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1. Design Principles for Compact, Backdrivable Actuation in Partial-Assist Powered Knee Orthoses

   https://doi.org/10.1109/TMECH.2021.3053226  

   Zhu, Hanqi ; Nesler, Christopher ; Divekar, Nikhil ; Peddinti, Vamsi ; Gregg, Robert ( January 2021 , IEEE/ASME Transactions on Mechatronics)

   null (Ed.)

   This paper presents the design and validation of a backdrivable powered knee orthosis for partial assistance of lower-limb musculature, which aims to facilitate daily activities in individuals with musculoskeletal disorders. The actuator design is guided by design principles that prioritize backdrivability, output torque, and compactness. First, we show that increasing the motor diameter while reducing the gear ratio for a fixed output torque ultimately reduces the reflected inertia (and thus backdrive torque). We also identify a tradeoff with actuator torque density that can be addressed by improving the motor's thermal environment, motivating our design of a custom Brushless DC motor with encapsulated windings. Finally, by designing a 7:1 planetary gearset directly into the stator, the actuator has a high package factor that reduces size and weight. Benchtop tests verify that the custom actuator can produce at least 23.9 Nm peak torque and 12.78 Nm continuous torque, yet has less than 2.68 Nm backdrive torque during walking conditions. Able-bodied human subjects experiments (N=3) demonstrate reduced quadriceps activation with bilateral orthosis assistance during lifting-lowering, sit-to-stand, and stair climbing. The minimal transmission also produces negligible acoustic noise. 

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2. Design and Control of a High-Torque and Highly-Backdrivable Hybrid Soft Exoskeleton for Knee Injury Prevention during Squatting

   https://doi.org/10.1109/LRA.2019.2931427  

   Yu, Shuangyue ; Huang, Tzu-Hao ; Wang, Dianpeng ; Lynn, Brian Patrick ; Sayd, Dina ; Silivanov, Viktor ; Park, Young Soo ; Tian, Yingli ; Su, Hao ( July 2019 , IEEE Robotics and Automation Letters)

   This paper presents design and control innovations of wearable robots that tackle two barriers to widespread adoption of powered exoskeletons, namely restriction of human movement and versatile control of wearable co-robot systems. First, the proposed quasi-direct drive actuation comprising of our customized high-torque density motors and low ratio transmission mechanism significantly reduces the mass of the robot and produces high backdrivability. Second, we derive a biomechanics model-based control that generates biological torque profile for versatile control of both squat and stoop lifting assistance. The control algorithm detects lifting postures using compact inertial measurement unit (IMU) sensors to generate an assistive profile that is proportional to the biological torque produced from our model. Experimental results demonstrate that the robot exhibits low mechanical impedance (1.5 Nm resistive torque) when it is unpowered and 0.5 Nm resistive torque with zero-torque tracking control. Root mean square (RMS) error of torque tracking is less than 0.29 Nm (1.21% error of 24 Nm peak torque). Compared with squatting without the exoskeleton, the controller reduces 87.5%, 80% and 75% of the of three knee extensor muscles (average peak EMG of 3 healthy subjects) during squat with 50% of biological torque assistance. 

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3. A Potential Energy Shaping Controller with Ground Reaction Force Feedback for a Multi-Activity Knee-Ankle Exoskeleton

   https://doi.org/10.1109/BioRob49111.2020.9224341  

   Divekar, Nikhil V. ; Lin, Jianping ; Nesler, Christopher ; Borboa, Sara ; Gregg, Robert D. ( November 2020 , 2020 8th IEEE RAS/EMBS International Conference for Biomedical Robotics and Biomechatronics (BioRob))

   This paper presents the design and implementation of a novel multi-activity control strategy for a backdrivable knee-ankle exoskeleton. Traditionally, exoskeletons have used trajectory-based control of highly geared actuators for complete motion assistance. In contrast, we develop a potential energy shaping controller with ground reaction force (GRF) feedback that facilitates multi-activity assistance from a backdrivable exoskeleton without prescribing pre-defined kinematics. Although potential energy shaping was previously implemented in an exoskeleton to reduce the user’s perceived gravity, this model-based approach assumes the stance leg is fully loaded with the weight of the user, resulting in excessive control torques as weight transfers to the contralateral leg during double support. The presented approach uses GRF feedback to taper the torque control output for any activity involving multiple supports, leading to a closer match with normative joint moments in simulations based on pre-recorded human data during level walking. To implement this strategy, we present a custom foot force sensor that provides GRF feedback to the previously designed exoskeleton. Finally, results from an able-bodied human subject experiment demonstrate that the exoskeleton is able to reduce muscular activation of the primary muscles related to the knee and ankle joints during sit-to-stand, stand-to-sit, level walking, and stair climbing. 

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4. Design and Validation of a Versatile High Torque Quasidirect Drive Hip Exoskeleton

   https://doi.org/10.1109/TMECH.2023.3334795  

   Bajpai, Aakash ; Carrasquillo, Carlos ; Carlson, Jessica ; Park, Julian ; Iyengar, Divya ; Herrin, Kinsey ; Young, Aaron J. ; Mazumdar, Anirban ( December 2023 , IEEE/ASME Transactions on Mechatronics)

   The field of wearable robotics has made significant progress toward augmenting human functions from multimodal ambulation to manual lifting tasks. However, most of these systems are designed to be task-specific and only focus on a single type of movement (e.g., ambulation). In this work, we design, fabricate, and characterize a versatile hip exoskeleton testbed for lifting and ambulation tasks. The exoskeleton testbed is actuated with custom-built quasidirect drive actuators. We produce an orthotic interface to transmit high torques and assemble a custom mechatronic control system for the exoskeleton testbed. We also detail controllers for level ground walking, incline walking, and symmetric knee to waist lifting. We quantify the actuator torque tracking performance quantified through benchtop and human experiments. During knee-to-waist cyclic lifting, the powered condition exhibited a 16.7% reduction in net metabolic cost compared to the no exoskeleton condition (three subjects). For additional tasks (inclined walking, level-walking), the device provided metabolic reductions when compared with the unpowered case (single subject). These testbed results illustrate the potential for versatile hip assistance and can be used to design future optimized devices. 

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5. Design and Validation of a Powered Knee–Ankle Prosthesis With High-Torque, Low-Impedance Actuators

   https://doi.org/10.1109/TRO.2020.3005533  

   Elery, Toby ; Rezazadeh, Siavash ; Nesler, Christopher ; Gregg, Robert D. ( July 2020 , IEEE Transactions on Robotics)

   In this article, we present the design of a powered knee–ankle prosthetic leg, which implements high-torque actuators with low-reduction transmissions. The transmission coupled with a high-torque and low-speed motor creates an actuator with low mechanical impedance and high backdrivability. This style of actuation presents several possible benefits over modern actuation styles in emerging robotic prosthetic legs, which include free-swinging knee motion, compliance with the ground, negligible unmodeled actuator dynamics, less acoustic noise, and power regeneration. Benchtop tests establish that both joints can be backdriven by small torques ( ∼ 1–3 N ⋅ m) and confirm the small reflected inertia. Impedance control tests prove that the intrinsic impedance and unmodeled dynamics of the actuator are sufficiently small to control joint impedance without torque feedback or lengthy tuning trials. Walking experiments validate performance under the designed loading conditions with minimal tuning. Finally, the regenerative abilities, low friction, and small reflected inertia of the presented actuators reduced power consumption and acoustic noise compared to state-of-the-art powered legs. 

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