Force Sensors in

Robotic Design
Low-Profile, Low-Power,
High-Performing Tactile Sensors

Robots Defined:
Since the Industrial Revolution (and perhaps even earlier), engineers
and humankind at large have embraced the notion that robots should
coexist and cooperate with humans, by performing tasks a human
cannot (or may not want to) do [1].
When robots come to mind, we often envision a futuristic figure,
with moving arms and legs, a turning head, and perhaps even
providing verbal feedback. With technological advances, robots have
indeed evolved to become more lifelike and more accessible. These
humanoid robots, however, represent just one segment of the
robotic population. This eBook also includes discussion of
automated systems which may or may not look like robots in the
traditional sense.
For the purposes of this paper, a robot is defined as a device that
can be programmed to perform a complex series of actions while
responding appropriately to environmental feedback.

Role of Sensors in Robots

Robots depend on a variety of sensors to interact effectively with the
physical environment.
Chemical sensors, for example, help mobile robots follow chemical
trails laid on the ground or locate the source of chemical plumes [2].
Proximity sensors detect the presence of nearby objects without
any contact by emitting an electromagnetic field and looking for any
changes in the field.
Range sensors, give the robot a realistic view by capturing the 3D
structure of the world by measuring the depth to nearby surfaces [3].
Tactile sensors measure contact between a robot and an object,
facilitating appropriate manipulation, exploration, and response.

Tactile Force Sensor: FlexiForce by Tekscan

This eBook will focus on tactile force sensors and will demonstrate
how their physical attributes and ease of integration ensure optimal
robotic performance. Applications include enabling appropriate
grip force for accurate handling of delicate objects, such as surgical
tissue and silicon wafers; the sensors are also ideal for helping a robot
maintain a steady balance or demonstrate a more fluid stepping
motion, delivering a more human-like gait.

Force Sensors in Robotic Design

Tactile Sensors in Medical Robot Applications

Thin, flexible force sensors open doors to a variety of medical
applications, such as robotic surgery, where a non-intrusive sensor can
lend a sense of touch to procedures that would otherwise be difficult to
perform accurately.
Medical robots comprise almost 30% of the robotics market [4].
Surgical applications represent a significant portion of that market
share. Surgical robots offer improved range of motion in laparoscopic
techniques. In cases of remote surgery, force sensors embedded in
robotic arms can communicate the level of forces applied, and the
surgeon, operating the robot remotely, can make adjustments in the
procedure based on the output.
One challenge has been that robots have lacked the sense of touch,
or haptic feedback, which is so vital in many procedures, such as
applying force to sutures. Cambridge Research & Development
(CRD), a pioneer in developing non-invasive, haptic man-machine
interfaces that provide tactile force feedback, has recently completed
research on a new haptic robotic interface to overcome this challenge.
The interface, called the Neo, uses linear actuation to provide force
feedback and mimic the sensation of force through a device that can
be worn anywhere on the surgeons body. A very sensitive and paperthin FlexiForce sensor was placed in the front fenestration of a double
fenestrated grasper [5]. This sensor-enabled grasper is connected
to the haptic interface worn by the surgeon. The force sensor can
then measure applied force, which is read by the haptic interface and
translated into pressure applied by the device, using a mechanism that
moves up and down in response to force. The brain rapidly associates
the pressure being applied by
the Neo with sense of touch,
enabling the surgeon to
adapt the use of force in
response to pressure
from the Neo. The small
size and thinness of the
integrated FlexiForce
sensor enables the
device to provide a full
range of tactile sensation,
without having to increase
the size of the instrument
being used.

30%

Medical Robots Comprise Almost 30%

of the Robotics Market

Surgical Gripper Containing FlexiForce Sensor

Photo courtesy of UCLA School of Medicine

The Thickness of FlexiForce Sensor Measures Less than 0.008 Inches

Force Sensors in Robotic Design

The robotics industry understands that the true potential of robotic and cybernetics lies in the
ability of man and machine to meld. Full bio-compatibility is in our future, but advancements have
to be made now if we are truly going to realize the potential of our robotic counterparts. With
this new haptic interface, we feel we are providing a solution which will lead to new and exciting
capabilities from the surgery room to space.
Ken Steinberg, CEO
Cambridge Research & Development

Industrial Robot Components

An industrial robotic arm consists of five key components. The
controller, often considered the brain of the arm, contains the
overall logic of the robot [6]. The arm positions the end effector,
which connects to the robots arm and acts much like a hand. The
end effector comes into direct contact with the object the robot is
handling. The drive, much like a muscle, moves the links, or sections
between the joints (i.e. arm), into their designated positions. Finally,
there is the sensor, which allows the arm to receive feedback about its
environment. The sensor can assist end effectors by allowing them to
adjust their handling; for example, it can tell the end effector to adjust
its grip force depending on variances in part size, material, or weight [7].

Industrial Robot Arm

Tactile Sensors in Industrial

Robot Applications

Among the many industrial robotic applications are pick-and-place

robots, which have been noted for improving productivity as they can
work at a consistent pace around the clock. Force sensors integrated
into these machines can tell the robot when an item has been grasped
and when it has been released. Tactile sensors introduce another
dimension of information by providing haptic feedback, which is
necessary in handling delicate objects like semiconductor wafers. This
feedback essentially tells the end effector how much or how little
force to apply in handling the object.

A Sense of Touch is Crucial in

Handling Delicate Objects

Robotic welding is another example of an automated industrial system

that can benefit from tactile force feedback. Robotic arms equipped
with tactile sensors, like FlexiForce sensors, ensure that appropriate
force is applied to the welding tip during the welding process, and can
monitor the contact force between the two parts being bonded. This
force identification improves effectiveness and accuracy of the system,
reducing defective product.

Tactile Force Sensors

Provide this Haptic Feedback

Force Sensors in Robotic Design

Military Robot Applications: Maximizing

Safety and Performance Extends to Quality
of Life Improvements
Military applications for robots abound, both in research and in the
field. Search and rescue robots are crucial in disastrous situations,
either where it is too dangerous for humans to search for survivors
among wreckage and debris, or to augment a rescue team that may
be short-handed.
Tactile force sensors are crucial; sensors embedded in a robots
bumpers can help alert the robot about an obstruction in its path and
initiate a corrective action like a change in course or direction. Force
sensors in the robots grippers ensure a proper grasp on itemsa
firm enough grasp to pick up an object and bring it for analysis, to
deliver water or other supplies to a trapped victim, or to help safely
remove detected debris to ensure it doesnt disturb the pile, causing a
collapse. In bomb detonating situations, a proper grip force is crucial to
avoid accidental detonation of an explosive device.
Robotic applications initiated and researched by the military can
extend to other areas, particularly prosthetic and therapeutic
applications, to support mobility and rehabilitation. In fact, industry
insiders have projected the prosthetic and therapeutic robotics
markets to reach $3.6 billion by 2025 [8]. One example is the robotic
exoskeleton, which has been highlighted as a device with two primary
functions:

$3.6B by 2025

Prosthetic & Therapeutic Robotic

Markets Forecast

Augmenting capabilities of able-bodied individuals, such as

soldiers carrying out difficult tasks or workers performing
heavy labor
Acting as a mobility device, in which case the robotic
exoskeleton can help the elderly or people with disabilities or
injuries gain or regain limb function [9]
In robotic exoskeletons, force sensors embedded under the feet
help the wearer maintain balance and stimulate a more natural gait.
This offers those with limited mobility an improved quality of life
by providing the freedom of movement without the use of devices
like wheelchairs or walkers. In addition, increased mobility carries
significant benefits to overall health.

According to a July 2014 article in Machine Design magazine,

researchers at the Advanced Platform Technology Center in Ohio are
working on the development of technology that would offer a sense
of feeling in the prosthetics of people who have suffered loss of upper
limbs. FlexiForce sensors adhered to the artificial hand measure the
distance or opening between the thumb and the fingers, as well as
forces at the tip of the thumb, middle finger, and index finger. This
provides users with a sense of how much force they are applying when
they grasp an object [10].

Example of Robotic Exoskeleton

Force Sensors in Robotic Design

Humanoid Robots
Humanoid robots displaying proper balance while walking, running, or dancing appear infinitely more lifelike than those that dont. A robot with better balance means fewer falls, which translates to less damage to
the robot itself, better handling of objects it might be carrying, and a more impressive display. Aldebaran
Robotics (now SoftBank Robotics) in developing the Nao Robot,
embedded FlexiForce sensors into its feet to help monitor balance.
The sensors ensure that the robot properly shifts its weight so it does
not tip over while walking or dancing.
The importance of the sensors and proper balance relates to the robots
overall programming. Nao robots are programmed to walk in an omnidirectional walking pattern and have the ability to walk over different
types of surfaces. When the weight of one part of the robot shifts, the
center of mass of the machine must realign in order to attain proper
balance. A properly functioning, aesthetically pleasing, well-balanced
robot is a valuable tool for researchers and students. The progressive
nature of these machines provides insight into the future of robotics
and the fields of engineering and mathematics.

FlexiForce Sensors Embedded in the

Feet of the Nao Robot Help it
Maintain Proper Balance

Tactile Sensors Explained

One example of a thin, tactile force sensor is the FlexiForce sensor
manufactured by Tekscan, Inc. FlexiForce sensors consist of
proprietary piezoresistive material sandwiched between two pieces
of flexible polyester.
The polyester has printed silver conductors on each inner half. These
conductive traces form electrical connections to external circuits.
These force sensors are resistors that vary in a linear fashion in terms
of conductance vs. force under an applied load.

FlexiForce Sensor Construction

The FlexiForce Sensor Displays Linear Conductance, Inversely

Proportional to Applied Force

Force Sensors in Robotic Design

For a comprehensive picture, it is useful to compare FlexiForce

sensors with other types of tactile sensor technologies. One design
uses a piezoresistive material, similar to that of FlexiForce sensors,
sandwiched between flexible plastic sheets. This design puts both
conductive areas on the same substrate. A point to note about this
design is that the output depends on the sensor area over which the
force is distributed. A force acting on a large percentage of sensor area
produces a lower reading than the same amount of force concentrated
on a smaller area. In this regard, such sensors behave as pressure
sensors rather than force sensors.

Example Drive Circuit for FlexiForce Sensor

Another type of tactile sensor uses capacitance as the sensing

mechanism. The typical makeup has two conductive plates separated
by an elastic dielectric material. Compressing the dielectric reduces the
plate spacing and provides a response proportional to displacement.
One difficulty with capacitive tactile sensors is that they generally
must be driven with a high-frequency ac signal. This is because the
displacement change with applied force is relatively small, and so is the
change in capacitance. The electronics needed to convert capacitance
change to force can be somewhat complicated; this added complexity
translates to higher cost and higher power requirements.
In contrast, FlexiForce sensors are driven with dc. Simple drive
electronics plus a thin profile makes FlexiForce sensors ideal
candidates for several areas of application in robotics thanks to ease of
integration and low power requirements. There are standard, off-theshelf models, with sensing areas as small as 7.6 mm to as large as 31.8
mm. In many cases, designers will prototype with a standard sensor to
prove a concept, and then devise a custom version. Custom FlexiForce
sensors can have nearly any shape, even with irregular features.

FlexiForce Sensors can be Customized in

Nearly Any Shape and in a Range of Sizes

Conclusion
We have seen the potential of robots in enhancing the effectiveness of
medical procedures, increasing safety, improving industrial processes,
and boosting quality of life. Thin, flexible resistive force sensors provide
the vital component of tactile feedback in a robotic system without
adding weight or size to the setup. In addition, FlexiForce sensors carry
the unique advantage of simple integration electronics and low power
requirements, keeping costs to a minimum.
To learn more about FlexiForce sensors and opportunities for
embedding tactile force sensors into your product,
visit www.tekscan.com/tactile-force.

Force Sensors in Robotic Design

References
[1] History of robots. Wikipedia. Retrieved August 11, 2016 from https://en.wikipedia.org/wiki/History_of_robots
[2] Ishida, H., Wada, Y., Matsukura, H. Chemical sensing in robotic applications: a review. IEEE Sensors Journal.
2012, July 23; 12(11):3163-3173. http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=6247459&url=http%3A%
2F%2Fieeexplore.ieee.org%2Fiel5%2F7361%2F4427201%2F06247459.pdf%3Farnumber%3D6247459
[3] Fisher, R., Konolige, K. Handbook of Robotics: Range Sensors. 2008, June 26. http://homepages.inf.ed.ac.uk/
rbf/PAPERS/robodraft.pdf
[4] Green, T., Saenko, M.(2016, May 19). Healthcare robotics [Webinar]. In Robotics Business Review Webcasts.
Retrieved from https://www.roboticsbusinessreview.com/webcast/healthcare-robotics/
[5] New haptic man-machine interface integrates FlexiForce sensors to improve robotic surgery. Tekscan.
Retrieved August 11, 2016 from https://www.tekscan.com/applications/new-haptic-man-machine-interfaceintegrates-flexiforce-sensors-improve-robotic-surgery
[6] Microcontrollers. Robotshop. Retrieved August 18, 2016 from http://www.robotshop.com/en/
microcontrollers.html
[7] What are the main parts of an industrial robot? RobotWorx. Retrieved August 11, 2016 from https://www.
robots.com/faq/show/what-are-the-main-parts-of-an-industrial-robot
[8] Green, T., Saenko, M.(2016, May 19). Healthcare robotics [Webinar]. In Robotics Business Review Webcasts.
Retrieved from https://www.roboticsbusinessreview.com/webcast/healthcare-robotics/
[9] Overview of robotic exoskeleton suits for limb movement assist. Smashing Robotics. Retrieved August 11, 2016
from http://www.smashingrobotics.com/complete-robotic-exoskeleton-suits-list-for-limb-movements/
[10] Mraz, S. (2014, July 25). Technology adds the sense of touch to prosthetic hands. Machine Design. Retrieved
August 11, 2016 from http://machinedesign.com/medical/technology-adds-sense-touch-prosthetic-hands

Disclaimer: The contents of this publication may be of interest to medical professionals or other health care
providers. Such persons should exercise their own judgment in determining whether a particular product, treatment, therapy option, procedure, program or service is appropriate or legal for their practice or their patients.

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