Wear-Clearance-Impact Coupling in the Jansen Linkage: A Gait-Durability-Optimized Design Slows Joint Loosening

摘要

A companion study introduced joint durability into the dimensional design of the Theo Jansen walking linkage and found its classical "holy numbers" Pareto-dominated, but it modelled the revolute joints as ideal, clearance-free pins, so its wear figures were relative rankings, not a prediction of in-service degradation. Here we relax that idealization. We build a forward-dynamic model of the Jansen leg in which a revolute joint becomes a clearance joint with a continuous normal contact law (Lankarani-Flores, hysteresis-damped) and Ambrosio friction, integrated as a constraint-stabilized differential-algebraic system, and couple it to the Archard law in a wear->clearance->impact feedback loop. Three findings emerge. First, neglecting clearance underestimates the peak joint load: the clearance model gives a peak contact force of ~104 N at the load-bearing pin against ~48 N for the ideal joint (~2x amplification), rising to ~426 N when two joints carry clearance at once. Second, the coupling is strongly impact-sensitive--single trajectories are non-monotonic and can reverse the design ranking, a chaos consistent with the literature--so designs must be compared statistically; over an ensemble of 16 randomized phases the optimized joint is robustly more durable, with per-cycle wear ~9-7x lower (peak force ~4x lower) at one clearance joint and still ~1.7x lower on both with two (p<0.01 throughout). Third, the wear is strongly non-uniform--it concentrates on a ~10 deg load arc--so assuming uniform clearance growth underestimates local clearance growth by ~36x. The clearance-free durability advantage thus survives the chaotic, multi-joint, non-uniformly-worn coupling in the ensemble mean. We deliver the first clearance-coupled forward-dynamic model of the Jansen leg and specify a falsifiable protocol to test each prediction.