Joint actuators with a compact size and high power density are necessary for robots with rotating joints, making the hydraulic actuator (HyA) an ideal actuator candidate. This paper presents a joint HyA with the following characteristics: compact installation size of 70 mm × 92.5 mm × 145 mm, low weight of 1.93 kg, high output torque of 742.2 Nm/531.09 Nm in two directions under 210 bar, high torque to weight ratio of 265.5 Nm/kg, low internal leakage of about 9 mL/min, zero external leakage, low starting pressure of 0.26 MPa/0.39 MPa in two directions, and a large rotation angle of 135 degrees. Compared with HyAs that have been applied in robot joints, the HyA proposed in this paper can greatly reduce the joint weight, reduce the joint size, and ensure the control performance of the joint movement.

In addition, a dynamic model of the HyA is established. Based on this, some dynamic design suggestions are given. Furthermore, a simple position and torque control algorithm for the HyA is proposed. Finally, some experiments are carried out to verify the performance of the HyA.

Variable stiffness can improve the capability of human–robot interacting. Based on the mechanism of a flexible rack and gear, a rotational joint actuator named vsaFGR is proposed to regulate the joint stiffness. The flexible gear rack can be regarded as a combination of a non-linear elastic element and a linear adjusting mechanism, providing benefits of compactness. The joint stiffness is in the range of 217–3527 N.m/rad, and it is inversely proportional to the 4th-order of the gear displacement, and nearly independent from the joint angular deflection, providing benefits of quick stiffness regulation in a short displacement of 20 mm. The gear displacement with respect to the flexible gear rack is perpendicular to the joint loading force, so the power required for stiffness regulating is as low as 14.4 W, providing benefits of energy saving. The working principles of vsaFGR are elaborated, followed by presentation on the mechanics model and the prototype. The high compactness, great stiffness range and low power cost of vsaFGR are proved by simulations and experiments.