Topology Optimization and Additive Manufacturing for Electrohydraulic Actuators in Hydraulic Foot Robots

In recent years, hydraulic quadrupedal robots have received increasing attention for their good adaptability and high load carrying capacity. However, weight management remains a key challenge for mobile robotic systems, especially considering the limited on-board energy. Topology optimization has now become a tool to significantly reduce weight and size while maintaining structural integrity. A comprehensive design methodology for electro-hydraulic actuator structures for quadruped robots that integrates topology optimization design, internal runner optimization and additive manufacturing is proposed. The use of topology optimization not only ensures the mechanical properties required for the practical application of the electrohydraulic actuator, but also reduces the mass and volume of the electrohydraulic actuator by more than 15.2%. Through the optimized design of the bionic flow channel, the pressure loss of the rotor is reduced by 40%, and the energy transfer efficiency is significantly improved. In addition, this work successfully demonstrates the integration of topology optimization and additive manufacturing, which provides new ideas for the study of advanced electrohydraulic actuators for legged robots. This innovation not only improves the performance of hydraulic quadruped robots, but also establishes a new paradigm for the design and fabrication of complex robotic systems.