Design and Characterization of a Low-Cost and Efficient Torsional Spring for ES-RSEA

The design of torsional springs for series elastic actuators (SEAs) is challenging, especially when balancing good stiffness characteristics and efficient torque robustness. This study focuses on the design of a lightweight, low-cost, and compact torsional spring for use in the energy storage-rotary series elastic actuator (ES-RSEA) of a lumbar support exoskeleton. The exoskeleton is used as an assistive device to prevent lower back injuries. The torsion spring was designed following design for manufacturability (DFM) principles, focusing on minimal space and weight. The design process involved determining the potential topology and optimizing the selected topology parameters through the finite element method (FEM) to reduce equivalent stress. The prototype was made using a waterjet cutting process with a low-cost material (AISI-4140-alloy) and tested using a custom-made test rig. The results showed that the torsion spring had a linear torque-displacement relationship with 99% linearity, and the deviation between FEM simulation and experimental measurements was less than 2%. The torsion spring has a maximum torque capacity of 45.7 Nm and a 440 Nm/rad stiffness. The proposed torsion spring is a promising option for lumbar support exoskeletons and similar applications requiring low stiffness, low weight-to-torque ratio, and cost-effectiveness.

Design and motion control scheme of a new stationary trainer to perform lower limb rehabilitation therapies on hip and knee joints

Limb disability is one of the serious problems and rehabilitation of lower limb requires an assistive force to the patient. A new design for stationary trainer for performing rehabilitation therapies for lower limb at the knee as well as hip joints in the sitting/lying positions is presented in this article. A passive orthosis (similar to an exoskeleton) is suggested in this system to provide a support to lower limb of the patient. The suggested mechanism also comprises of an active Cartesian manipulator based upon a spatial three parallel prismatic–revolute–revolute–revolute kinematic arrangement to perform the required limb therapeutic motions in the transverse/horizontal/lateral and sagittal/longitudinal plane. Numerically, the usefulness of the designed stationary trainer is confirmed using computer-based simulations along with a motion control scheme by performing various clinically suggested therapeutic motion tracking (passive range of motions) tasks. The article demonstrates the accomplishment of the control scheme for various training procedures of the lower limb.

Modeling and Control of a Cable-Driven Rotary Series Elastic Actuator for an Upper Limb Rehabilitation Robot

This paper focuses on the design, modeling, and control of a novel remote actuation, including a compact rotary series elastic actuator (SEA) and Bowden cable. This kind of remote actuation is used for an upper limb rehabilitation robot (ULRR) with four powered degrees of freedom (DOFs). The SEA mainly consists of a DC motor with planetary gearheads, inner/outer sleeves, and eight linearly translational springs. The key innovations include (1) an encoder for direct spring displacement measurement, which can be used to calculate the output torque of SEA equivalently, (2) the embedded springs can absorb the negative impact of backlash on SEA control performance, (3) and the Bowden cable enables long-distance actuation and reduces the bulky structure on the robotic joint. In modeling of this actuation, the SEA's stiffness coefficient, the dynamics of the SEA, and the force transmission of the Bowden cable are considered for computing the inputs on each powered joint of the robot. Then, both torque and impedance controllers consisting of proportional-derivative (PD) feedback, disturbance observer (DOB), and feedforward compensation terms are developed. Simulation and experimental results verify the performance of these controllers. The preliminary results show that this new kind of actuation can not only implement stable and friendly actuation over a long distance but also be customized to meet the requirements of other robotic system design.

Design and Validation of a Partial-Assist Knee Orthosis with Compact, Backdrivable Actuation

This paper presents the mechatronic design and initial validation of a partial-assist knee orthosis for individuals with musculoskeletal disorders, e.g., knee osteoarthritis and lower back pain. This orthosis utilizes a quasi-direct drive actuator with a low-ratio transmission (7:1) to greatly reduce the reflected inertia for high backdrivability. To provide meaningful assistance, a custom Brushless DC (BLDC) motor is designed with encapsulated windings to improve the motor's thermal environment and thus its continuous torque output. The 2.69 kg orthosis is constructed from all custom-made components with a high package factor for lighter weight and a more compact size. The combination of compactness, backdrivability, and torque output enables the orthosis to provide partial assistance without obstructing the natural movement of the user. Several benchtop tests verify the actuator's capabilities, and a human subject experiment demonstrates reduced quadriceps muscle activation when assisted during a repetitive lifting and lowering task.

Switching Assistance for Exoskeletons During Cyclic Motions

This paper proposes a novel control algorithm for torque-controlled exoskeletons assisting cyclic movements. The control strategy is based on the injection of energy parcels into the human-robot system with a timing that minimizes perturbations, i.e., when the angular momentum is maximum. Electromyographic activity of main flexor-extensor knee muscles showed that the proposed controller mostly favors extensor muscles during extension, with a statistically significant reduction in muscular activity in the range of 10–20% in 60 out of 72 trials (i.e., 83%), while no effect related to swinging speed was recorded (speed variation was lower than 10% in 92% of the trials). In the remaining cases muscular activity increment, when statistically significant, was less than 10%. These results showed that the proposed algorithm reduced muscular effort during the most energetically demanding part of the movement (the extension of the knee against gravity) without perturbing the spatio-temporal characteristics of the task and making it particularly suitable for application in exoskeleton-assisted cyclic motions.

Analysis on an Origami-structured Actuator that Enhances Both Backdriveability and Power Amplification

In the author's previous study, an origami-structured compliant actuator, named OSCA, was invented for human-robot interaction where sufficient moment output is required under a limited power supply. In this study, the compressibility of airflow within the actuator that essentially provides elasticity as well as backdriveability is in the spotlight. Elasticity can increase the actuator's power output in the same way as does a series elastic actuator (SEA). This study demonstrates that an OSCA operated with a servo valve is equivalent to an SEA with a typical spring. That is, power output amplification can be achieved with congruent stiffness of the air within the actuator.

Compliant lower limb exoskeletons: a comprehensive review on mechanical design principles

Exoskeleton technology has made significant advances during the last decade, resulting in a considerable variety of solutions for gait assistance and rehabilitation. The mechanical design of these devices is a crucial aspect that affects the efficiency and effectiveness of their interaction with the user. Recent developments have pointed towards compliant mechanisms and structures, due to their promising potential in terms of adaptability, safety, efficiency, and comfort. However, there still remain challenges to be solved before compliant lower limb exoskeletons can be deployed in real scenarios. In this review, we analysed 52 lower limb wearable exoskeletons, focusing on three main aspects of compliance: actuation, structure, and interface attachment components. We highlighted the drawbacks and advantages of the different solutions, and suggested a number of promising research lines. We also created and made available a set of data sheets that contain the technical characteristics of the reviewed devices, with the aim of providing researchers and end-users with an updated overview on the existing solutions.

Intrinsic Sensing and Evolving Internal Model Control of Compact Elastic Module for a Lower Extremity Exoskeleton

To achieve strength augmentation, endurance enhancement, and human assistance in a functional autonomous exoskeleton, control precision, back drivability, low output impedance, and mechanical compactness are desired. In our previous work, two elastic modules were designed for human–robot interaction sensing and compliant control, respectively. According to the intrinsic sensing properties of the elastic module, in this paper, only one compact elastic module is applied to realize both purposes. Thus, the corresponding control strategy is required and evolving internal model control is proposed to address this issue. Moreover, the input signal to the controller is derived from the deflection of the compact elastic module. The human–robot interaction is considered as the disturbance which is approximated by the output error between the exoskeleton control plant and evolving forward learning model. Finally, to verify our proposed control scheme, several experiments are conducted with our robotic exoskeleton system. The experiment shows a satisfying result and promising application feasibility.

Design, optimisation and testing of a compact, inexpensive elastic element for series elastic actuators

This paper presents the development of a compact torsion spring for use as an elastic element in a lightweight series elastic actuator for an active orthosis. This orthosis is going to be utilised as an assistive device for motorically impaired stroke-patients. In the design a two-step optimisation strategy was implemented to meet all requirements for the torsion spring. The first step was to identify a promising topology for the element. In the second step, the shape was optimised based on a finite element model using two different optimisation methods in order to minimise the von Mises equivalent stresses. Four promising variants of the identified topology were extracted from these calculations, one of which was then chosen as the final design. A prototype was manufactured by a laser cutting process, which is a new procedure in the context of elastic elements for series elastic actuators. The calculation results were validated successfully by measurement of the spring properties of this prototype.

Design and Validation of a Torque Dense, Highly Backdrivable Powered Knee-Ankle Orthosis

This paper presents the mechatronic design and experimental validation of a novel powered knee-ankle orthosis for testing torque-driven rehabilitation control strategies. The modular actuator of the orthosis is designed with a torque dense motor and a custom low-ratio transmission (24:1) to provide mechanical transparency to the user, allowing them to actively contribute to their joint kinematics during gait training. The 4.88 kg orthosis utilizes frameless components and light materials, such as aluminum alloy and carbon fiber, to reduce its mass. A human subject experiment demonstrates accurate torque control with high output torque during stance and low backdrive torque during swing at fast walking speeds. This work shows that backdrivability, precise torque control, high torque output, and light weight can be achieved in a powered orthosis without the high cost and complexity of variable transmissions, clutches, and/or series elastic components.

Muscular activity when walking in a non-anthropomorphic wearable robot

Wearable robots should be designed not to alter human physiological motion. Perturbations introduced by a robot can be quantified by measuring EMG activity. This paper presents tests on the LENAR, an intrinsically back-drivable non-anthropomorphic lower limb wearable robot designed to provide hip and knee flexion/extension assistance. In previous works the robot was demonstrated to exhibit low mechanical impedance and to introduce minor alterations to human kinematic patterns during walking. In this paper muscular activity is assessed, demonstrating small alterations in the EMG patterns during the interaction with the robot, in both unpowered and assistive mode.