Over the past 20 years research into miniature actuators has been increasing. In addition to having a compact geometry, desirable characteristics for miniature actuators include having a large power-to-weight ratio, fast response, fine resolution of movement and high power efficiency. In the first part of this thesis the design of a miniature rotary robot joint is presented. Two single acting miniature cylinders each with a bore diameter of 4 mm drive the joint using water as the hydraulic fluid. The cylinders are mated to a rack and pinion mechanism that converts the opposing linear motion of the cylinders shafts into rotation. Also within the design, a novel position sensor using magnetic field sensing technology is presented. Overall, the joint measures 11 mm wide x 8.8 mm high x 150 mm long.

In the second part of this thesis a hydraulic servo positioning system is presented along with a novel valve modeling technique and two position control strategies. Four low-cost, 3-way on/off solenoid valves were used to control the flow of the water in and out of the cylinders. The two nonlinear position controllers employed were a position-velocity-acceleration plus model-based feedforward controller (PVA+FF) and a novel PVA + FF plus sliding mode controller. For experiments involving horizontal rotation of the joint while carrying no load the PVA +FF controller achieved a steady-state error of ± 0.77° or ± 0.06 mm in terms of rack position. The steady-state error produced by the PVA + FF plus sliding mode controller was ± 0.85° or ± 0.07 mm. The maximum tracking error produced by both controllers was 5° or 0.41 mm and occurred during the initial cycloidal rising portion of a 120° displacement. The root mean square error (RMSE) of the PVA + FF and PVA + FF plus sliding mode controllers were 42% and 54% less than that produced by a linear PVA controller.

Both controllers were found to be robust to changes in payload. This was experimentally verified by adding masses of 6.5 g and 13.5 g to the end of the output link of the joint. By conducting similar experiments in the vertical direction it was found that the PVA + FF plus sliding mode controller was more robust, achieving on average a 30% reduction in RMSE compared to the FF + PVA controller.