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As AI technology becomes increasingly integrated into robots, robot drive-unit design is also evolving. In addition to selecting and assembling motors, reducers, and control components separately, manufacturers are increasingly integrating multiple components into a single actuator for use at robot joints.
This trend becomes particularly important in AI robots with many joints. As the number of joints increases, the number of required drive units and cables also grows, while the available installation space becomes more limited. When developing an AI robot, designers must therefore consider not only the specifications of individual components but also how compactly and efficiently the drive system can be integrated within the robot.
This article examines why integrated actuators are becoming more important in AI-powered robots, the role actuators play in converting control commands into physical motion, and the key characteristics of the Bonsystems BCSA.
Why the Actuator Becomes Important in AI Robots
Key Summary AI robots with multiple joints require motors, reducers, sensors, cables, and other components within limited internal space. Compact and efficient drive-unit integration therefore becomes increasingly important.
AI systems perceive their surroundings through cameras and sensors and determine the appropriate action for the robot to perform. However, translating those decisions into physical movement requires drive units that can move the robot’s joints.
Each robot joint uses several components, including a motor and reducer. As the number of joints increases, the number of required drive units also grows, making component placement and cable routing increasingly complex.
This is particularly important in human-like robots such as humanoids, which must accommodate many joints within a compact body. The size and structure of each drive unit can affect not only the thickness of the arms and legs but also the space available for sensors, cables, and other components.
For this reason, integrating motors, reducers, and other drive components into a single actuator can simplify joint design and improve component integration.
Why Modular Actuators Matter in AI Robot Design
Key Summary An integrated actuator combines a motor, reducer, and other components into a single structure, helping simplify joint design and component layout.
When a drive unit is built using separately selected motors and reducers, the interface between the two components, housing, shaft alignment, and surrounding structure must all be designed accordingly. If the requirements differ from one robot joint to another, this design process may need to be repeated.
An integrated actuator combines the motor, reducer, and other drive components within a single structure. Because its overall profile and installation position can be defined in advance, it can make the internal layout of the joint easier to plan.
Using actuators with a common architecture across multiple joints can also help standardize drive-unit integration. Different actuator sizes or specifications can then be selected according to the robot’s overall size, joint position, and operating requirements.
However, actuator selection should not be based on profile size alone. Required torque, range of motion, installation orientation, and cable routing must also be considered to determine whether an actuator is suitable for the robot’s structure and operating conditions.
How Actuators Translate AI Decisions into Motion
Key Summary An actuator translates AI-driven and control-system commands into physical joint motion.
AI determines what action the robot should perform based on information about its surroundings and task requirements. When grasping or moving an object, for example, the system determines the direction of arm movement and the required motion of each joint.
The actuator then executes these commands by generating physical joint motion. It transmits motor output through the drive system to move the robot’s arms, legs, and other joints.
The reducer inside the actuator lowers motor speed while increasing the torque available at the joint. Working together, the motor and reducer convert control commands into the torque and movement required for physical operation.
Even as AI technology continues to advance, robots still require reliable hardware to operate in physical environments. The actuator provides the physical link between AI-driven control and robot motion.
Points to Consider When Selecting an Actuator
Key Summary When selecting an actuator, required torque should be considered together with profile size, thickness, weight, installation conditions, and cable-routing space.
An AI robot joint contains more than just the actuator. Sensors, cables, structural frames, exterior components, and other devices must often be integrated within the same limited space. The amount of space occupied by the actuator can therefore have a significant impact on the overall robot design.
As actuator thickness increases, the frame and outer structure around the joint may also need to become larger. In contrast, a thinner and more compact actuator can free up additional space for sensors, wiring, and other components.
Cable routing must also be considered. The internal layout should prevent cables from bending excessively or interfering with surrounding structures as the joint moves.
In robots where multiple joints are connected in series, actuator dimensions and cable-routing requirements are repeated throughout the system. It is therefore important to evaluate actuator size, installation method, and cable paths from the early stages of robot development.
Actuator Configuration Suited to the Robot Joint
Key Summary The required actuator size and configuration vary depending on the position, function, and operating conditions of each robot joint.
A single actuator size and configuration cannot meet the requirements of every joint. High-load joints such as the shoulder and hip may require greater torque, while smaller joints such as the wrist may require compact drive units that fit within confined spaces.
Actuator selection should therefore consider joint position, function, installation space, required torque, and range of motion. At the same time, using too many actuator variants across a single robot can increase design and management complexity.
For this reason, standardizing the system around a limited number of actuator specifications can help simplify development while still meeting the requirements of different joint types.
A modular actuator architecture can therefore support different joint requirements while maintaining a more consistent overall drive-system design.
The Bonsystems BCSA Actuator
Key Summary The Bonsystems BCSA is an integrated actuator that combines a frameless motor and cycloidal reducer in a thin, compact structure.
Based on cycloidal reducer and actuator design technology, Bonsystems develops drive solutions for robot joints and industrial automation equipment. By integrating key drive components such as the reducer and motor, Bonsystems supports stable drive-system design even within confined spaces.
The BCSA is an integrated actuator that combines a frameless motor and a cycloidal reducer. This integrated design reduces the space required by the drive unit and provides greater flexibility in robot joint design where both joint profile and internal component layout must be considered.
A multi-joint AI robot must accommodate actuators, sensors, control components, cables, and wiring within limited joint space. As the number of joints increases, the size and layout of each drive unit can significantly affect the robot’s overall form, motion, and ease of assembly.
With its thin, compact structure, the BCSA is designed to make efficient use of limited internal space and provide a drive solution for robot joints where compact design and high integration density are important.
The BCSA V4 series uses Bonsystems’ Pinless structure. This design reduces certain coupling elements used in conventional pin-based configurations and simplifies the reducer’s internal component structure. A simplified internal structure can improve space efficiency and help reduce design complexity when integrating the drive unit within confined joint spaces or avoiding interference with surrounding components.
The BCSA can be applied in various configurations depending on joint position, function, and required operating conditions. It can be used across a wide range of applications, including collaborative robots, humanoid robots, service robots, logistics robots, and automation equipment requiring precise motion.
Rather than simply supplying reducers and motors, Bonsystems provides drive solutions that take into account the robot’s structure and operating environment. More precise robot motion and more compact joint design, the Bonsystems BCSA provides an integrated drive solution for next-generation robots and automation equipment..
Frequently Asked Questions (FAQ)
Q1. Why does the actuator matter in an AI robot?
A. AI robots often use many joints in areas such as the arms, legs, waist, and wrists. As the number of joints increases, motors, reducers, sensors, and wiring must be integrated within limited internal space, making the joint structure more complex. An integrated actuator combines key drive components into a single unit, helping simplify and standardize joint design.
Q2. Doesn’t AI move the robot directly?
A. AI analyzes information collected by cameras, sensors, and other devices and determines the appropriate action for the robot. The actuator and other hardware components physically execute that action. In other words, AI determines the desired movement, while the actuator converts control commands into physical joint motion.
Q3. What role does the actuator play in an AI robot?
A. The actuator converts commands from the AI and robot control system into physical joint movement. It uses motor output and a reduction mechanism to generate the torque required at the joint. It is a core drive unit that enables each joint to operate at the required position, speed, and torque.
Q4. What should be checked when selecting an actuator?
A. Drive requirements such as torque, speed, and range of motion should be considered first. Actuator size, thickness, weight, installation orientation, mounting method, cable routing, and space for sensors and wiring should also be evaluated. The actuator should ultimately be selected based on the overall robot architecture and the operating requirements of each joint.
Q5. Why does the actuator’s thickness matter?
A. Actuator thickness can directly influence the joint profile and the robot’s overall dimensions. In robots that integrate many joints within limited space, thicker drive units can create additional constraints on exterior design and internal component placement. Actuator thickness and overall profile are therefore important design factors that influence compactness and space efficiency.
References
• [1] Bonsystems Official Website — https://www.bonsystems.com
• [2] International Federation of Robotics (IFR) — https://ifr.org
• [3] Korea Institute for Robot Industry Advancement (KIRIA) — https://www.kiria.org
• [4] Korea Institute of Robotics & Technology Convergence (KIRO) — https://www.kiro.re.kr
