Screw fastening is a ubiquitous yet automation-resistant task in machinery assembly, particularly in small-batch production where flexibility, cost, and space constraints limit the adoption of conventional robotic systems. Existing solutions often rely on multi-motor designs with complex mechanisms and controls, resulting in high costs, bulky structures, and limited adaptability to varying screw types or confined workspaces. This paper presents a novel screw fastening manipulator that addresses these challenges through mechanical simplification and functional integration. The proposed two-actuator design automates four essential operations – grasping, pressing, tightening, and releasing – within a compact and efficient form factor. A cable-driven reorientation mechanism enables precise screw alignment in restricted environments, while the screw fastening manipulator autonomously regulates the screw feed rate, enabling the robot arm to remain stationary during the tightening process. This decoupling reduces system complexity and ensures consistent screw insertion. Furthermore, a physics-based Bayesian inference model is employed for real-time torque estimation and autonomous phase detection without the need for additional sensors. This sensorless control approach enhances system robustness, reduces hardware dependencies, and ensures optimal torque application through probabilistic decision-making. Experimental validations using M2.5–M6 ISO metric screws – common in home appliance assembly – demonstrate the adaptability, precision, and suitability of the screw fastening manipulator for constrained, small-batch manufacturing environment.
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