Robot configuration design is hampered by the lack of established, well-known design rules, and designers cannot easily grasp the space of possible designs and the impact of all design variables on a robot’s performance. Realistically, a human can only design and evaluate several candidate configurations, though there may be thousands of competitive designs that should be investigated. In contrast, an automated approach to configuration synthesis can create tens of thousands of designs and measure the performance of each one without relying on previous experience or design rules. This thesis creates Darwin2K, an extensible, automated system for robot configuration synthesis. This research focuses on the development of synthesis capabilities required for many robot design problems: a flexible and effective synthesis algorithm, useful simulation capabilities, appropriate representation of robots and their properties, and the ability to accomodate application-specific synthesis needs. Darwin2K can synthesize and optimize kinematics, dynamics, structural geometry, actuator selection, and task and control parameters for a wide range of robots.

We present Darwin2K, a widely-applicable, extensible software tool for synthesizing and optimizing robot configurations. The system uses an evolutionary optimization algorithm that is independent of task, metrics, and type of robot, enabling the system to address a wide range of synthesis problems. Darwin2K can synthesize fixed-base and mobile robots (including free-flying robots, mobile manipulators, modular robots, and multiple or bifurcated manipulators), and includes a toolkit of simulation and analysis algorithms which are useful for many synthesis tasks. Some of these capabilities, such as dynamic simulation, are novel in automated synthesis of robots. An extensible software architecture enables new synthesis tasks to be addressed while maximizing use of existing system capabilities; this