Trunk support exoskeleton with powered actuator

Abstract

Some embodiments described herein relate to a torso supporting exoskeleton for reducing muscle strength of the back of a wearer during lumbar anteflexion. The torso supporting exoskeleton can include a supporting torso frame, a first thigh link, a second thigh link, an actuator, a shaft pulley, a housing pulley, a shaft cable, and a housing cable. The actuator can include an actuator housing and an actuator shaft. The actuator is capable of generating an actuator resistance torque between the actuator housing and the actuator shaft when the wearer bends forward relative to a vertical line of gravity in a sagittal plane. The actuator resistance torque between the actuator housing and the actuator shaft is capable of generating tension in the housing cable and the shaft cable, thereby generating an extension torque between the respective first and second thigh links and the support torso frame.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 362,778, filed on April 11, 2022, and U.S. Provisional Patent Application No. 63 / 362,779, filed on April 11, 2022. Each of these applications is incorporated herein by reference in its entirety.

[0003] The entirety of assigned international application number ("AN ACTUATOR FOR ANEXOSKELETON", inventors Wayne TUNG et al., attorney docket number 5085.004PC03) filed on the same date as these applications is incorporated herein by reference. Technical Field

[0004] The present disclosure relates generally to exoskeleton systems, and more particularly, to torso support exoskeleton systems. Background Art

[0005] It may be desirable to reduce forces on the wearer's back during lumbar flexion (eg, during bending or stooping). Summary of the invention

[0006] Some embodiments described herein relate to a trunk support exoskeleton for reducing muscle forces on the back of a wearer during lumbar flexion. The trunk support exoskeleton can include a support trunk frame, a first thigh link, a second thigh link, an actuator, an axis pulley, a housing pulley, an axis cable, and a housing cable. The support trunk frame can be configured to be coupled to the wearer's trunk. The first thigh link can be configured to be coupled to one of the wearer's thighs. The second thigh link can be configured to be coupled to the other of the wearer's thighs. Each of the first thigh link and the second thigh link can be rotatably coupled to the support trunk frame so that the corresponding first thigh link or the second thigh link can be flexed or extended relative to the support trunk frame. The actuator can be coupled to the support trunk frame. The actuator can include an actuator housing and an actuator shaft. The actuator shaft and the actuator housing can rotate relative to the support trunk frame. The axis pulley can be coupled to the actuator shaft. The housing pulley can be coupled to the actuator housing. The shaft cable may have a first end wound around the shaft pulley and a second end coupled to the first thigh link. The housing cable may have a first end wound around the housing pulley and a second end coupled to the second thigh link. The actuator is capable of generating an actuator resistance torque between the actuator housing and the actuator shaft when the wearer bends forward relative to the vertical gravity line in the sagittal plane. The actuator resistance torque between the actuator housing and the actuator shaft is capable of generating tension in the housing cable and the shaft cable, thereby generating an extension torque between the corresponding first and second thigh links and the supporting trunk frame.

[0007] In some embodiments, the first thigh link may include a first thigh link pulley. In some embodiments, the second thigh link may include a second thigh link pulley. In some embodiments, the second end of the shaft cable is wrapped around the first thigh link pulley so that the tension in the shaft cable provides an extension torque between the first thigh link and the supporting trunk frame. In some embodiments, the second end of the housing cable is wrapped around the second thigh pulley so that the tension in the housing cable provides an extension torque between the second thigh link and the supporting trunk frame.

[0008] In some embodiments, the actuator does not generate an actuator resistance torque between the actuator housing and the actuator shaft when the wearer is not bent forward relative to the vertical line of gravity.

[0009] In some embodiments, when the wearer is not bent forward relative to the vertical line of gravity, the actuator produces a relatively small actuator resistance torque between the actuator housing and the actuator shaft, thereby allowing substantially free movement of the thigh link.

[0010] In some embodiments, when the wearer is not bent forward relative to the vertical line of gravity and the thigh link is in a reciprocating mode indicative of walking, the actuator produces a relatively small actuator resistance torque, thereby allowing substantially free movement of the thigh link.

[0011] In some embodiments, the shaft cable and the housing cable each include an element or combination of elements selected from the group consisting of: wires, cables, belts, fabric ropes, plastic ropes, cords, twine, chains, steel ropes, and cords.

[0012] In some embodiments, the actuator includes an element or combination of elements selected from the group consisting of: an AC (alternating current) motor, a brushed DC (direct current) motor, a brushless DC motor, an electronically commutated motor (ECM), a stepper motor, and combinations thereof.

[0013] In some embodiments, the actuator includes a transmission system.

[0014] In some embodiments, the transmission system includes an element or combination of elements selected from the group consisting of: a harmonic drive, a planetary gear, a ball screw mechanism, a lead screw mechanism, a worm gear, and combinations thereof.

[0015] In some embodiments, the transmission system includes an element or combination of elements selected from the group consisting of: gears, worm gears, gear trains, pulleys, cables, belts, toothed belts, toothed pulleys, planetary gears, harmonic drives, spur gears, flexible belts, wire ropes, ropes, ball screw mechanisms, and lead screw mechanisms.

[0016] In some embodiments, the torso support exoskeleton includes a controller for sending a signal to the actuator to generate an actuator resistance torque between the actuator housing and the actuator shaft when the wearer bends forward relative to the vertical line of gravity.

[0017] In some embodiments, the actuator resistance torque is a function of the degree to which the wearer is bent forward relative to the vertical line of gravity.

[0018] In some embodiments, the actuator resistance torque increases as the angle of the supporting torso frame relative to the vertical gravity line increases.

[0019] In some embodiments, the actuator resistance torque decreases as the angle of the supporting torso frame relative to the vertical gravity line decreases.

[0020] In some embodiments, the actuator resistance torque is a function of the angular velocity of the supporting torso frame in the sagittal plane.

[0021] In some embodiments, the actuator resistance torque decreases as the forward angular velocity of the supporting torso frame in the sagittal plane increases.

[0022] In some embodiments, the actuator resistance torque increases as the forward angular velocity of the supporting torso frame in the sagittal plane decreases.

[0023] In some embodiments, the actuator resistance torque decreases as the rearward angular velocity of the supporting torso frame in the sagittal plane increases.

[0024] In some embodiments, the actuator resistance torque increases as the rearward angular velocity of the supporting torso frame in the sagittal plane decreases.

[0025] In some embodiments, when the wearer is not bent forward relative to the vertical line of gravity, the controller sends a signal to the actuator to generate a relatively small actuator resistance torque between the actuator housing and the actuator shaft.

[0026] In some embodiments, a trunk supporting exoskeleton includes a tilt sensor and a controller. In some embodiments, the tilt sensor generates a tilt signal indicating an angle of the supporting trunk frame relative to a vertical gravity line in a sagittal plane. In some embodiments, when the tilt signal indicates that the angle of the supporting trunk frame relative to the vertical gravity line is greater than a predetermined angle, the controller sends a signal to the actuator to generate an actuator resistance torque between the actuator housing and the actuator shaft.

[0027] In some embodiments, the tilt sensor includes an element or combination of elements selected from the group consisting of: an inertial measurement unit (IMU), an inclinometer, an encoder, and an angle sensor.

[0028] In some embodiments, the actuator resistance torque is a function of the tilt signal.

[0029] In some embodiments, when the tilt signal indicates that the wearer is not bent forward relative to the vertical gravity line, the controller sends a signal to the actuator to generate a relatively small actuator resistance torque between the actuator housing and the actuator shaft.

[0030] In some embodiments, the torso supporting exoskeleton includes an axle cable sheath surrounding the axle cable. In some embodiments, the axle cable sheath is fastened to the supporting torso frame so as to adjust the size of the supporting torso frame without adjusting the size of the axle cable.

[0031] In some embodiments, the torso support exoskeleton includes a housing cable sheath surrounding the housing cable. In some embodiments, the housing cable sheath is fastened to the support torso frame so as to adjust the size of the support torso frame without adjusting the size of the housing cable.

[0032] In some embodiments, the actuator generates the actuator resistance torque by using electricity.

[0033] In some embodiments, the actuator includes an actuator spring. In some embodiments, the first end of the actuator spring is coupled to the actuator shaft. In some embodiments, the second end of the actuator spring is free within a first rotation range of the actuator shaft relative to the actuator housing. In some embodiments, the second end of the actuator spring is constrained by the actuator housing within a second rotation range of the actuator shaft relative to the actuator housing. In some embodiments, within the first rotation range, the actuator generates an actuator resistance torque by using electricity. In some embodiments, within the second rotation range, the spring generates at least a portion of the actuator resistance torque.

[0034] In some embodiments, the actuator spring comprises an element or combination of elements selected from the group consisting of: a coil spring, a leaf spring, a bungee cord, a torsion spring, an elastomeric cord, an elastic cord, a fabric cord, a plastic cord, a rope, a twisted rope, a wire rope, an elastic, and a string.

[0035] In some embodiments, within a first rotation range of the actuator shaft relative to the actuator housing, the actuator generates an actuator resistance torque by using electricity. In some embodiments, within a second rotation range of the actuator shaft relative to the actuator housing, the actuator resistance torque is the sum of the torque generated by the spring and the torque generated by using electricity.

[0036] In some embodiments, the supporting torso frame includes a lower frame portion configured to partially surround the wearer's torso and to couple to the first thigh link and the second thigh link at either side of the wearer.

[0037] In some embodiments, the supporting torso frame includes a spinal frame portion coupled to a lower frame portion.

[0038] In some embodiments, the length of the spinal frame portion is adjustable to accommodate wearers of different heights.

[0039] In some embodiments, the width of the lower frame portion is adjustable to accommodate wearers of different width sizes.

[0040] In some embodiments, the depth of the lower frame portion is adjustable to accommodate wearers of different depth sizes.

[0041] In some embodiments, the support torso frame includes an upper frame portion that is coupled to the spine frame portion and is configured to apply support torso forces to the torso and chest region of the wearer.

[0042] In some embodiments, the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to the wearer's spine.

[0043] In some embodiments, the spinal frame portion is configured to rotate relative to the lower frame portion along an axis substantially parallel to the wearer's spine.

[0044] In some embodiments, the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to one of a mediolateral flexion axis and an extension axis of the wearer's lumbar spine.

[0045] Some embodiments described herein relate to a trunk support exoskeleton for reducing muscle forces on a wearer's back during lumbar flexion. The trunk support exoskeleton may include a support trunk frame, a first thigh link, a second thigh link, and an actuator. The support trunk frame may be configured to be coupled to the wearer's trunk. The first thigh link may be configured to be coupled to one of the wearer's thighs. The second thigh link may be configured to be coupled to the other of the wearer's thighs. Each of the first thigh link and the second thigh link may be rotatably coupled to the support trunk frame so that the corresponding first thigh link or the second thigh link may be flexed or extended relative to the support trunk frame. The actuator may be coupled to the support trunk frame. The actuator may include an actuator housing and an actuator shaft. The actuator may be freely rotatable relative to the support trunk frame. The actuator shaft may be coupled to the first thigh link, and the actuator housing may be coupled to the second thigh link. When the wearer bends forward in the sagittal plane, the actuator can generate an actuator resistance torque between the actuator housing and the actuator shaft, thereby generating an extension torque between the corresponding first thigh link and the second thigh link and the supporting torso frame.

[0046] In some embodiments, the trunk support exoskeleton includes an axis pulley, a housing pulley, an axis cable, and a housing cable. In some embodiments, the axis pulley is coupled to an actuator shaft. In some embodiments, the housing pulley is coupled to an actuator housing. In some embodiments, the axis cable has a first end wound around the axis pulley and a second end coupled to a first thigh link. In some embodiments, the housing cable has a first end wound around the housing pulley and a second end coupled to a second thigh link. In some embodiments, the actuator resistance torque can generate tension in the housing cable and the axis cable, thereby generating an extension torque between the corresponding first thigh link and the second thigh link and the supporting trunk frame. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present disclosure and, together with the description, further serve to explain the principles of the present disclosure and enable those skilled in the relevant art to make and use the present disclosure.

[0048] Figure 1 A perspective view of an individual wearing a torso support exoskeleton is shown.

[0049] Figure 2 Shows Figure 1 A perspective view of the torso-supporting exoskeleton.

[0050] Figure 3 Shows Figure 1 Another perspective view of the torso support exoskeleton.

[0051] Figure 4 Shows wearing Figure 1 Side view of an individual with a trunk supporting an exoskeleton, wherein the individual is bending forward in the sagittal plane.

[0052] Figure 5 Shown for Figure 1 A perspective view of the actuators of a torso support exoskeleton with housing pulleys and shaft pulleys.

[0053] Figure 6 Shows Figure 5 A cross-sectional view of an actuator.

[0054] Figure 7 Shows Figure 5 A perspective view of an actuator with the shaft pulley removed for illustration purposes.

[0055] Figure 8 Shows Figure 5 A cross-sectional view of an actuator with the shaft pulley removed for illustration purposes.

[0056] Fig. 9 Shows Figure 5A perspective view of an actuator with the housing pulley and shaft pulley removed for illustration purposes.

[0057] Fig.10 Shows Figure 5 A cross-sectional view of an actuator with the housing pulley and shaft pulley removed for illustration purposes.

[0058] Fig.11 Shows Figure 1 An enlarged view of a portion of the torso-supporting exoskeleton.

[0059] Fig.12 An enlarged view of a portion of a torso support exoskeleton is shown, illustrating an alternative connection between the axis cable and the thigh link.

[0060] Fig.13 It is shown Figure 1 Schematic diagram of how the resistive torque between the housing and the shaft of the actuator of the torso support exoskeleton generates the extension torque between the thigh link and the torso support frame of the torso support exoskeleton.

[0061] Fig.14 Schematic diagram showing the forces on the back of an individual when bending forward in the sagittal plane.

[0062] Fig.15 A flow chart showing a control algorithm for controlling a torso support exoskeleton.

[0063] Fig.16 Shows Figure 1 An enlarged view of a portion of the torso-supporting exoskeleton.

[0064] Fig.17 Shows Figure 1 An enlarged view of a portion of the torso-supporting exoskeleton.

[0065] Fig.18 Shows Figure 1 An enlarged view of a portion of the torso-supporting exoskeleton.

[0066] Fig.19 Shown for Figure 1 A cross-sectional view of the actuators of the torso-supporting exoskeleton.

[0067] Fig. 20 Shown for Figure 1 A cross-sectional view of the actuators of a torso support exoskeleton, showing an alternative arrangement of the actuator's springs. DETAILED DESCRIPTION

[0068] A trunk support exoskeleton can be used to reduce muscle forces on the wearer's back during lumbar flexion, which occurs during actions such as bending and stooping. An individual may wish to wear the exoskeleton during these activities for support, and continue to wear the exoskeleton during other activities, including walking, walking uphill, or climbing stairs or ladders (e.g., for convenience). Some embodiments of the present invention provide an exoskeleton that reduces muscle forces on the wearer's back during bending and stooping, while still allowing the wearer to walk, walk uphill, or climb stairs or ladders comfortably.

[0069] In some embodiments, the exoskeleton includes a supporting torso frame, first and second thigh links, and an actuator that generates an extension torque between the thigh links and the supporting torso frame to provide support to the wearer during bending or stooping.

[0070] In some embodiments, the actuator generates an extension torque between the first and second thigh links and the supporting trunk frame only when the wearer bends forward in the sagittal plane. In some embodiments, the actuator does not generate an extension torque between the first and second thigh links and the supporting trunk frame when the user is walking, climbing, or scrambling.

[0071] In some embodiments, the actuator generates a torque between the housing of the actuator and the shaft of the actuator, which in turn generates an extension torque between the thigh link and the supporting trunk frame. In some embodiments, the torque generated by the actuator between the actuator housing and the actuator shaft is transmitted through a pulley and wire system to generate an extension torque between the thigh link and the supporting trunk frame.

[0072] In some embodiments, the actuator housing and the actuator shaft can rotate relative to each other (e.g., in response to non-reciprocating motion of a thigh link coupled to the actuator housing and the actuator shaft, which occurs, for example, when the wearer's legs do not move in opposite directions at the same speed). Non-reciprocating motion occurs naturally during activities such as walking, climbing, or climbing. For example, during certain phases of the walking gait cycle, both legs of an individual move in the same direction.

[0073] In some embodiments, the movement of the first thigh link and the second thigh link relative to the supporting torso frame (e.g., when the wearer walks while wearing the torso supporting exoskeleton) can transmit forces to the actuator housing and the actuator shaft through a wire and pulley system. In embodiments where the actuator housing and the actuator shaft can rotate relative to each other, when the forces are unequal and opposite (i.e., in response to, for example, non-reciprocating motion of the thigh link that occurs when the wearer's legs do not move at the same speed in opposite directions), these forces can cause the actuator housing and the actuator shaft to rotate relative to each other. Allowing the actuator housing and the actuator shaft to rotate relative to each other in response to the non-reciprocating motion of the thigh link can allow the wearer to feel more comfortable while walking, climbing, or climbing while wearing the torso supporting exoskeleton. If the actuator housing and the actuator shaft cannot rotate relative to each other in response to the non-reciprocating motion of the thigh link, the tension in the wire connecting the actuator housing and the actuator shaft to the first thigh link and the second thigh link can resist the non-reciprocating motion, thereby making walking, climbing, or climbing uncomfortable or impossible for the user.

[0074] In some embodiments, the actuator can rotate relative to the supporting torso frame (e.g., in response to non-reciprocating motion of a thigh link coupled to the actuator housing and the actuator shaft).

[0075] Allowing the actuator to rotate relative to the supporting torso frame in response to the non-reciprocating motion of the thigh link may allow the wearer to feel more comfortable when walking, climbing, or scrambling while wearing the torso supporting exoskeleton. If the actuator is not able to rotate relative to the supporting torso frame in response to the non-reciprocating motion of the thigh link, the tension in the wires connecting the actuator housing and the actuator shaft to the first thigh link and the second thigh link may resist the non-reciprocating motion, thereby making walking, climbing, or scrambling uncomfortable or impossible for the user.

[0076] These and other embodiments are discussed in more detail below with reference to the accompanying figures.

[0077] Figures 1 to 4 An embodiment of a trunk support exoskeleton 100 is shown. As will be described, the trunk support exoskeleton 100 can be worn by a wearer 200 to reduce muscle forces on the wearer's back during lumbar flexion, which occurs during movements such as bending and stooping. Figure 1 A perspective view of a torso supporting exoskeleton 100 worn by a wearer 200 is shown. Figure 2 A perspective view of the torso supporting exoskeleton 100 is shown with the wearer 200 removed to further illustrate the components of the torso supporting exoskeleton 100 . Figure 3 Another perspective view of torso supporting exoskeleton 100 is shown.

[0078] Figure 4A wearer 200 wearing the torso support exoskeleton 100 is shown bending forward in the sagittal plane. In this position, lumbar flexion occurs. Angle 240 represents the degree to which the wearer 200 is bent in the forward direction.

[0079] As shown in the figure, for example, Figure 1 In the embodiment of the present invention, the trunk support exoskeleton 100 may include a support trunk frame 102 configured to be connected to a wearer's torso 202, a first thigh link 104 and a second thigh link 106 configured to be connected to respective thighs 204 and 206 of the wearer 200, and an actuator 118 for generating an extension torque between the first thigh link 104 and the support trunk frame 102 and between the second thigh link 106 and the support trunk frame 102.

[0080] As used herein and elsewhere in the present disclosure, the wearer torso 202 may include the wearer's chest, abdomen, pelvis, and back. The wearer torso 202 may be, for example, the wearer's body excluding the head and limbs, or the central portion of the wearer from which the neck and limbs extend.

[0081] As described above, the torso supporting exoskeleton 100 may include a first thigh link 104 and a second thigh link 106 configured to be coupled to respective thighs 204 and 206 of the wearer 200. When the first thigh link 104 and the second thigh link 106 are coupled to the respective thighs 204 and 206, the first thigh link 104 and the second thigh link 106 move with the wearer's thighs 204 and 206, respectively, such that the respective first thigh link 104 and the second thigh link 106 flex and extend relative to the supporting torso frame 102.

[0082] In some embodiments, the first thigh link 104 and the second thigh link 106 are rotatably coupled to the supporting trunk frame 102 so that the first thigh link 104 or the second thigh link 106 can be flexed or extended relative to the supporting trunk frame 102. Figure 4 As shown by arrow 220 in FIG. 1 , when the first thigh link 104 and the supporting torso frame 102 rotate toward each other, the first thigh link 104 flexes relative to the supporting torso frame 102. Similarly, when the second thigh link 106 and the supporting torso frame 102 rotate toward each other, the second thigh link 106 flexes relative to the supporting torso frame 102. Figure 4 As shown by arrow 222 in , when the first thigh link 104 and the supporting torso frame 102 rotate away from each other, the first thigh link 104 extends relative to the supporting torso frame 102. Similarly, when the second thigh link 106 and the supporting torso frame 102 rotate away from each other, the second thigh link 106 extends relative to the supporting torso frame 102.

[0083] As mentioned above, and as Figure 1 and Figure 2 As shown, the torso support exoskeleton 100 can include an actuator 118. In some embodiments, as will be discussed, the actuator 118 can generate an extension torque between the first thigh link 104 and the support torso frame 102 and between the second thigh link 106 and the support torso frame 102 to provide support for the wearer during lumbar flexion. In some embodiments, as will be discussed, the actuator 118 is coupled to the support torso frame 102, but is free to rotate relative to the support torso frame 102.

[0084] Reference below Figure 1 and Figures 5 to 10 Discuss actuator 118. Figure 5 and Figure 6 As shown, in some embodiments, the actuator 118 includes an actuator housing 120, a housing pulley 124, a housing cable 128 (such as Figure 7 ), actuator shaft 122, shaft pulley 126 and shaft cable 130. Figure 7 and Figure 8 , the actuator 118 is shown with the shaft pulley 126 removed for illustration purposes. Fig. 9 and Fig.10 , the actuator 118 is shown with the housing pulley 124 and the shaft pulley 126 removed for illustration purposes.

[0085] In some embodiments, the actuator housing 120 and the actuator shaft 122 can rotate relative to each other along the axis 243. The actuator 118 can be coupled to any point of the supporting torso frame 102. However, both the actuator housing 120 and the actuator shaft 122 can rotate freely relative to the supporting torso frame 102.

[0086] In some embodiments, the actuator 118 can generate torque between the actuator housing 120 and the actuator shaft 122 .

[0087] like Figure 5 and Figure 6 As shown, the shaft pulley 126 can be coupled to the actuator shaft 122 and rotate with the actuator shaft 122 (e.g., when the actuator 118 generates torque between the actuator housing 120 and the actuator shaft 122). Any suitable method can be used to couple the shaft pulley 126 and the actuator shaft 122 so that the shaft pulley 126 and the actuator shaft 122 rotate together. For example, a fastener can be used to couple the shaft pulley 126 to the actuator shaft 122.

[0088] like Figure 7 and Figure 8As shown, the housing pulley 124 can be coupled to the actuator housing 120 and rotate along the axis 243 with the actuator housing 120 (e.g., when the actuator 118 generates torque between the actuator housing 120 and the actuator shaft 122). Any suitable method can be used to couple the housing pulley 124 and the actuator housing 120 so that the housing pulley 124 and the actuator housing 120 rotate together. For example, fasteners can be used to couple the housing pulley 124 and the actuator housing 120.

[0089] In some embodiments, a first end of the axial cable 130 may be connected to (e.g., wrapped around) the axial pulley 126, and a second end of the axial cable 130 may be connected to the first thigh link 104, such that tension in the axial cable 130 (e.g., caused by the torque generated by the actuator 118 between the actuator housing 120 and the actuator shaft 122) generates an extension torque between the first thigh link 104 and the supporting trunk frame 102.

[0090] The shaft cable 130 can be or include any device or combination of devices capable of performing the functions shown. Examples of the shaft cable 130 include, but are not limited to, wires, cables, belts, fabric ropes, plastic ropes, ropes, twine, chains, bicycle-type chains, steel wire ropes, string, and combinations thereof. In some embodiments, the shaft cable 130 includes a multi-strand steel wire rope having a maximum strength of about 200 pounds.

[0091] In some embodiments, a first end of the shell cable 128 may be connected to (e.g., wrapped around) the shell pulley 124, and a second end of the shell cable 128 may be connected to the second thigh link 106, such that tension in the shell cable 128 (e.g., caused by the torque generated by the actuator 118 between the actuator housing 120 and the actuator shaft 122) produces an extension torque between the second thigh link 106 and the supporting torso frame 102.

[0092] The housing cable 128 can be or include any device or combination of devices capable of performing the functions shown. Examples of the housing cable 128 include, but are not limited to, wires, cables, belts, fabric ropes, plastic ropes, cords, twine, chains, bicycle-type chains, steel wire ropes, string, and combinations thereof. In some embodiments, the housing cable 128 includes a multi-strand steel wire rope having a maximum strength of about 200 pounds.

[0093] In some embodiments, for example, Fig.11As shown, the first thigh link 104 includes a first thigh link pulley 108 that rotates with the first thigh link 104 about an axis 158 relative to the support trunk frame 102. In some embodiments, the second end of the shaft cable 130 is coupled to (e.g., wrapped around) the first thigh link pulley 108 so that the tension in the shaft cable 130 produces an extension torque between the first thigh link 104 and the support trunk frame 102. In some embodiments, for example, Fig.12 As shown, the second end of the axle cable 130 is directly connected to the first thigh link 104 such that tension in the axle cable 130 generates a torque about the axis 158 .

[0094] In some embodiments, the second thigh link 106 includes a second thigh link pulley 110 that rotates with the second thigh link 106 relative to the supporting torso frame 102 about an axis 160. In some embodiments, the second end of the housing cable 128 is coupled to (e.g., wrapped around) the second thigh link pulley 110 such that tension in the housing cable 128 produces an extension torque between the second thigh link 106 and the supporting torso frame 102. In some embodiments, the second end of the housing cable 128 is directly connected to the second thigh link 106 such that tension in the housing cable 128 produces a torque about the axis 160.

[0095] As described above, in some embodiments, the actuator 118 can generate torque between the actuator housing 120 and the actuator shaft 122 . Fig.13 The schematic diagram shows how this torque is transmitted through the pulley and wire system described above. Fig.13 In Figure 1, the system is flattened into a two-dimensional schematic to illustrate the torque transfer. Fig.13 As shown, when the actuator 118 generates a resistive torque between the actuator housing 120 and the actuator shaft 122, the torque is transmitted to the housing pulley 124 (which is coupled to the actuator housing 120 and rotates with it) and the shaft pulley 126 (which is coupled to the actuator shaft 122 and rotates with it). In turn, the torque transmitted to the housing pulley 124 and the shaft pulley 126 generates tension in the housing cable 128 and the shaft cable 130. These tensions provide an extension torque between the thigh links 104 and 106 and the supporting trunk frame 102 in the direction of arrow 222.

[0096] exist Figure 5 and Figure 6 In the embodiment, the shaft pulley 126 and the housing pulley 124 have equal diameters. However, in other embodiments (e.g., Fig.13 As shown in FIG. 1 , the shaft pulley 126 and the housing pulley 124 may have unequal diameters. Figures 1 to 4In the illustrated embodiment, the first thigh link pulley 108 and the second thigh link pulley 110 have equal diameters. However, in other embodiments, the first thigh link pulley 108 and the second thigh link pulley 110 may have unequal diameters. In embodiments where the shaft pulley 126 and the housing pulley 124 have equal diameters and the first thigh link pulley 108 and the second thigh link pulley 110 have equal diameters, the torque between the actuator housing 120 and the actuator shaft 122 is transmitted equally to the thigh links 104 and 106. Therefore, the extension torque between the supporting trunk frame 102 and the thigh link will be equal to twice the torque generated by the actuator 118. However, in embodiments where the shaft pulley 126 and the housing pulley 124 have unequal diameters or the first thigh link pulley 108 and the second thigh link pulley 110 have unequal diameters, unequal torques may be transmitted to the thigh links 104 and 106.

[0097] return Figure 4 In operation, when the wearer 200 bends forward in the sagittal plane so that the predetermined portion 147 of the support trunk frame 102 exceeds the predetermined angle 242 with the vertical gravity line 244, the actuator 118 can generate a resistive torque between the actuator housing 120 and the actuator shaft 122. As discussed, this resistive torque can generate tension in the housing cable 128 and the shaft cable 130 (e.g., via the torque generated between the housing pulley 124 and the shaft pulley 126), which can then generate an extension torque between the support trunk frame 102 and the first thigh link 104 and the second thigh link 106. The extension torque between the thigh link 104 and the support trunk frame 102 can attempt to rotate the first thigh link 104 and the support trunk frame 102 away from each other. Similarly, the extension torque between the second thigh link 106 and the support trunk frame 102 can attempt to rotate the second thigh link 106 and the support trunk frame 102 away from each other.

[0098] The extension torque between the supporting torso frame 102 and the first thigh link 104 and the second thigh link 106 can apply a supporting torso force 230 (e.g., Figure 4 ). The support torso force 230 applied by the support torso frame 102 to the wearer's torso 202 can help reduce muscle forces in the general area 208 of the wearer's lower back. Figure 4 In the embodiment of the present invention, the supporting torso force 230 is generally applied to the wearer's chest area 210. However, depending on the design of the upper frame portion 306 of the supporting torso frame 102, the supporting torso force 230 can be applied to different parts of the wearer's torso 202. At the same time, the first thigh link 104 and the second thigh link 106 can apply forces to the wearer's thighs 204 and 206.

[0099] In some embodiments, when the wearer 200 is not bending forward in the sagittal plane (i.e., when the predetermined portion 147 of the support trunk frame 102 does not exceed the predetermined angle 242 with the vertical gravity line 244), the actuator 118 does not generate a resistive torque between the actuator shaft 122 and the actuator housing 120. In such an embodiment, the actuator 118 does not generate an extension torque between the support trunk frame 102 and the first thigh link 104 and the second thigh link 106. This means that as long as the wearer 200 is not bending forward in the sagittal plane, the wearer 200 can walk, go up and down stairs and slopes without any force being applied to the wearer 200 from the support trunk frame 102.

[0100] However, if the wearer 200 bends forward in the sagittal plane (i.e., when the predetermined portion 147 of the supporting torso frame 102 exceeds the predetermined angle 242 with the vertical gravity line 244, such as Fig.12 As shown), the supporting torso force 230 from the supporting torso frame 102 will help support the wearer's torso 202.

[0101] Examples of the predetermined angle 242 may be 5 degrees, 10 degrees, or 15 degrees. In some embodiments, the predetermined angle 242 may be zero.

[0102] In some embodiments, when the wearer 200 is not bending forward in the sagittal plane, the actuator 118 generates a relatively small resistive torque between the actuator shaft 122 and the actuator housing 120. This relatively small resistive torque generated by the actuator 118 can allow the thigh links 104 and 106 to move substantially freely relative to the supporting torso frame 102. This relatively small resistive torque generated by the actuator 118 can keep the thigh links 104 and 106 in contact with the wearer's thigh during walking. This relatively small resistive torque generated by the actuator 118 can be selected to be small enough not to resist or hinder the wearer during walking, but rather to cause the thigh links to move with the wearer's thigh.

[0103] As described above, an individual may wish to wear exoskeleton 100 to provide support when bending forward in the sagittal plane as described above, and also continue to wear exoskeleton 100 (e.g., for convenience) during other activities, including walking, walking uphill, or climbing stairs or ladders. In some embodiments, to enable the wearer to walk, walk uphill, or climb stairs or ladders comfortably while wearing exoskeleton 100, actuator housing 120 and actuator shaft 122 may rotate relative to each other along axis 243 in response to non-reciprocating motion of thigh links 104 and 106, which may occur, for example, when the wearer's legs are not moving in opposite directions at the same speed.

[0104] In some embodiments, when the actuator 118 is not generating a resistive torque between the actuator housing 120 and the actuator shaft 122 (e.g., when the wearer 200 is not bending forward in the sagittal plane), the actuator housing 120 and the actuator shaft 122 may rotate relative to each other in response to the non-reciprocating motion of the thigh links 104 and 106.

[0105] In some embodiments, when the actuator 118 generates a relatively small resistive torque between the actuator housing 120 and the actuator shaft 122, the actuator housing 120 and the actuator shaft 122 can rotate relative to each other in response to the non-reciprocating motion of the thigh links 104 and 106.

[0106] In some embodiments, extension of the first thigh link 104 or the second thigh link 106 relative to the supporting torso frame 102 (e.g., when the wearer 200 walks) can transmit forces to the actuator shaft 122 and the actuator housing 120 through the above-described system of wires 128, 130 and pulleys 124, 126. In embodiments where the actuator housing 120 and the actuator shaft 122 are rotatable relative to each other, when the forces are unequal and opposite (e.g., in response to non-reciprocating motion of the wearer's legs), these forces can cause the actuator housing 120 and the actuator shaft 122 to rotate relative to each other. If the actuator housing 120 and the actuator shaft 122 are unable to rotate relative to each other in response to non-reciprocating motion of the individual's legs, the tension in the wires 128, 130 connecting the actuator housing 120 and the actuator shaft 122 to the first thigh link 104 and the second thigh link 106 may resist the non-reciprocating motion of the thigh links 104 and 106 relative to the supporting torso frame 102, making walking, climbing or scrambling uncomfortable or impossible for the wearer.

[0107] In some embodiments, to enable the wearer to comfortably walk, walk uphill, or climb stairs or ladders while wearing the exoskeleton 100, the actuator 118 is rotatably coupled to the supporting torso frame 102 such that the actuator 118 is free to rotate relative to the supporting torso frame 102. In some embodiments, there may be a friction torque that opposes the rotation of the actuator 118 relative to the supporting torso frame 102.

[0108] The actuator 118 can be coupled to the supporting torso frame 102 via any suitable mechanism that allows the actuator 118 to rotate relative to the supporting torso frame 102. For example, in some embodiments, the actuator 118 is coupled to the supporting torso frame 102 via a ball bearing mechanism. As another example, in some embodiments, a bushing can allow the actuator 118 to rotate relative to the supporting torso frame 102. For example, in Figures 1 to 10 In the illustrated embodiment, the ball bearing 140 ( Fig. 9The outer race 142 of the ball bearing 140 is coupled to the support trunk frame 102, and the inner race 144 of the ball bearing 140 is coupled to the actuator housing 120. This arrangement allows the actuator housing 120 to rotate relative to the support trunk frame 102.

[0109] The coupling of the actuator housing 120 to the supporting torso frame 102 is not limited to the arrangement shown. Rather, the actuator housing 120 may be coupled to the supporting torso frame 102 via any suitable mechanism that allows the actuator housing 120 to rotate relative to the supporting torso frame 102. For example, a bushing may be used to allow the actuator housing 120 to rotate relative to the supporting torso frame 102.

[0110] As described above, in some embodiments, the actuator 118 can rotate relative to the supporting torso frame 102, and in some embodiments, the actuator housing 120 and the actuator shaft 122 can rotate relative to each other. In some embodiments, the actuator 118 can rotate relative to the supporting torso frame 102, and the actuator housing 120 and the actuator shaft 122 can rotate relative to each other. That is, in some embodiments, the actuator housing 120 and the actuator shaft 122 can rotate relative to the supporting torso frame 102 and relative to each other.

[0111] In some embodiments, the trunk support exoskeleton 100 includes a controller 146 that sends signals to the actuator 118 to generate a resistive torque between the actuator housing 120 and the actuator shaft 122 (e.g., when the wearer 200 bends forward in the sagittal plane, as discussed). The controller 146 can be or include any device or combination of devices capable of performing the functions shown. Examples of the controller 146 include, but are not limited to, analog devices; analog computing modules; digital devices, including, but not limited to, small, medium, and large integrated circuits, application specific integrated circuits, programmable gate arrays, and programmable logic arrays; and digital computing modules, including, but not limited to, microcomputers, microprocessors, microcontrollers, and programmable logic controllers. In some embodiments, the controller 146 includes an element or combination of elements selected from the group consisting of: an electromechanical relay or a MOSFET switch.

[0112] In some embodiments, the torso supporting exoskeleton 100 includes a tilt sensor 150 that generates a tilt signal 156. In some embodiments, the tilt signal 156 may indicate the angle of the supporting torso frame 102 in the sagittal plane with respect to the vertical gravity line 244. The angle is Figure 4 It is represented by 240.

[0113] Tilt sensor 150 may be or include any device or combination of devices capable of performing the functions shown. Examples of tilt sensor 150 include, but are not limited to, an inertial measurement unit (IMU), an inclinometer, an encoder, and an angle sensor.

[0114] In operation, when the tilt signal 156 indicates that the wearer 200 or the support torso frame 102 is bent forward in the sagittal plane (i.e., when the tilt signal indicates that the support torso frame 102 is at an angle greater than the predetermined angle 242 to the vertical gravity line 244 in the sagittal plane), the controller 146 may send a signal to the actuator 118 to generate a resistive torque between the actuator housing 120 and the actuator shaft 122. As discussed, the resistive torque generated between the actuator housing 120 and the actuator shaft 122 may generate tension in the housing cable 128 and the shaft cable 130, and the tension in the housing cable 128 and the shaft cable 130 may provide an extension torque between the support torso frame 102 and the thigh links 104 and 106.

[0115] An example calculation of the resistive torque of the actuator 118 is shown below.

[0116] As context, Fig.14 Schematic diagram showing the forces on the back of an individual when bending forward in the sagittal plane without a trunk-supporting exoskeleton. In static or quasi-static conditions, and without the individual lifting any load, the bending moment (torque) applied at L5 / S1 can be given by [M B gl B sin(∝)] represents, where M B represents the mass of the individual's upper body (including the individual's torso, head, and arms), and the portion lifted by the individual's arms, g represents the acceleration due to gravity, and l B is the distance between the upper body center of mass and the L5 / S1 point. ∝ represents the angle of the individual's trunk to the vertical gravity line 244. During load handling and dynamic movements, bending moments increase.

[0117] As described above, when the wearer 200 wearing the torso supporting exoskeleton 100 bends forward in the sagittal plane, the actuator 118 may generate an extension torque between the supporting torso frame 102 and the first thigh link 104 and the second thigh link 106. The extension torque generated by the actuator 118 may generate a supporting torso force 230 on the wearer that opposes the bending moment due to the torso and partial weight. This means that the bending moment (torque) applied at L5 / S1 may be reduced to a new value: [(M B l B )g sin(∝)-FL], where L is the distance from the supporting trunk force 230 to the point L5 / S1, as Fig.14 This illustrates the basic concept of a trunk support exoskeleton, where the trunk support exoskeleton reduces the bending moment at L5 / S1, thereby reducing the likelihood of injury during repetitive movements.

[0118] Erector spinae muscle tension MAs the supporting trunk force 230 increases, it decreases. In more general cases, the erector spinae muscle force F M , the angular velocity and acceleration are and It can be expressed as:

[0119]

[0120] C is a constant, and represents the speed-dependent torque. I is the effective moment of inertia of the upper body, and Indicates acceleration related torque.

[0121] Spine compression force F CS Similarly, it decreases as the supporting trunk force 230 increases and can be expressed as:

[0122]

[0123] This analysis assumes that F CS and F M The force F acts perpendicularly to the supporting trunk 230. In theory, if the exoskeleton supporting torque FL is chosen as equation (3), then the force F M decreases to zero (Equation 4), and the force F CS Basically reduces (Equation 5):

[0124]

[0125] F M =0 (4)

[0126]

[0127] This means that, in theory, the erector spinae force F can be controlled by controlling the supporting trunk force 230 acting on the wearer 200. M Reduce to zero and compress the spine force F CS However, the parameters in equation (3) may be difficult to measure or calculate accurately. For example, M B is not a known quantity, l B is only an estimate, and the measurement of ∝ is imprecise. However, any attempt to cancel the terms of equation (1) by using equation (3) will result in a spinal compressive force F CS and erector spinae strength F M In most cases, the bending acceleration As these equations show, when the supporting trunk force 230 increases, the erector spinae muscle force and the spinal compression force (given by F CS and F M shown) are reduced.

[0128] The term FL is referred to as a support torque because it supports the wearer 200 during bending and stooping. Fig.14 It can be seen that the support torque is an extension torque. In some embodiments, the exoskeleton support torque FL can be selected as

[0129]

[0130] If the acceleration can be ignored, then K1 and K2 represent approximate values ​​of the parameters of equation (3). As shown by equation (6), in some embodiments, the exoskeleton support torque FL includes a torque as a function of the angle ∝. In some embodiments, as shown by equation (6), the exoskeleton support torque FL includes a torque as a function of the angle ∝. The torque is a function of the angular velocity. In some applications, the acceleration related term is small and can be ignored. can be measured or estimated with little noise, then equation (6) contains Can improve device performance.

[0131] If the shaft pulley 126 and the housing pulley 124 have equal diameters, and if the first thigh link pulley 108 and the second thigh link pulley 110 have equal diameters, then T R The indicated resistive torque of the actuator 118 is expressed by equation (7)

[0132]

[0133] In some embodiments, as shown by Equation 7, the resistance torque is a function of the tilt signal 156. In some embodiments, the resistance torque is a function of the degree of forward bending of the wearer in the sagittal plane. In some embodiments, the resistance torque increases as the angle of the support trunk frame 102 with the vertical gravity line 244 increases. In some embodiments, the resistance torque decreases as the angle of the support trunk frame 102 with the vertical gravity line 244 decreases. In some embodiments, the resistance torque is a function of the angular velocity of the support trunk frame 102 in the sagittal plane. In some embodiments, the resistance torque decreases as the forward angular velocity of the support trunk frame 102 in the sagittal plane increases. For example, this allows the wearer 200 to bend forward in the sagittal plane without having to push the support trunk frame 102 with great effort. In some embodiments, the resistance torque increases as the forward angular velocity of the support trunk frame 102 in the sagittal plane decreases. In some embodiments, the resistance torque decreases as the backward angular velocity of the support trunk frame 102 in the sagittal plane increases. In some embodiments, the resistive torque increases as the rearward angular velocity of the supporting torso frame 102 in the sagittal plane decreases.

[0134] In some embodiments, when the tilt signal 156 indicates that the wearer 200 is no longer bending forward in the sagittal plane, the controller 146 stops sending a signal to the actuator 118 to generate the resistive torque according to equation (7).

[0135] In some embodiments, when the tilt signal 156 indicates that the wearer 200 is not bending forward in the sagittal plane, the controller 146 sends a signal to the actuator 118 to generate a substantially small resistive torque between the actuator housing 120 and the actuator shaft 122 .

[0136] In some embodiments, when the tilt signal 156 indicates that the wearer 200 is not bending forward in the sagittal plane, the controller 146 sends a signal to the actuator 118 to generate zero torque.

[0137] In some embodiments, the actuator 118 provides a biasing resistance torque T in Equation 7 偏置 A small amount of tension is provided in the housing cable 128 and the shaft cable 130. As shown in Equation 8, T 偏置 This results in a small initial tension in the housing cable 128 and the shaft cable 130 .

[0138]

[0139] Fig.15 1 is a flow chart showing a control algorithm for exoskeleton 100. The control software may be initiated by reading one or more of the voltage of battery 145, the temperature of actuator 118 or a component thereof (e.g., electric motor 116), tilt signal 156, or the rate of change of tilt signal 156.

[0140] In embodiments where the voltage of the battery 145 is checked, the actuator 118 may be disabled if the voltage of the battery 145 is less than a minimum voltage and the calculated resistance torque is less than a threshold torque.

[0141] In embodiments where the actuator temperature is checked, the resistive torque may be reduced if the actuator temperature is above an allowable temperature.

[0142] In embodiments where the tilt signal 156 and / or the rate of change of the tilt signal 156 is read, the resistive torque of the actuator 118 may be calculated using Equation 8. is positive (i.e., the wearer 200 is bent forward in the sagittal plane), then the coefficient K2 (used in Equation 6) may be selected as K 2F Otherwise, the coefficient K2 can be chosen to be K 2B In some embodiments, K 2F Greater than K 2B This allows for less resistive torque when bending forward in the sagittal plane.2F and K 2B value to provide appropriate comfort for the wearer 200.

[0143] In some embodiments, the calculated resistance torque may be checked to see if it is negative or positive. In some embodiments, if the calculated resistance torque is negative, the resistance torque may be set to zero.

[0144] In some embodiments, the resistive torque may be checked to see if it is greater than the maximum torque of the actuator 118 (or the maximum torque that can be produced by the electric motor 116 of the actuator 118). This maximum torque is referred to as T max If the calculated resistance torque is greater than the maximum torque T max , then the resistance torque can be set to T max .

[0145] Now refer to Figure 1 and Figures 16 to 18 Additional aspects related to supporting the torso frame 102 are discussed. Figure 1 As shown, in some embodiments, the supporting torso frame 102 includes a lower frame portion 302 , a spine frame portion 304 , and an upper frame portion 306 .

[0146] like Figure 1 As shown, in some embodiments, when the torso support exoskeleton 100 is worn, the lower frame portion 302 is substantially located behind the wearer 200. In some embodiments, the lower frame portion 302 is configured to partially surround the wearer's torso 202 and hips. In some embodiments, the lower frame portion 302 is coupled to the first thigh link 104 and the second thigh link 106 from both sides of the wearer 200.

[0147] The spine frame portion 304 can be coupled to (e.g., rotatably coupled to) the lower frame portion 302. In some embodiments, the spine frame portion 304 can rotate relative to the lower frame portion 302 about an axis 320. For example, this can allow the wearer 200 to freely rotate his upper body relative to his lower body. In some embodiments, the axis 320 is substantially parallel to the wearer's spine. Arrow 322 shows the direction of rotation of the spine frame portion 304 relative to the lower frame portion 302 about the axis 320. In some embodiments, the spine frame portion 304 is located behind the wearer 200 when the torso support exoskeleton 100 is worn.

[0148] The upper frame portion 306 can be connected to (e.g., rotatably connected to) the spinal frame portion 304. In some embodiments, the upper frame portion 306 can rotate relative to the spinal frame portion 304 around the axis 320. For example, this can allow the wearer 200 to freely rotate his upper body relative to his lower body. In some embodiments, the axis 320 is substantially parallel to the wearer's spine. Arrow 322 shows the rotation direction of the upper frame portion 306 relative to the spinal frame portion 304 around the axis 320. In some embodiments, the upper frame portion 306 can rotate relative to the spinal frame portion 304 around the axis 324. For example, this can allow the wearer 200 to freely rotate his upper body relative to his lower body. In some embodiments, the axis 324 is substantially parallel to one of the wearer's lumbar mediolateral flexion axis and extension axis. Arrow 328 shows the rotation direction of the upper frame portion 306 relative to the spinal frame portion 304 around the axis 324.

[0149] In some embodiments, the upper frame portion 306 is configured to contact the wearer's torso 202 so that the upper frame portion 306 can apply a force to the front of the wearer's torso 202 (e.g., Figure 6 In some embodiments, the upper frame portion 306 is configured to contact the chest region 210 of the wearer's torso 202 so that the upper frame portion 306 can apply a force to the chest region of the wearer's torso 202 (e.g., Figure 4 In some embodiments, the upper frame portion 306 is configured to contact the shoulder region 218 of the wearer's torso 202 such that the upper frame portion 306 can apply a force (e.g., the supporting torso force 230) to the shoulder region 218 of the wearer's torso 202. Figure 2 and Figure 3 As shown, in some embodiments, the upper frame portion 306 includes shoulder straps 308. In some embodiments, as shown in FIG. Figure 2 and Figure 3 As shown, the upper frame portion 306 includes a chest strap 310 .

[0150] As described above, in some embodiments, the spine frame portion 304 is rotatable relative to the lower frame portion 302, and in some embodiments, the upper frame portion 306 is rotatable relative to the spine frame portion 304. In some embodiments, both upper frame portions 306 are rotatable relative to the spine frame portion 304, and the spine frame portion 304 is rotatable relative to the lower frame portion 302.

[0151] In some embodiments, the height of the support trunk frame 102 is adjustable. In some embodiments, the support trunk frame 102 includes an adjustment mechanism 326 (e.g., Figure 2 304 to adjust the height of the support trunk frame 102. For example, in some embodiments, the upper frame portion 306 is configured to slide linearly along the spine frame portion 304 to adjust the height of the support trunk frame 102. In some embodiments, the height of the support trunk frame 102 can be increased or decreased, such as by Figure 2 As shown by arrows 374 and 378 in FIG.

[0152] In some embodiments, the width of the lower frame portion 302 is adjustable to accommodate different groups of people. In some embodiments, the supporting trunk frame 102 includes an adjustment mechanism 255 (e.g., Fig.16 ), to adjust the width of the lower frame portion 302. For example, in some embodiments, the adjustment mechanism 255 can increase or decrease the width of the lower frame portion 302, such as by Fig.16 As shown by arrows 332 and 334 in FIG.

[0153] In some embodiments, the depth of the lower frame portion 302 is adjustable to accommodate different groups of people. In some embodiments, the support trunk frame 102 includes an adjustment mechanism 329 (e.g., Fig.17 ), to adjust the depth of the lower frame portion 302. For example, in some embodiments, the adjustment mechanism 329 can increase or decrease the depth of the lower frame portion 302, such as by Fig.17 As shown by arrows 336 and 338 in FIG.

[0154] As described above, in some embodiments, the width, length, and depth of the support torso frame 102 may be adjustable to accommodate different wearers. Fig.16 and Fig.18 As shown, the shaft cable sheath 236 surrounds the shaft cable 130 and is secured to the support trunk frame 102 at locations 250 and 252. This arrangement can help facilitate sizing of the support trunk frame 102 without requiring adjustment of the size of the shaft cable 130. Similarly, in some embodiments, the housing cable sheath 238 surrounds the housing cable 128 and is secured to the support trunk frame 102. This arrangement can help facilitate sizing of the support trunk frame 102 without requiring adjustment of the size of the housing cable 128. Fig.18 It is schematically shown how the axial cable 130 may be framed by the jacket 236 .

[0155] Now refer to Fig.19 and Fig. 20 Additional aspects related to the actuator 118 are discussed.

[0156] The actuator 118 can be or include any device or combination of devices capable of performing the functions shown. Examples of actuators 118 include electric motors, including but not limited to AC (alternating current) motors, brushed DC (direct current) motors, brushless DC motors, electronically commutated motors (ECMs), stepper motors, and combinations thereof. In some embodiments, the actuator 118 includes a transmission system such as a harmonic drive, a planetary gear, a ball screw mechanism, a lead screw mechanism, a worm gear, and combinations thereof. In some embodiments, the actuator 118 includes a hydraulic actuator.

[0157] In some embodiments, the actuator 118 includes an electric motor 116 configured to generate torque between the actuator shaft 122 and the actuator housing 120 by using electric power. The electric motor 116 can be or include any device or combination of devices capable of performing the functions shown. Examples of electric motors include, but are not limited to, an element or combination of elements selected from the group consisting of: an electric motor, including but not limited to an AC (alternating current) motor, a brushed DC (direct current) motor, a brushless DC motor, an electronically commutated motor (ECM), a stepper motor, and combinations thereof.

[0158] In some embodiments, the actuator 118 includes a transmission system to modify and adjust the torque of the actuator 118. The transmission system can be or include any device or combination of devices capable of performing the functions shown. Examples of transmission systems include, but are not limited to, gears, worm gears, gear trains, pulleys, cables, belts, toothed belts, toothed pulleys, planetary gears, harmonic drives, spur gears, flexible belts, wire ropes, ropes, ball screw mechanisms, and lead screw mechanisms.

[0159] In some embodiments, such as Fig.19 and Fig. 20 As shown, the actuator 118 includes an actuator spring 196 to generate a resistive torque between the actuator shaft 122 and the actuator housing 120 .

[0160] In some embodiments, the actuator 118 includes both the electric motor 116 and the actuator spring 196 to generate a resistive torque between the actuator shaft 122 and the actuator housing 120 .

[0161] like Fig.19 As shown, the actuator spring 196 may include a first end 246 and a second end 248. The first end 246 of the actuator spring 196 may be directly or indirectly coupled to the actuator shaft 122 such that when the actuator shaft 122 rotates relative to the actuator housing (e.g., in response to bending of the wearer 200 in the sagittal plane), the first end 246 of the actuator spring 196 rotates with the actuator shaft 122.

[0162] The second end 248 of the actuator spring 196 may be free when the actuator shaft 122 is in a first rotational range 260 of the actuator shaft 122 relative to the actuator housing 120. When the actuator shaft 122 is rotated relative to the actuator housing 120 beyond the first rotational range (e.g., by rotating in a clockwise direction relative to the actuator housing 120), the second end 248 of the actuator spring 196 may be constrained by the actuator housing 120. In other words, within the second rotational range, the second end 248 of the actuator spring 196 may be directly or indirectly coupled to the actuator housing 120 such that the second end 248 of the actuator spring 196 rotates with the actuator housing 120. When the actuator shaft 122 is in the second rotation range 262 where the second end 248 of the spring 196 is constrained, further rotation of the actuator shaft 122 relative to the actuator housing 120 in the same direction (e.g., clockwise) may cause the spring 196 to deflect, thereby causing the spring 196 to provide a spring resistance torque on the actuator shaft 122. In some embodiments, the actuator housing 120 may include a housing protrusion 254 (e.g., Fig.19 ), to constrain the second end 248 of the actuator spring 196. Fig.19 As shown, when the actuator shaft 122 is rotated relative to the actuator housing 120 (e.g., in a clockwise direction), the second end 248 engages the housing protrusion 254. After the second end 248 engages the housing protrusion 254, the second end 248 no longer rotates relative to the actuator housing 120. Further rotation of the actuator shaft 122 relative to the actuator housing 120 in the same direction causes the actuator spring 196 to flex and resist rotation of the actuator shaft 122 relative to the actuator housing 120.

[0163] The above configuration can passively generate resistance torque not only by using electricity, but also by using the actuator spring 196. In operation, when the actuator shaft 122 is in a first rotation range, the electric motor 116 can generate resistance torque between the actuator shaft 122 and the actuator housing 120 by using electricity. When the actuator shaft 122 is in a second rotation range, the actuator spring 196 can provide a spring resistance torque between the actuator shaft 122 and the actuator housing 120. In some embodiments, when the actuator shaft 122 is in the second rotation range, the electric motor 116 can also provide a motor resistance torque on the actuator shaft 122 relative to the actuator housing 120. In such an embodiment, the resistance torque is the sum of both the spring torque and the torque generated by the motor 116. The technique of adding the actuator spring torque in parallel with the electric motor torque discussed above is useful in increasing the torque capacity of the actuator 118.

[0164] Examples of actuator spring 196 include, but are not limited to, helical springs, torsion springs, leaf springs, coil springs, bungee cords, elastomeric cords, elastic cords, elastic fabric cords, plastic cords, elastomeric cords, twisted cords, wire rope elastics, thin cords, and combinations thereof.

[0165] exist Fig.19 In the illustrated embodiment, the first end 246 of the spring 196 is coupled to the actuator shaft 122. However, in other embodiments, for example Fig. 20 In the illustrated embodiment, the first end 246 of the spring 196 is alternatively coupled to the actuator housing 120 such that when the actuator housing 120 rotates relative to the actuator shaft 122 (e.g., in response to bending of the wearer 200 in the sagittal plane), the first end 246 of the actuator spring 196 rotates with the actuator housing 120. Fig. 20 As shown, when the actuator housing 120 is in a first rotation range 260 relative to the actuator shaft 122, the second end 248 of the spring 196 can rotate freely. When the actuator housing 120 rotates relative to the actuator shaft 122 (e.g., in a clockwise direction) beyond the first rotation range 260, the second end 248 of the spring 196 can be constrained (e.g., constrained by a shaft constraining element 234 coupled to the actuator shaft 122).

[0166] based on Fig.19 and Fig. 20 In the two embodiments of the present invention, it can be observed that, generally, the spring 196 includes a first end 246 and a second end 248. The first end 246 of the spring 196 can be coupled to one of the actuator shaft 122 or the actuator housing 120. When the actuator shaft 122 is in a first rotational range relative to the actuator housing 120, the second end 248 of the spring 196 can be free. Therefore, when the actuator shaft 122 is in the first rotational range, the spring 196 does not provide a spring resistance torque on the actuator shaft 122. When the actuator shaft 122 is in a second rotational range relative to the actuator housing 120, the second end 248 of the spring 196 can be constrained by the other of the actuator shaft 122 or the actuator housing 120. In operation, when the actuator shaft 122 is in the first rotational range, the motor 116 can provide a motor resistance torque on the actuator shaft 122 relative to the actuator housing 120. When the actuator shaft 122 is in the second rotational range, the spring 196 can provide a spring resistance torque on the actuator shaft 122 relative to the actuator housing 120. In some embodiments, the motor 116 can also provide a motor resistance torque on the actuator shaft 122 relative to the actuator housing 120 when the actuator shaft 122 is in the second rotational range.

Claims

1. A trunk support exoskeleton for reducing muscle forces on a wearer's back during lumbar flexion, the trunk support exoskeleton comprising: a supporting torso frame configured to be coupled to a wearer's torso; a first thigh link configured to couple to one of a wearer's thighs; a second thigh link configured to be coupled to the other of the wearer's thighs, wherein each of the first thigh link and the second thigh link is rotatably coupled to the supporting torso frame such that the respective first thigh link or the second thigh link can flex or extend relative to the supporting torso frame; an actuator coupled to a supporting torso frame, wherein the actuator comprises an actuator housing and an actuator shaft, wherein the actuator shaft and the actuator housing are rotatable relative to the supporting torso frame; a shaft pulley coupled to the actuator shaft; a housing pulley coupled to the actuator housing; an axial cable having a first end wound around the axial pulley and a second end coupled to the first thigh link; as well as a housing cable having a first end wound around the housing pulley and a second end coupled to the second thigh link, wherein the actuator generates an actuator resistance torque between the actuator housing and the actuator shaft when the wearer bends forward relative to the vertical gravity line in the sagittal plane, and The actuator resistance torque between the actuator housing and the actuator shaft generates tension in the housing cables and the shaft cables, thereby generating extension torques between the corresponding first thigh links and the second thigh links and the supporting trunk frame.

2. The trunk supporting exoskeleton of claim 1, wherein: The first thigh link comprises a first thigh link pulley, The second thigh link comprises a second thigh link pulley, The second end of the shaft cable is wrapped around the first thigh link pulley so that tension in the shaft cable provides an extension torque between the first thigh link and the supporting torso frame, and The second end of the housing cable is wrapped around the second thigh link pulley so that tension in the housing cable provides an extension torque between the second thigh link and the supporting torso frame.

3. The trunk supporting exoskeleton of claim 1 , wherein the actuator does not generate an actuator resistance torque between the actuator housing and the actuator shaft when the wearer is not bent forward relative to the vertical line of gravity.

4. A torso supporting exoskeleton as described in claim 1, wherein when the wearer is not bending forward relative to the vertical gravity line, the actuator produces a relatively small actuator resistance torque between the actuator housing and the actuator shaft, thereby allowing substantially free movement of the thigh link.

5. A torso supporting exoskeleton as claimed in claim 1, wherein when the wearer is not bent forward relative to the vertical gravity line and the thigh link is in a reciprocating mode indicative of walking, the actuator produces a relatively small actuator resistance torque, thereby allowing substantially free movement of the thigh link.

6. The torso supporting exoskeleton of claim 1, wherein the shaft cable and the shell cable each comprise an element or combination of elements selected from the group consisting of: wires, cables, belts, fabric ropes, plastic ropes, cords, twine, chains, steel cables, and string.

7. The trunk supporting exoskeleton of claim 1, wherein the actuator comprises an element or combination of elements selected from the group consisting of: an AC (alternating current) motor, a brushed DC (direct current) motor, a brushless DC motor, an electronically commutated motor (ECM), a stepper motor, and combinations thereof.

8. The trunk supporting exoskeleton of claim 1, wherein the actuator further comprises a transmission system.

9. The trunk supporting exoskeleton of claim 8, wherein the transmission system comprises an element or combination of elements selected from the group consisting of: a harmonic drive, a planetary gear, a ball screw mechanism, a lead screw mechanism, a worm gear, and combinations thereof.

10. The trunk supporting exoskeleton of claim 8, wherein the drive system comprises an element or combination of elements selected from the group consisting of: gears, worm gears, gear trains, pulleys, cables, belts, toothed belts, toothed pulleys, planetary gears, harmonic drives, spur gears, flexible belts, wire ropes, ropes, ball screw mechanisms, and lead screw mechanisms.

11. The trunk supporting exoskeleton of claim 1 , further comprising a controller for sending a signal to the actuator to generate the actuator resistance torque between the actuator housing and the actuator shaft when the wearer bends forward relative to the vertical gravity line.

12. A trunk supporting exoskeleton as claimed in claim 11, wherein when the wearer is not bent forward relative to the vertical gravity line, the controller sends a signal to the actuator to generate a substantially small actuator resistance torque between the actuator housing and the actuator shaft.

13. The torso supporting exoskeleton of claim 1, wherein the actuator resistance torque is a function of the degree to which the wearer is bent forward relative to the vertical line of gravity.

14. The trunk supporting exoskeleton of claim 1, wherein the actuator resistance torque increases as the angle of the supporting trunk frame relative to the vertical gravity line increases.

15. The torso supporting exoskeleton of claim 1, wherein the actuator resistance torque decreases as the angle of the supporting torso frame relative to the vertical gravity line decreases.

16. The trunk supporting exoskeleton of claim 1, wherein the actuator resistance torque is a function of the angular velocity of the supporting trunk frame in the sagittal plane.

17. The trunk supporting exoskeleton of claim 1, wherein the actuator resistive torque decreases as the forward angular velocity of the supporting trunk frame in the sagittal plane increases.

18. The trunk supporting exoskeleton of claim 1, wherein the actuator resistive torque increases as the forward angular velocity of the supporting trunk frame in the sagittal plane decreases.

19. The trunk supporting exoskeleton of claim 1, wherein the actuator resistive torque decreases as the rearward angular velocity of the supporting trunk frame in the sagittal plane increases.

20. The trunk supporting exoskeleton of claim 1, wherein the actuator resistive torque increases as the rearward angular velocity of the supporting trunk frame in the sagittal plane decreases.

21. The trunk supporting exoskeleton of claim 1, further comprising: a tilt sensor that generates a tilt signal indicative of an angle of the supporting torso frame in the sagittal plane relative to the vertical gravity line; as well as A controller is configured to send a signal to the actuator to generate the actuator resistance torque between the actuator housing and the actuator shaft when the tilt signal indicates that the angle of the supporting torso frame relative to the vertical gravity line is greater than a predetermined angle.

22. The trunk supporting exoskeleton of claim 21, wherein the tilt sensor comprises an element or combination of elements selected from the group consisting of: an inertial measurement unit (IMU), an inclinometer, an encoder, and an angle sensor.

23. The trunk supporting exoskeleton of claim 21, wherein the actuator resistance torque is a function of the tilt signal.

24. The trunk supporting exoskeleton of claim 21, wherein when the tilt signal indicates that the wearer is not bent forward relative to the vertical gravity line, the controller sends a signal to the actuator to generate a substantially small actuator resistance torque between the actuator housing and the actuator shaft.

25. The torso supporting exoskeleton of claim 1, further comprising an axle cable sheath surrounding the axle cable, wherein the axle cable sheath is secured to the supporting torso frame to facilitate resizing of the supporting torso frame without resizing the axle cable.

26. The torso supporting exoskeleton of claim 1, further comprising a shell cable sheath surrounding the shell cable, wherein the shell cable sheath is secured to the supporting torso frame to facilitate resizing of the supporting torso frame without resizing the shell cable.

27. The trunk supporting exoskeleton of claim 1, wherein the actuator generates the actuator resistance torque by using electricity.

28. The trunk supporting exoskeleton of claim 1, wherein The actuator comprises an actuator spring, The first end of the actuator spring is coupled to the actuator shaft, the second end of the actuator spring being free within a first range of rotation of the actuator shaft relative to the actuator housing, The second end of the actuator spring is constrained by the actuator housing within a second rotation range of the actuator shaft relative to the actuator housing, In the first rotation range, the actuator generates the actuator resistance torque by using electric power, and In the second rotational range, the spring generates at least a portion of the actuator resistance torque.

29. The trunk supporting exoskeleton of claim 28, wherein the actuator spring comprises an element or combination of elements selected from the group consisting of: a coil spring, a leaf spring, a bungee cord, a torsion spring, an elastomeric cord, an elastic cord, a fabric cord, a plastic cord, a rope, a twisted rope, a wire rope, an elastic, and a string.

30. A trunk supporting exoskeleton as described in claim 1, wherein within a first rotation range of the actuator shaft relative to the actuator housing, the actuator generates the actuator resistance torque by using electricity, and wherein within a second rotation range of the actuator shaft relative to the actuator housing, the actuator resistance torque is the sum of the torque generated by the spring and the torque generated by using the electricity.

31. The torso supporting exoskeleton of claim 1, wherein the supporting torso frame includes a lower frame portion configured to partially surround the wearer's torso and couple to the first and second thigh links at either side of the wearer.

32. The trunk supporting exoskeleton of claim 31 wherein the supporting trunk frame comprises a spine frame portion coupled to the lower frame portion.

33. A torso supporting exoskeleton as claimed in claim 32, wherein the length of the spine frame portion is adjustable to accommodate wearers of different heights.

34. The torso supporting exoskeleton of claim 31 , wherein the width of the lower frame portion is adjustable to accommodate wearers of varying width sizes.

35. The torso supporting exoskeleton of claim 31 , wherein the depth of the lower frame portion is adjustable to accommodate wearers of varying depth sizes.

36. The torso supporting exoskeleton of claim 1, wherein the supporting torso frame includes an upper frame portion coupled to a spine frame portion and configured to apply supporting torso forces on the wearer's torso and chest region.

37. A supporting torso as described in claim 36, wherein the upper frame portion is configured to rotate relative to the spine frame portion along an axis substantially parallel to the wearer's spine.

38. A supporting torso as described in claim 36, wherein the spine frame portion is configured to rotate relative to the lower frame portion along an axis substantially parallel to the wearer's spine.

39. A supporting torso as described in claim 36, wherein the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to one of the mediolateral flexion axis and the extension axis of the wearer's lumbar spine.

40. A trunk support exoskeleton for reducing muscle forces on a wearer's back during lumbar flexion, the trunk support exoskeleton comprising: a supporting torso frame configured to be coupled to a wearer's torso; a first thigh link configured to couple to one of a wearer's thighs, and a second thigh link configured to couple to the other of the wearer's thighs, wherein each of the first thigh link and the second thigh link is rotatably coupled to the supporting torso frame such that the respective first thigh link or the second thigh link can flex or extend relative to the supporting torso frame; an actuator coupled to the supporting torso frame, wherein the actuator includes an actuator housing and an actuator shaft, wherein the actuator is free to rotate relative to the supporting torso frame, and wherein the actuator shaft is coupled to the first thigh link and the actuator housing is coupled to the second thigh link, When the wearer bends forward in the sagittal plane, the actuator generates an actuator resistance torque between the actuator housing and the actuator shaft, thereby generating an extension torque between the corresponding first thigh link and the second thigh link and the supporting trunk frame.

41. The trunk supporting exoskeleton of claim 40, further comprising: a shaft pulley coupled to the actuator shaft; a housing pulley coupled to the actuator housing; an axial cable having a first end wound around the axial pulley and a second end coupled to the first thigh link; as well as a housing cable having a first end wound around the housing pulley and a second end coupled to the second thigh link, The actuator resistance torque generates tension in the housing cable and the shaft cable, thereby generating an extension torque between the corresponding first thigh link and the second thigh link and the supporting trunk frame.

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