The paper outlines DLR's mechatronic developments in the robotics area over the last five years. They aim at designing a new multisensory, modularly configurable light weight robot generation in a unified and integral way. A first step in this direction has been the development of a complex multisensory gripper based on a fully modular hard- and software-concept. It turned out to be a key element in ROTEX, the first real robot in space which flew with shuttle COLUMBIA in early 1993. Sensors and actuators in DLR's new ultra-light-weight robot show up miniaturized integration of mechanics, electronics and of course microprocessor control. Joint torque based on inductive sensing may be combined with different type of gearings: translational ones (using a new spindle drive concept), originally developed for grippers but easily usable, e.g. in tendon driven elbow-like joints, as well as compact, highly reducing rotational ones. In combination with optimized carbon fibre grid structures and optical information transfer between the joints a new, extremely light-weight type of robot arises. All power and signal electronics is integrated into the arm which shows up a 1:1 ratio between load and own weight

The paper outlines a concept for the design of a new generation of light weight robots using an integrated and unified approach for all relevant elements. A light multisensory gripper as the critical end-mass of any robot is presented that contains different-type redundant force-torque sensors, tactile arrays, 9 laser-range-finders including a scanner, and a tiny stereo-camera. A new electrical gripper drive has been developed, the weight to grasp force ratio of which aimed at an improvement factor of 5–10 compared to hitherto known systems. The same order of improvement has been the design goal for a new modular system of light-weight arms, the joint drives being integrated into ultra-light carbon-fibre-grid structures. These joint drives — as well as the gripper drives — are based on a complete redesign of the control system of commercially available stepping motors that turns them into electronically commutated high-speed and highly dynamics dc-motors, and a new type of light, compact gearing with reduction rates of 600 and more easily achievable.