy addition of numerous components. This paper presents the developed control architecture for an underdeveloped electro-hydraulic actuated humanoid. The proposed solution has the advantage of being a distributed, real-time, open-source, modular, and adaptable control architecture, enabling simple integration of numerous sensors and actuators to emulate human actions and safely interact with them. The contribution of this paper is an enhancement of the updated rate compared to other humanoids by 20% and by 40 % in the latency of the master. The results demonstrate the potential of using EtherCAT fieldbus and open-source software to develop a stable robot control architecture capable of integrating safety and security algorithms in later stages.