Revolutionary robotics: reduce energy consumption by 90%!

Revolutionary robotics: reduce energy consumption by 90%!

From March 31 to April 4, 2025, the Hannover Messe will be the venue for innovative robot technologies, presented by professors Stefan Seelecke and Paul Motzki from the Saarland University. In Hall 2, at the Saarland stand B10, they will present their groundbreaking Shape memory technology before. This technology promises to dramatically reduce energy consumption in industry - by up to 90% compared to current systems.

Energy is one of the largest cost factors in industry. High consumption levels not only have a significant impact on operating costs, but also on the climate. The new drive technology based on shape memory materials is a solution to this challenge. Robotic arms typically consume energy continuously, and many of today's gripping systems are pneumatic, which creates additional noise. Previous technologies encounter limitations in miniaturization and reprogramming that need to be overcome.

The benefits of shape memory technology

The development of the new robotic gripping systems that will be presented during the trade fair uses specific shape memory alloys (SMA). These materials are able to remember their original shape, which is important in making lightweight and flexible robotic grippers. Prototypes of vacuum grippers and pliers grippers will be presented on site. These gripping systems can handle workpieces energy-efficiently, even energy-free.

An innovative approach relies on fully electric gripping systems that employ bundles of nickel-titanium wire that act as artificial muscles. Nickel-titanium has two different crystal lattice structures that transform when a current pulse is applied. This allows for impressive movements. A wire with a diameter of just 500 micrometers can pull over 10 kilograms and leads to a world record: 20 wires with a diameter of 25 micrometers achieve a pulling force of 5 Newtons at 200 Hertz.

Adaptable gripping systems

The engineers have developed elastic gripping systems that can adapt to different workpieces. It is an advantage that the grippers do not require any additional sensors; the wires automatically provide relevant data. A pliers gripper prototype has a gripping force of 4 Newtons and is scalable, both in terms of size and force. In addition, the vacuum gripper only creates a sustainable vacuum using short current pulses.

The research team is looking for partners at the Hannover Messe to further develop this technology. Shape memory technology is used in numerous areas, including medical technology, the automotive industry and aerospace. FGLs are characterized by their ability to enable reversible expansions of 8-10%. A special property of nickel-titanium alloys is that they have two crystal structures: martensite in the low-temperature phase and austenite in the high-temperature phase.

Future outlook and challenges

The researchers see a great future for shape memory technology, particularly in automation technology and for lightweight, efficient components. The need for lighter materials also affects mechatronics, where shape memory technology plays a crucial role. At the Ruhr University Bochum, research is being carried out on new forms of these alloys that can be used not only in actuators, but also in medical technology, such as vascular prostheses or artificial heart valves.

While price projections suggest that shape memory technology could become more cost-effective, engineers face some challenges. The expansion of the temperature range for the use of nickel-titanium alloys and the inexperience in handling SMA lead to obstacles that must be overcome. Nevertheless, demand for these innovative materials remains high, promising exciting opportunities for the future.