Multi-sensor thermo–electro–mechanical characterization of an SMA wire for wearable actuation design

Shape Memory Alloy (SMA) wires are widely used in wearable and soft-robotic systems due to their high power-to-weight ratio and muscle-like behavior. However, their strong thermo-electro-mechanical coupling requires precise experimental characterization to ensure safe and efficient operation. This study presents an Arduino-based multi-sensor platform for characterizing a 0.38 mm Flexinol® NiTi SMA wire under controlled electrical actuation. The system integrates non-contact infrared temperature sensing (MLX90614-BCC), force measurement using a load cell with HX711, displacement monitoring via VL6180X time-of-flight sensor, and real-time electrical tracking using ACS712 current and voltage modules. Regulated current pulses and PWM-controlled Joule heating were applied following a defined protocol, with prior calibration to ensure accuracy. Results demonstrate the transient thermal response, force–time behavior, stroke characteristics, and electrical input profiles under varying conditions. The synchronized multi-parameter acquisition identifies safe operating windows for wearable rehabilitation applications and provides a scalable framework for optimizing SMA-driven robotic systems.

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