Unidirectional actuated exoskeleton device
Inventors
Mooney, Luke • Duval, Jean-Francois
Assignees
Publication Number
US-12303409-B2
Publication Date
2025-05-20
Expiration Date
2037-10-12
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Abstract
The present invention is directed to an autonomous exoskeleton device that includes one or more actuators, one or more controllers, one or more sensors with one or more unidirectional transmissions. The present invention provides a mechanical joint in parallel with a biological joint. The exoskeleton device preferably includes and electric motor and winch, chain, belt, cam transmission or other mechanism for providing unidirectional force to assist rotation about the biologic joint. Moreover, a controller, a motor angle sensor, joint angle sensor and/or force sensor may be used for additional control and monitoring of the device. The motor may be any type of motor, but is preferably brushless in configuration where its diameter is larger than its length to provide a compact and lightweight exoskeleton device.
Core Innovation
The invention is directed to an autonomous exoskeleton device that incorporates one or more actuators, controllers, sensors, and unidirectional transmissions. This exoskeleton provides a mechanical joint operating in parallel with a biological joint, such as the ankle or knee, and is intended to address issues related to device mass, force/torque output, comfort, efficiency, and controllability. A preferred embodiment utilizes a brushless electric motor and mechanisms such as a winch, chain, belt, or cam transmission to deliver unidirectional force to aid rotational movement about the biological joint.
The device is designed to be lightweight, compact, and efficient, while capable of providing substantial force and torque to assist motion without interfering with the natural range of movement. The exoskeleton features a mechanical structure including a pad, shank, joint cross member, lever arm, and a specialized footplate integrated into footwear for optimal force transfer and comfort. The system can employ various sensors, such as motor angle, joint angle, or force sensors, to improve monitoring and control.
This invention specifically addresses the problem of balancing the need for a low-mass exoskeleton device with the requirement to deliver high force and torque, all while maintaining comfort, efficiency, easy control, and energy efficiency. By using unidirectional transmissions and integrating sophisticated control and sensor systems, the exoskeleton can apply assistive forces at the right time during movement, and quickly disengage if necessary, thereby overcoming limitations of prior art exoskeletons.
Claims Coverage
The patent includes two independent claims that define the structure and method of use of an exoskeleton system with unidirectional actuators, bilateral communication, and sensor-based control.
Bilateral exoskeleton system with unidirectional actuators and sensor-based control
The system comprises: - A left exoskeleton member for the left leg and a right exoskeleton member for the right leg, each including: - A pad to couple to a lower leg portion - A shank with connections at both ends - A lever arm connected to a joint cross member, with a first joint for plantar flexion - A foot plate coupled to the user's foot and pivotally connected to the joint cross member about a second joint near perpendicular to the first joint's axis of rotation - A left actuator and right actuator, each driven by its own motor and featuring a unidirectional transmission, mechanically connected to the respective leg and being mechanically disengageable such that no torque is applied to the leg when disengaged - At least one sensor configured to sense a characteristic of the exoskeleton during leg movement, supplying sensor data - A first control device on the left and a second control device on the right, connected to the respective exoskeletons and communicating with each other (wired or wirelessly), configured to use sensor data to control the device
Method for operating bilateral exoskeleton system using unidirectional actuators and sensor feedback
The method comprises: 1. Providing a left and right exoskeleton member, each arranged on the respective leg 2. Equipping each leg with an actuator driven by a distinct motor and featuring a unidirectional transmission, where disengagement leads to no torque output 3. Coupling a pad to the user's lower leg, connecting a shank, lever arm, and foot plate as specified in the system 4. Using at least one sensor to sense characteristics of the exoskeleton during movement and generate sensor data 5. Employing first and second control devices—communicating wirelessly or via wired connection—to use sensor data for controlling the respective exoskeleton members
The inventive features focus on a bilateral exoskeleton system with unidirectional actuation, sensor-driven control, and coordinated bilateral communication for effective, customizable support of human motion.
Stated Advantages
The exoskeleton device is compact, lightweight, and inexpensive to manufacture.
It provides powerful assistance and is easy to control.
The system does not interfere with natural body motion and allows for efficient energy transfer to the user.
It is comfortable for the user and can adapt to many leg sizes and shapes.
The device can be quickly secured, adjusted, and discarded if needed.
The exoskeleton can efficiently apply unidirectional force to assist with joint movement.
It enables enhanced controllability and energy efficiency due to the use of advanced sensors and control electronics.
The bilateral exoskeletons can communicate with each other for coordinated operation.
Documented Applications
Use as an exoskeleton worn on one or both legs to assist with joint movement, such as plantar flexion and dorsiflexion, during human walking.
Integration into existing footwear, including military or tactical boots, to transmit actuator forces for enhanced mobility and protection.
Adaptation of the exoskeleton device for alternative joints, such as use at the knee joint.
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