Reverse driveable actuator for exoskeletos

Abstract

The present invention relates to an actuator, optionally for an exoskeleton, comprising: a motor for providing speed and force to a deceleration assembly; the two-stage speed reduction assembly comprises an input pulley and an output pulley; the two-stage speed reduction assembly is configured to perform speed reduction and force increase; wherein the motor, the input pulley and the output pulley are coaxially positioned within the actuator and / or in the same plane and / or are located within the actuator with respect to one another.

Description

[0001] Related Applications

[0002] This application claims the benefit of priority of European patent application No. 22382778.3 filed on August 10, 2022, the contents of which are incorporated herein by reference in their entirety.

[0003] FIELD AND BACKGROUND OF THE INVENTION

[0004] The invention relates, in some embodiments thereof, to an actuator, and more particularly, but not exclusively, to a backdrivable actuator for an exoskeleton.

[0005] “Challenges and solutions for application and wider adoption of wearable robots” by Jan Babic et al. discloses that the output torque of electric motors is low relative to the needs of wearable robots, which is why electric motors are usually paired with high reduction gearboxes. The dominant gearbox technologies in wearable robots are harmonic gears and planetary gearboxes, which provide high reduction ratios in a compact size. However, the low efficiency and poor back-driving capabilities of harmonic gears and planetary gearboxes detract from the overall performance of the actuator and wearable robots in general. The research community currently follows two paths to address this problem. On the one hand, new gearbox technologies with improved features are being explored. These gearboxes achieve high gear reduction with high efficiency and compact size by using Wolfrom gearbox topology combined with performance-enhancing modifications such as carrier-free design (gear bearing drive) and tooth profile shift modification (bilateral drive). On the other hand, quasi-direct drive has emerged as a new drive paradigm. Quasi-direct drive combines a high-torque motor with a low-reduction gearbox to produce an energy-efficient actuator with high back-driving capability. Ideally, these gearboxes are single-stage (gear ratio below 10), since efficiency is primarily related to the number of stages.

[0006] "Comfort-Centered Design of a Lightweight and Backdrivable Knee Exoskeleton" published by Junlin Wang et al. discloses the design principles of a comfort-centered wearable robot and its application in a lightweight and backdrivable knee exoskeleton. Discomfort relief is considered as a mechanical design and control problem, and three solutions are proposed in the publication: 1) A new wearable structure optimizes the strap attachment configuration and suit layout to improve the excessive shear force in the conventional wearable structure design; 2) The rolling knee joint and double hinge mechanism reduce the misalignment in the sagittal and frontal planes, respectively, without increasing mechanical complexity and inertia; 3) The low-impedance mechanical transmission reduces the reflected inertia and damping of the actuator to the person, so the exoskeleton is highly backdrivable.

[0007] "Design and clinical implementation of an open-source bionic leg" by Alejandro F. Azocar et al. discloses the design and clinical implementation of an integrated robotic knee-ankle prosthesis that facilitates real-world testing of its biomechanics and control strategies. The bionic leg is open source, it includes software for low-level control and communication with the control system, and its hardware design is customizable, resulting in reduced mass and cost, improved ease of use, and independent operation of the knee and ankle joints.

[0008] “Functional Evaluation of a Force Sensor-Controlled Upper-Limb Power-Assisted Exoskeleton with High Backdrivability” by Chang Liu et al. discloses a study showing a lightweight upper-limb power-assisted exoskeleton with high backdrivability. In addition, a motion capture system was used to measure and analyze the workspace of the wearer’s upper limb after wearing the exoskeleton. The results were used to evaluate the exoskeleton’s ability to support the wearer’s movement. In addition, a small and compact three-axis force sensor was used for power assistance, and the effect of the power assistance was evaluated by measuring the wearer’s surface electromyography, force, and joint angle signals.

[0009] “Quasi-Direct Drive Actuation for a Lightweight Hip Exoskeleton with High Backdrivability and High Bandwidth” by Shuangyue Yu et al. discloses the design and human-machine interaction modeling of a portable hip exoskeleton based on a custom quasi-direct drive (QDD) actuation (i.e., a high torque density motor with low gear ratio gears). Shuangyue Yu et al. conducted a model-based performance benchmark comparison of representative actuators in terms of torque performance, control bandwidth, back-drive capability, and force tracking accuracy. Shuangyue Yu et al. created a lightweight bilateral hip exoskeleton to reduce joint loads during normal activities, including walking and squatting. Experiments showed that the exoskeleton was able to produce high nominal torque (17.5Nm), high back-drive capability (0.4Nm back-drive torque), high bandwidth (62.4Hz), and high control accuracy (1.09Nm root mean square tracking error, 5.4% of the required peak torque).

[0010] Additional background technology includes U.S. Pat. No. US10702441B2, which discloses an exoskeleton comprising a first support member and a second support member connected to a wearer of the exoskeleton, a joint connecting the first support member to the second support member, and an actuator. The actuator comprises a ball screw, a ball nut assembly connected to the ball screw, and a first tensile member and a second tensile member. The ball nut assembly has a first line reactor and a second line reactor. The first tensile member is guided through the first line reactor, and the second tensile member is guided through the second line reactor. Movement of the ball nut assembly along the ball screw in a first direction causes the second support member to move relative to the first support member in a first rotational direction around the joint. Movement of the ball nut assembly along the ball screw in a second direction causes the second support member to move relative to the first support member in a second rotational direction around the joint.

[0011] U.S. Patent Application Publication No. US20210290470A1 discloses a joint actuator assembly for a legged mobile device, the joint actuator assembly including a motor driving a joint connector for driving a joint of the mobile device, and a three-stage reduction transmission device for generating a high torque, low speed output. The first stage may include a small sprocket mechanically connected to the output shaft of the motor and a large sprocket driven by a cable chain to provide a first reduction. The second stage may include a small central bevel gear mechanically connected to the output of the first stage, and two relatively larger first and second external bevel gears meshing with the central gear to provide a second reduction. The third stage may include a cable reel assembly, the cable reel assembly including an output reel and a cable element interconnecting the output end of the second stage and the output reel to provide a third reduction.

[0012] U.S. Patent Application Publication No. US20210338515A1 discloses a joint actuator assembly, which includes a motor, a rotary drive member driven by the motor for driving a driven component, and a transmission assembly located between the motor and the rotary drive member, which provides a deceleration from the motor to the rotary drive member. The rotary drive member includes a magnetic coupling, which includes a plurality of magnetic elements, which are configured to be magnetically coupled with a relative magnetic coupling of the driven component. The actuator and the driven component can be combined into a mobile device including a magnetic coupling system, which has a first magnetic coupling on the actuator, and the first magnetic coupling is magnetically coupled to a second magnetic coupling on the driven component. The magnetic coupling system includes a plurality of magnetic elements positioned as part of one or both of the first magnetic coupling and the second magnetic coupling. The first coupling and the second coupling have relative mating surfaces that are connected together at a coupling position.

[0013] International Patent Application Publication No. WO2013140390A1 discloses a motorized exoskeleton device for facilitating user movement, the device comprising a trunk base for attachment to the user's trunk; a pair of limb members configured to be coupled to the user's lower limbs. Each limb member comprises a first support segment and a second support segment, wherein the first support segment is located above the second support segment; two motorized joints, wherein one motorized joint connects the first support segment to the second support segment, and the other motorized joint connects the first support segment to the trunk base; and two motors configured to move the motorized joints, wherein the motors are coupled to the upper support segment.

[0014] U.S. Patent No. US9566705B2 discloses an exoskeleton for applying force to at least one lower limb of a user, the exoskeleton comprising a control system having a sensor interface for sensor signals; a power interface, the power interface being used to transmit control signals to a motorized joint; a processor, the processor being coupled to the sensor and the power interface; and a computer-readable medium, the computer-readable medium storing a computer program executable on the processor, the computer program having a code segment, the code segment being used to: estimate a configuration of the user's body relative to a gravity vector based on the sensor signal; calculate a control torque of the motorized joint based on the configuration, the control torque compensating for the gravity dynamics of the user; calculate a gravity energy gradient of the motorized joint; attenuate the control torque based on the gravity energy gradient; calculate a final control torque based on the attenuated control torque, and configure the control signal based on the attenuated control torque.

[0015] Japanese Patent No. JP6765989B2 discloses a control device in a long lower limb orthosis, which: calculates a thigh phase angle at a sampling point based on an angle-related signal input from a thigh posture detection device; applies the thigh phase angle at a sampling point to assisting force control data pre-stored in the control device, the assisting force control data indicating a relationship between the thigh phase angle and an assisting force to be applied to a lower thigh orthosis; calculates the assisting force to be applied to the lower thigh orthosis at a sampling point; and performs operation control of an actuator to output the assisting force.

[0016] Korean Patent No. KR101724884B1 discloses a step of deriving the angle and angular velocity of the knee joint of the supporting leg and the hip joint of the swinging leg of a robot; a comparison step of comparing the values ​​of the angle and angular velocity of the supporting leg and the swinging leg with preset reference values ​​of the angle and angular velocity; when the derived angle and angular velocity of the supporting leg and the swinging leg meet a predetermined reference condition, calculating an auxiliary torque value using the angle or angular velocity derived from the supporting leg; and a method and system for stair walking control of a wearable robot, the method and system including an application step applied to the knee joint.

[0017] US Patent No. US10213357B2 discloses a mobile exoskeleton that can be selectively operated in at least two different modes, wherein one mode constitutes an unworn propulsion mode, which is used when the user is not wearing the exoskeleton, and the other mode constitutes a default or worn propulsion mode, which is used when the user is wearing the exoskeleton. With this arrangement, a physical therapist or other operator who wishes to move the unworn exoskeleton can balance the unworn exoskeleton while using the control system and actuators of the exoskeleton to propel the unworn exoskeleton. Thus, the exoskeleton walks by taking steps forward commanded by the operator using any of a plurality of input arrangements, while the operator balances and manipulates the exoskeleton by physically guiding the exoskeleton using handles or other interactive surfaces of the exoskeleton.

[0018] U.S. Patent Application Publication No. US20210085552A1 discloses a gait motion assisting device, which includes an actuator unit and a terminal device capable of wirelessly communicating with a control device of the actuator unit, wherein the actuator unit controls a driver so that an assisting force calculated by applying a gait motion timing based on a detected thigh phase angle to output mode saved data is applied to the calf. The terminal device can receive an assisting force setting value including an assisting force application period in a gait cycle, and create output mode setting data indicating a relationship between the gait motion timing and the magnitude of the assisting force to be applied to the calf based on the assisting force setting value. The control device is configured to overwrite and save the output mode setting data received from the terminal device as output mode saved data.

[0019] U.S. Patent Application Publication No. US20210275382A1 discloses a joint actuator assembly, which includes a motor, a rotary drive member driven by the motor for driving a driven component, and a transmission assembly located between the motor and the rotary drive member, which provides a deceleration from the motor to the rotary drive member. The rotary drive member includes a magnetic / electric coupling, which includes a magnetic coupling member configured to be magnetically coupled with a relative magnetic coupling of the driven component and an electric element configured to provide an electrical connection to the relative electric element of the driven component. The actuator and the driven component can be combined into a mobile device including a magnetic / electric coupling system, which includes a first magnetic / electric coupling on the actuator assembly, which is magnetically coupled and electrically coupled with a second magnetic / electric coupling on the driven component. The magnetic coupling system includes a plurality of magnetic elements and relative electric elements located on the first magnetic / electric coupling and / or the second magnetic / electric coupling, which are used to make an electrical connection when the actuator assembly and the driven component are connected together.

[0020] U.S. Patent Application Publication No. US20210039248A1 discloses a motion control system including an actuator having an actuating member having a proximal end attached to the actuator on a first side of a joint and a distal end attached to an anchoring element attachment point on a second side of the joint. A first sensor is configured to output a signal defining a gait cycle, and a second sensor is configured to output a signal representing a tensile force in at least one actuating member. A controller receives output signals from the first sensor and the second sensor, and in response to the output signals, automatically actuates the actuator during a first portion of the gait cycle to apply a force greater than a predetermined threshold tensile force to the anchoring element attachment point via the actuating member to generate a beneficial moment around the joint, and automatically actuates the actuator during at least a second portion of the gait cycle to reduce the tensile force at the anchoring element attachment point to a level equal to or below the predetermined threshold tensile force to avoid generating an unfavorable moment around the joint.

[0021] U.S. Patent Application Publication No. US20200276698A1 discloses a wearable system including an exoskeleton suit or exoskeleton; an actuator configured to generate force in the exoskeleton suit or exoskeleton; a sensor configured to measure information for evaluating an objective function associated with providing physical assistance to a wearer, interaction between the wearer and the exoskeleton suit or exoskeleton, and / or operation of the exoskeleton suit or exoskeleton; and a controller configured to: actuate the actuator according to an actuation curve, evaluate the objective function based on information measured by at least one sensor to determine a resulting change in the objective function, adjust parameters of the actuation curve based on the resulting change in the objective function, and continue to actuate, evaluate, and adjust to optimize the actuation parameters for maximizing or minimizing the objective function. The wearable system is configured to assist or promote improvement of the wearer's gait and optimize using gradient descent or Bayesian methods. SUMMARY OF THE INVENTION

[0023] The following is a non-exclusive list of some examples that include embodiments of the invention. The invention also includes embodiments that include less than all of the features in the examples and embodiments that use features from multiple examples, even if not explicitly listed below.

[0024] Example 1. An actuator, comprising:

[0025] a. at least one motor, the at least one motor for providing a first speed and a first force to at least one reduction assembly;

[0026] b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force increase in the force received from the at least one motor;

[0027] Wherein, the at least one motor, the at least one input pulley and the at least one output pulley are located inside the actuator with respect to each other.

[0028] Example 2. The actuator of Example 1, wherein the at least one motor, the at least one input pulley, and the at least one output pulley are coaxially positioned and located in a same plane within the actuator.

[0029] Example 3. An actuator according to example 1 or example 2, wherein the at least one reduction assembly performs a reduction from about 1:10 to about 1:50.

[0030] Example 4. An actuator according to any one of Examples 1 to 3, wherein the at least one speed reduction assembly comprises:

[0031] a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor;

[0032] b. a first belt positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley;

[0033] c. said at least one output pulley;

[0034] d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

[0035] Example 5. An actuator according to Example 3, wherein the at least one additional pulley is external to the at least one motor, the at least one input pulley, and the at least one output pulley, but is on the same plane as the at least one motor, the at least one input pulley, and the at least one output pulley.

[0036] Example 6. An actuator according to any of Examples 1 to 5, wherein the at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:6.

[0037] Example 7. The actuator of any of Examples 1 to 6, wherein the at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:6.

[0038] Example 8. An actuator according to any one of Examples 1 to 7, wherein the at least one motor is a high torque motor.

[0039] Example 9. An actuator according to any one of Examples 1 to 8, wherein the actuator is characterized by having a low to medium reverse drive torque from about 0.5 Nm to about 2.5 Nm, and the actuator is configured to provide a high nominal torque from about 10 Nm to about 100 Nm.

[0040] Example 10. An actuator according to any one of Examples 1 to 9, wherein the actuator is configured to allow the motor to be driven in reverse.

[0041] Example 11. An actuator according to any one of Examples 1 to 10, wherein the motor is configured to allow the actuator to be driven in reverse.

[0042] Example 12. An actuator according to any one of Examples 1 to 11, wherein the motor is a back-drivable motor.

[0043] Example 13. An actuator according to any one of Examples 1 to 12, wherein:

[0044] a. The at least one deceleration assembly does not include a belt;

[0045] b. said at least one input pulley is an input gear meshing with at least one additional gear; and

[0046] c. The at least one additional gear meshes with the output gear.

[0047] Example 14. An actuator according to any one of Examples 1 to 13, further comprising at least one energy source configured to provide energy to the actuator.

[0048] Example 15. The actuator of any one of Examples 1 to 14, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

[0049] Example 16. The actuator of any one of Examples 1 to 15 further comprises at least one brake configured to lock the actuator in an emergency.

[0050] Example 17. An actuator according to any one of Examples 1 to 16, wherein the at least one motor and the at least one two-stage reduction assembly are configured to provide the actuator with performance for delivering a maximum torque / weight ratio from about 40 Nm / Kg to about 100 Nm / Kg.

[0051] Example 18. An actuator comprising:

[0052] a. at least one motor, the at least one motor for providing a first speed and a first force to at least one reduction assembly;

[0053] b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force increase in the force received from the at least one motor;

[0054] The two-stage reduction assembly provides a reduction ratio of about 1:10 to about 1:50;

[0055] Wherein, the at least one motor is a back-drivable motor having a back-drive torque of about 0.5 Nm to about 2.5 Nm and a nominal torque of about 10 Nm to about 100 Nm.

[0056] Example 19. The actuator of Example 18, wherein the at least one motor, the at least one input pulley, and the at least one output pulley are located internal to each other in the actuator.

[0057] Example 20. The actuator of Example 18, wherein the at least one motor, the at least one input pulley, and the at least one output pulley are coaxially positioned and located in a same plane within the actuator.

[0058] Example 21. The actuator of any one of Examples 18 to 20, wherein the at least one speed reduction assembly comprises:

[0059] a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor;

[0060] b. a first belt positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley;

[0061] c. said at least one output pulley;

[0062] d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

[0063] Example 22. An actuator according to Example 21, wherein the at least one additional pulley is external to the at least one motor, the at least one input pulley and the at least one output pulley, but on the same plane as the at least one motor, the at least one input pulley and the at least one output pulley.

[0064] Example 23. An actuator according to any of Examples 18 to 22, wherein the at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:6.

[0065] Example 24. The actuator of any of Examples 18 to 23, wherein the at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:6.

[0066] Example 25. An actuator according to any one of Examples 18 to 24, wherein:

[0067] a. The at least one deceleration assembly does not include a belt;

[0068] b. said at least one input pulley is an input gear meshing with at least one additional gear; and

[0069] c. The at least one additional gear meshes with the output gear.

[0070] Example 26. An actuator according to any one of Examples 18 to 25, further comprising at least one energy source configured to provide energy to the actuator.

[0071] Example 27. The actuator of any one of Examples 18 to 26, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

[0072] Example 28. The actuator of any one of Examples 18 to 27 further comprises at least one brake configured to lock the actuator in an emergency.

[0073] Example 29. An actuator comprising:

[0074] a. at least one motor, the at least one motor for providing a first speed and a first force to at least one reduction assembly;

[0075] b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force increase in the force received from the at least one motor;

[0076] Wherein, the at least one motor and the at least one two-stage reduction assembly are configured to provide the actuator with a capability for delivering a maximum torque / weight ratio of about 40 Nm / Kg to about 100 Nm / Kg.

[0077] Example 30. An actuator according to Example 29, wherein the at least one motor is a high torque motor.

[0078] Example 31. An actuator according to Example 28 or Example 29, wherein the at least one motor and the at least one two-stage reduction assembly are configured to provide the performance to the actuator without compromising the back-driving capability performance of the actuator.

[0079] Example 32. An actuator according to any one of Examples 28 to 31, wherein the at least one motor, the at least one input pulley and the at least one output pulley are located internal to each other in the actuator.

[0080] Example 33. An actuator according to any one of Examples 28 to 31, wherein the at least one motor, the at least one input pulley and the at least one output pulley are coaxially positioned and located in the same plane within the actuator.

[0081] Example 34. An actuator according to any of Examples 28 to 33, wherein the at least one reduction assembly performs a reduction from about 1:10 to about 1:50.

[0082] Example 35. The actuator of any one of Examples 28 to 34, wherein the at least one speed reduction assembly comprises:

[0083] a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor;

[0084] b. a first belt positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley;

[0085] c. said at least one output pulley;

[0086] d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

[0087] Example 36. An actuator according to Example 35, wherein the at least one additional pulley is external to the at least one motor, the at least one input pulley and the at least one output pulley, but is on the same plane as the at least one motor, the at least one input pulley and the at least one output pulley.

[0088] Example 38. An actuator according to any of Examples 28 to 37, wherein the at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:6.

[0089] Example 39. The actuator of any of Examples 28 to 38, wherein the at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:6.

[0090] Example 40. An actuator according to any one of Examples 28 to 39, wherein the motor is characterized by having a low to medium reverse drive torque of about 0.5 Nm to about 2.5 Nm, and the motor is configured to provide a high nominal torque of about 10 Nm to about 100 Nm.

[0091] Example 41. An actuator according to any one of Examples 28 to 40, wherein:

[0092] a. The at least one deceleration assembly does not include a belt;

[0093] b. said at least one input pulley is an input gear meshing with at least one additional gear; and

[0094] c. The at least one additional gear meshes with the output gear.

[0095] Example 42. An actuator according to any one of Examples 28 to 41, further comprising at least one energy source configured to provide energy to the actuator.

[0096] Example 43. An actuator according to any one of Examples 28 to 42, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

[0097] Example 44. An actuator according to any one of Examples 28 to 43, further comprising at least one brake configured to lock the actuator in an emergency.

[0098] Example 45. An actuator comprising:

[0099] a. at least one motor, the at least one motor for providing a first speed and a first force to at least one reduction assembly;

[0100] b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force increase in the force received from the at least one motor;

[0101] wherein the at least one motor, the at least one input pulley and the at least one output pulley are located internally of each other in the actuator, thereby allowing the actuator to comprise a width of up to 10 cm;

[0102] wherein the two-stage reduction assembly provides a reduction ratio of about 1:10 to about 1:50;

[0103] wherein the actuator is characterized by having a low to medium back-drive torque of about 0.5 Nm to about 2.5 Nm and a nominal torque of about 10 Nm to about 100 Nm;

[0104] Wherein, the at least one motor and the at least one two-stage reduction assembly are configured to provide the actuator with a capability for delivering a maximum torque / weight ratio of about 40 Nm / Kg to about 100 Nm / Kg.

[0105] Example 46. An actuator according to Example 45, wherein the at least one motor, the at least one input pulley and the at least one output pulley are coaxially positioned and located in a same plane within the actuator.

[0106] Example 47. An actuator according to Example 45 or Example 46, wherein the at least one motor and the at least one two-stage reduction assembly are configured to provide the performance to the actuator without compromising the reverse drive capability performance of the reverse-drivable motor.

[0107] Example 48. The actuator of any one of Examples 45 to 47, wherein the at least one speed reduction assembly comprises:

[0108] a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor;

[0109] b. a first belt positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley;

[0110] c. said at least one output pulley;

[0111] d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

[0112] Example 49. An actuator according to Example 48, wherein the at least one additional pulley is external to the at least one motor, the at least one input pulley, and the at least one output pulley, but is on the same plane as the at least one motor, the at least one input pulley, and the at least one output pulley.

[0113] Example 50. An actuator according to any of Examples 45 to 49, wherein the at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:6.

[0114] Example 51. An actuator according to any of Examples 45 to 50, wherein the at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:6.

[0115] Example 52. An actuator according to any one of Examples 45 to 51, wherein:

[0116] a. The at least one deceleration assembly does not include a belt;

[0117] b. said at least one input pulley is an input gear meshing with at least one additional gear; and

[0118] c. The at least one additional gear meshes with the output gear.

[0119] Example 53. An actuator according to any one of Examples 45 to 52, further comprising at least one energy source configured to provide energy to the actuator.

[0120] Example 54. An actuator according to any one of Examples 45 to 53, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

[0121] Example 55. An actuator according to any one of Examples 45 to 54, further comprising at least one brake configured to lock the actuator in an emergency.

[0122] Example 56. An exoskeleton comprising:

[0123] a. at least one actuating portion;

[0124] b. At least one actuator according to Example 1 or Example 18 or Example 29 or Example 45.

[0125] Example 57. An exoskeleton according to Example 56, wherein the at least one actuation application portion is attached to one or more segments selected from the group consisting of: thigh, calf, foot, torso, forearm, upper arm and hand.

[0126] Example 58. An exoskeleton according to Example 56 or Example 57, further comprising at least one circuit configured to control the motor of the at least one actuator.

[0127] Example 59. An exoskeleton according to any of Examples 56 to 58, wherein the at least one output unit provides an output range of motion (ROM) of about 45° to about 180° to the at least one actuation application portion.

[0128] Example 60. An exoskeleton according to any of Examples 56 to 59, wherein the at least one actuator is located inside a dedicated unit in the exoskeleton, and wherein the dedicated unit is located on one or more segments selected from the group consisting of: thigh, calf, foot, torso, forearm, upper arm, and hand.

[0129] Example 61. An exoskeleton according to any of Examples 56 to 60, wherein the at least one output unit is located outside the dedicated unit.

[0130] Example 61. An exoskeleton according to any one of Examples 56 to 60, wherein the at least one output unit is located at the location of the at least one actuation application portion.

[0131] Example 62. An exoskeleton according to any one of Examples 56 to 61, further comprising at least one energy source configured to provide energy to the exoskeleton.

[0132] Unless otherwise defined, all technical terms and / or scientific terms used herein have the same meanings as those generally understood by those of ordinary skill in the art to which the invention belongs. Although methods and materials similar or equivalent to those described herein may be used in the practice or testing of embodiments of the invention, exemplary methods and / or materials are described below. In the event of a conflict, the patent specification including the definitions will prevail. In addition, materials, methods and examples are illustrative only and are not intended to be necessarily restrictive.

[0133] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0134] Some embodiments of the present invention are described herein with reference to the accompanying drawings by way of example only. With specific reference now to the accompanying drawings in detail, it should be emphasized that the details shown are by way of example and for the purpose of illustrative discussion of embodiments of the present invention. In this regard, the description using the accompanying drawings makes it apparent to those skilled in the art how embodiments of the present invention may be practiced.

[0135] In the attached picture:

[0136] Figure 1a to Figure 1b A linear layout actuator according to some embodiments of the present invention is shown ( Figure 1a ) and an exemplary compact layout actuator ( Figure 1b ) between the layout configurations;

[0137] Figure 2 is a schematic diagram of an exemplary two-stage reduction actuator according to some embodiments of the present invention;

[0138] Figure 3a to Figure 3b is a schematic diagram of two sides of an exemplary actuator having a motor for use in an exoskeleton according to some embodiments of the present invention;

[0139] Figures 4a to 4c is a schematic diagram of an actuator incorporated into an exoskeleton according to some embodiments of the present invention;

[0140] Figure 5a to Figure 5c is a schematic diagram of an exemplary exoskeleton including coaxial actuators according to some embodiments of the present invention;

[0141] Figure 5d is a schematic diagram of an exemplary brake according to some embodiments of the present invention;

[0142] Figures 6a to 6d is a schematic diagram of an exemplary belt tensioning mechanism according to some embodiments of the present invention;

[0143] Figure 7 A schematic diagram showing an exemplary configurable thigh segment of an exoskeleton according to some embodiments of the present invention;

[0144] Figure 8a is a graph showing an exemplary contribution of each element in the calculation of theoretical back-drive torque without including inertial contributions to back-drive capability according to some embodiments of the present invention;

[0145] Figure 8b is a graph showing an exemplary comparison of Hall power loss between a known system and the present system according to some embodiments of the present invention;

[0146] Fig. 9is a schematic diagram of an exemplary actuator according to some embodiments of the present invention being exemplarily integrated into an exoskeleton;

[0147] Fig.10 is a schematic diagram of an exemplary beltless actuator according to some embodiments of the present invention;

[0148] Fig.11a is a schematic diagram of an exemplary use of an exemplary actuator with a Bowden cable system according to some embodiments of the present invention;

[0149] Fig.11b is a schematic diagram of an exemplary use of an exemplary Bowden cable system in a soft exoskeleton according to some embodiments of the present invention;

[0150] Fig.11c is a schematic diagram of an exemplary use of an exemplary Bowden cable system in a soft exoskeleton according to some embodiments of the present invention;

[0151] Fig.11d is a schematic diagram of an exemplary use of an exemplary cable-driven actuator in a rigid exoskeleton according to some embodiments of the present invention;

[0152] Figure 12a to Figure 12b is a schematic diagram of an exemplary alternative use of an exemplary actuator according to some embodiments of the present invention;

[0153] Fig.13a is an image of an exemplary frameless motor according to some embodiments of the present invention;

[0154] Fig.13b is an image of an exemplary test bench according to some embodiments of the present invention;

[0155] Fig.13c is a graph showing exemplary encoder linearity test results according to some embodiments of the present invention;

[0156] Fig.13d is a graph showing exemplary torque constant test results according to some embodiments of the present invention;

[0157] Fig.13e is a graph showing exemplary time constants at each torque according to some embodiments of the present invention, meaning how long a certain torque can be delivered without overheating / damaging the motor;

[0158] Fig.13f is a graph showing position and current curves for commanding an actuator during fatigue testing according to some embodiments of the present invention;

[0159] Figure 13g Exemplary resistance motor features according to some embodiments of the present invention are shown;

[0160] Fig.13h shows the main components of a test bench according to some embodiments of the present invention;

[0161] Fig.13i is a graph showing position, speed, and current curves for 12 cycles (1 sit, 1 stand, and 10 steps) according to some embodiments of the present invention;

[0162] Fig.13j shows an image of an uncovered actuator after all fatigue tests have been performed according to some embodiments of the present invention;

[0163] Figure 13k An image showing how a timing belt according to some embodiments of the present invention may be affected by tooth skipping;

[0164] Figure 13l A graph showing the evolution of input-output errors throughout a fatigue test according to some embodiments of the present invention;

[0165] Figure 13m shows a graph showing the worst operating condition of a motor during fatigue testing according to some embodiments of the present invention; and

[0166] Fig.13n A graph is shown that shows that the temperature according to some embodiments of the present invention never reaches 100° C., which is the maximum operating temperature specified by the manufacturer (T-type motor).

[0167] Description of Specific Embodiments of the Invention

[0168] The invention relates, in some embodiments thereof, to an actuator, and more particularly, but not exclusively, to a backdrivable actuator for an exoskeleton.

[0169] Overview

[0170] One aspect of some embodiments of the invention relates to a back-drivable actuator comprising a coaxial input-output layout and a combination of a high torque motor and a high efficiency low ratio transmission system. In some embodiments, the actuator comprises a two-stage synchronous belt drive embedded in a compact package. In some embodiments, a potential advantage of this configuration is that back drive capability, torque and speed are not affected by this configuration. In some embodiments, the actuator comprises a tensioning mechanism comprising a compact footprint that potentially allows each belt to be tensioned independently and precisely.

[0171] In some embodiments, a potential advantage of the actuator of the present invention is that by using a backdrivable actuator as disclosed herein, the system is lighter, more compact, cheaper, more efficient, and has a higher bandwidth than a conventional high reduction ratio gearbox. In some embodiments, this is also achieved by avoiding the suboptimal dynamics of a high reduction gearbox and by potentially avoiding possible delays caused by adding sensors within the system. In some embodiments, the actuator of the present invention potentially allows for better human-machine interaction and potentially allows people with incomplete injuries to use exoskeletons.

[0172] In some embodiments, the exoskeleton includes two silent, efficient and back-drivable actuators with about 60 Nm maximum torque and about 36 Nm nominal torque. In some embodiments, the exoskeleton includes a knee safety brake of about 36 Nm. In some embodiments, the exoskeleton includes an improved length adjustment mechanism. In some embodiments, the exoskeleton includes improved cable routing. In some embodiments, the exoskeleton includes a closure system to avoid pinching of fingers.

[0173] One aspect of some embodiments of the present invention relates to a reversibly drivable actuator for a lower limb exoskeleton. In some embodiments, the actuator is cheaper to manufacture when compared to known actuators using a high reduction ratio. In some embodiments, the actuator is lighter when compared to known actuators. In some embodiments, the actuator is configured to provide a maximum torque of about 40Nm / Kg to about 100Nm / Kg. In some embodiments, the potential advantage of the actuator is that the configuration allows high torque to be provided in a more efficient manner when compared to other actuators. For example, a known planetary gearbox including a T-type motor AK10-9 is configured to provide a torque of about 50Nm / Kg, while a known harmonic gear including a FLA-20A-100CD is configured to provide a torque of about 60Nm / Kg, and a disadvantage of the known harmonic gear is that it is not highly reversibly drivable. In some embodiments, the weight of the entire device including the actuator is about 8Kg to about 15kg. In some embodiments, the weight of the actuator alone is about 600 gr to about 800 gr, optionally about 500 gr to about 900 gr, optionally about 400 gr to about 1.2 Kg. In some embodiments, the actuator is used in an exoskeleton device that is configured to assist a user in walking, standing and / or sitting. In some embodiments, the actuator is configured to establish the ideal torque, speed and range of motion (ROM) required to provide power for these use cases. In some embodiments, the actuator has a lower reduction ratio when compared to known actuators. In some embodiments, the actuator is configured to provide high torque and high bandwidth while also being lightweight. In some embodiments, the actuator is configured to provide high back-drive capability when compared to known actuators, meaning that the actuator is configured to be manually moved from the output end effortlessly. In some embodiments, the potential advantage of having a high back-drive capability is that it potentially improves the implementation of force control; for example, in this case, the reduction system is as transparent as possible to allow simplification that the output torque is almost completely proportional to the input torque and avoid the use of a torque sensor.

[0174] One aspect of some embodiments of the present invention relates to an actuator that provides high torque, includes high back-drive capability, is characterized by low mass, and is potentially less expensive when compared to known actuators. In some embodiments, the actuator provides a maximum output torque of about 64 Nm. In some embodiments, the actuator provides a maximum output torque of about 50 Nm to about 80 Nm, optionally about 40 Nm to about 100 Nm. In some embodiments, the actuator provides a maximum output torque of about 33 min. -1 About 100 minutes -1to a maximum output angular velocity of . In some embodiments, the actuator comprises a peak output power of about 100W to about 750W. In some embodiments, high reverse drive capability is allowed due to the provision of a high torque motor in combination with a low reduction ratio gearbox, the low reduction ratio gearbox comprising a high efficiency transmission mechanism of about 90% to about 98%. In some embodiments, the high torque motor is a brushless motor with a large number of pole pairs and a high diameter to thickness ratio. In some embodiments, the actuator is characterized by a low reduction ratio, which allows reducing the effect of inertia losses on the actuator, thereby obtaining an efficient system. In some embodiments, the actuator is characterized by an effective reduction mechanism. In some embodiments, weight and size reduction and repositioning are achieved due to the use of a coaxial input and output layout.

[0175] One aspect of some embodiments of the present invention relates to a back-drivable coaxial actuator, optionally for use in an exoskeleton, the back-drivable coaxial actuator being a quasi-direct drive actuator including a two-stage transmission configured to provide a reduction ratio greater than 10. In some embodiments, the actuator includes a high torque motor coupled to a two-stage synchronous belt drive, thereby producing an energy-efficient actuator with high back-driving capability that provides high torque and speed while keeping the system light and compact. In some embodiments, the back-driving capability of the actuator helps to implement state-of-the-art control strategies without the use of expensive sensors. In some embodiments, the actuator is very compact in terms of the maximum output torque, speed, and back-driving capability provided by the actuator. In some embodiments, the coaxial actuator is provided by having an electric motor within the output pulley / gear, which enables a more dense / compact packaging. Furthermore, in some embodiments, this enables the use of a two-stage synchronous belt drive in a four-actuated joint exoskeleton despite space constraints.

[0176] One aspect of some embodiments of the present invention relates to an actuator comprising a motor configured to provide a high torque output, comprising components that allow a medium to high reduction ratio to be provided, which also allows a compact actuator. In some embodiments, the ratio is greater than 10 and less than 50, for example between 12 and 36.

[0177] Before explaining at least one embodiment of the present invention in detail, it should be understood that the present invention is not necessarily limited in its application to the details of the construction and arrangement of the components and / or methods set forth in the following description and / or shown in the drawings and / or examples. The present invention can be practiced or implemented in other embodiments or in various ways.

[0178] Example Layout of Example Actuators

[0179] Reference now Figure 1a and Figure 1b , Figure 1a and Figure 1b A linear layout actuator according to some embodiments of the present invention is shown ( Figure 1a ) and an exemplary compact layout actuator ( Figure 1b ) layout configuration. In some embodiments, the actuator uses a two-stage transmission system. Typically, for example, Figure 1a As shown, the two-stage transmission actuator is organized into a series linear layout. In the series linear layout, the input pulley 102 is connected to the intermediate pulley 106 by means of a first belt 104, and the intermediate pulley 106 is connected to the output pulley 110 by means of a second belt 108. In addition, for example Figure 1a As shown, the input pulley 102, the intermediate pulley 106 and the output pulley 110 are arranged one after another in space. Figure 1b As shown, the actuator includes a compact coaxial layout. In some embodiments, similar to Figure 1a The tandem linear actuator shown in FIG. 1 includes an input pulley 102 connected to an intermediate pulley 106 by means of a first belt 104, and the intermediate pulley 106 is connected to an output pulley 110 by means of a second belt 108. Figure 1a Unlike the actuator shown, the parts of the actuator are not arranged spatially one after another. In some embodiments, the input pulley 102 driven by the electric motor is positioned inside the area of ​​the output pulley 110, thereby generating a coaxial layout. In some embodiments, the coaxial layout can reduce the length of the actuator by about 20% to about 30%, optionally by about 15% to about 40%, optionally by about 10% to about 50%, for example by 30%, 35%, 45%, when compared to a series linear layout. For example, Figure 1a The series linear actuator shown includes an estimated length of about 315 mm, while Figure 1b The compact actuator shown comprises an estimated length of about 220 mm. In some embodiments, a potential advantage of providing a compact footprint for the actuator is that it potentially enables the assembly of two actuators between the knee and hip joints (in the thigh body section) in the exoskeleton even for the shortest configuration (see below).

[0180] Exemplary two-stage reduction actuator

[0181] Reference now Figure 2 , shows a schematic diagram of an exemplary two-stage reduction actuator according to some embodiments of the present invention. In some embodiments, the actuator uses a two-stage synchronous belt drive system designed to obtain a desired reduction ratio. In some embodiments, the reduction ratio of the actuator is adjusted, for example, by changing the number of teeth of the pulley. In some embodiments, the actuator is configured to allow a reduction ratio of about 10 to about 20. For example, Figure 2 As shown (the same part has Figure 1b 1:4.20 ratio, and a second stage reduction is achieved between the intermediate pulley 106 and the output pulley 110, for example, a reduction ratio of 1:4.28. This means that the total reduction is a ratio of 1:4.33*1:3.85=1:17.96. It should be understood that these are exemplary numbers, and other ratios can be used to achieve higher or lower ratios as required by the actuator application. In some embodiments, the ratio of the actuator is about 1:10 to about 1:20, optionally about 1:8 to about 1:30, optionally about 1:5 to about 1:40, for example 1:14, 1:16, 1:18, 1:20.

[0182] Exemplary Motors

[0183] Reference now Figure 3a and Figure 3b , shows a schematic diagram of two sides of an exemplary actuator in use with an exoskeleton according to some embodiments of the present invention. In some embodiments, the input pulley is actuated by a motor 302. In some embodiments, the motor 302 is a high torque motor. In some embodiments, the high torque motor is a large diameter flat brushless motor with a large pole count and a very high Kt (torque current constant). Figure 3b A torque motor 302 is shown. In some embodiments, the motor includes one or more of the following features: high peak torque (Nm), low weight (gr), low height (mm), and / or large diameter (mm). For example, the motor includes a peak torque of about 6 Nm, a weight of about 366 gr, a height of about 18.6 mm, and / or a diameter of about 86.8 mm. In some embodiments, the motor includes a ring with permanent magnets and an iron core with stator coils. In some embodiments, the motor does not include a frame. In some embodiments, a potential advantage of using a frameless motor is that it potentially allows design freedom and additionally saves weight and space of the entire device.

[0184] In some embodiments, an exemplary motor used in the system is a T-Motor frameless U10 Kv25 motor, optionally with a RMB20 rotary magnetic encoder module. In some embodiments, exemplary technical features of the motor include one or more of the following: a maximum current of about 9A, optionally having a maximum current of about 8A to about 15A, optionally having a maximum current of about 5A to about 30A, optionally having a maximum current of about 3A to about 50A; a nominal torque of about 1.6Nm, optionally having a nominal torque of about 1.4Nm to about 2Nm, optionally having a nominal torque of about 1Nm to about 3Nm, optionally having a nominal torque of about 0.5Nm to about 6Nm; a maximum torque of about 4.5Nm, optionally having a maximum torque of about 4Nm to about 6Nm, optionally having a maximum torque of about 3Nm to about 8Nm, optionally having a maximum torque of about 2Nm to about 12Nm; a maximum speed of about 1200rpm, optionally having a maximum speed of about 1000rpm to about 1500rpm, optionally having a maximum speed of about 800rpm to about 2000rpm, optionally having a maximum speed of about 300rpm to about 3000rpm.

[0185] The following table discloses exemplary technical parameters of four different motors, which will potentially assist those skilled in the art in understanding the present invention:

[0186]

[0187] In some embodiments, the motor receives energy and commands from a circuit that controls the motion of the motor, and thus the motion of the actuator. In some embodiments, the motor receives modulated energy that indicates the motion of the motor, and thus the motion of the actuator.

[0188] It should be understood that these features and / or parameters and / or values ​​are provided to enable those skilled in the art to understand the present invention. Other features and / or parameters and / or values ​​may be used in different settings and / or different configurations of the motor. All of these are also included within the scope of the present invention.

[0189] Exemplary bands

[0190] In some embodiments, the belts 104 / 108 are high torque drive (HTD) timing belts. In some embodiments, the belts 104 / 108 are high power (HP) belts. In some embodiments, HP belts are used due to the low permanent and elastic stretch of the wires of the HP belts, the friction and wear resistant fabric with high shear strength, and the good resistance and smooth operation, low shock loads and medium shock loads.

[0191] Example Integration of Example Actuators into Exoskeleton

[0192] Reference now Figure 4a , Figure 4b and Figure 4c , shows a schematic diagram of actuators incorporated into an exoskeleton according to some embodiments of the present invention. In some embodiments, one or more actuators are used in the exoskeleton as described above. In some embodiments, due to the compact footprint provided by coaxial actuators, two actuators can be assembled between the knee and hip even for the shortest configuration, such as for example Figure 4a (showing a leg portion of the exoskeleton), as shown in e.g. Figure 4b (showing one leg section of the exoskeleton, showing the internal mechanism and two actuators) and Figure 4c (an exploded view showing the outer shell of the exoskeleton and the internal structure of the exoskeleton) In some embodiments, portions of the exoskeleton are made of metal (e.g., aluminum, titanium, etc.). In some embodiments, portions of the exoskeleton are made of plastic and / or polymers (e.g., reinforced plastic).

[0193] Reference now Figure 5a , Figure 5b and Figure 5c , shows a schematic diagram of an exemplary exoskeleton including coaxial actuators according to some embodiments of the present invention. For the following explanation, the term "knee actuator" will be used to describe the actuator located near the knee joint, while the term "hip actuator" will be used to describe the actuator near the hip joint. In some embodiments, the knee actuator and the hip actuator are the same and / or include the same parts. In some embodiments, the knee actuator and the hip actuator are different and / or do not include the same parts.

[0194] Reference now Figure 5a , Figure 5a A schematic cross-sectional representation of a knee actuator of an exemplary exoskeleton according to some embodiments of the present invention is shown. Figure 5a The frameless torque motor 302 is shown and includes a motor stator 502 and a motor rotor 504 . Figure 5a Also shown are input pulley 102, intermediate pulley 106, and output pulley 110. In some embodiments, the exoskeleton includes a servo drive 506, which is responsible for converting the direct current (DC) from the power supply into the appropriate coil excitation to move the motor at the desired torque or speed. In some embodiments, the servo drive can operate in two modes: position control and torque control. In some embodiments, the exoskeleton includes one or more encoders 508a-508b ( Figure 5a Two are shown in Figure 5c), one or more encoders 508a to 508b are a type of rotation sensor that includes a non-contact and frictionless design that minimizes mechanical wear, weight, and volume. Not to mention high angular resolution that ensures excellent performance. For example, an exemplary encoder can be from RMB20 encoder. Figure 5a , exemplary locations where encoders 508a-508b may be placed in the actuator are schematically shown, for example, one location at the input rotor 508a and one location at the output rotor 508b. In some embodiments, this dual encoder design potentially provides accurate real-time information of the input rotor position and the output rotor position, thereby enabling in-depth monitoring of the deceleration system. In some embodiments, the knee actuator of the exoskeleton includes a brake 510 (see also Figure 5d ).

[0195] In some embodiments, as described above, the actuator integrates an electromagnetic brake 510 (e.g., Figure 5d ) and output encoder 508b (e.g., as Figure 5c ). In some embodiments, the electromagnetic brake 510 is used for safety purposes and is activated upon power loss, thereby locking the joint to support the user in an upright position during power loss. In some embodiments, the electromagnetic brake 510 is optionally used only for the knee joint of the exoskeleton, thereby locking the knee joint in the event of power loss, thereby preventing the user from falling to the ground. In some embodiments, the hip joint does not include the electromagnetic brake 510 and thus the hip joint is free (unlocked) in the event of power loss (similar to a typical passive leg brace). In some embodiments, in addition, the brake 510 increases the efficiency of the exoskeleton because the actuator is configured to use the brake to lock the joint when the user is upright, and not consume energy along with the motor for this purpose when standing (one of the situations where the user spends most of the time). Now refer to Figure 5d , Figure 5d A schematic diagram of an exemplary brake for use in an actuator of an exoskeleton system according to some embodiments of the present invention is shown. In some embodiments, a safety magnetic brake 510 stops the joint in the event of a power outage. In some embodiments, a potential advantage of having a magnetic brake is that it can potentially prevent any injury to the wearer in the event of a power outage and / or power interruption. In some embodiments, the brake 510 is placed coaxially with respect to the motor and coupled to the input stage of the actuator so as to amplify the braking force using a speed reduction mechanism. In some embodiments, the brake can be spring actuated or magnetically actuated.

[0196] In some embodiments, the actuator includes a dedicated mechanism that allows the position of the output to be known at all times while avoiding the need for two complex encoders. Figure 5cAs shown, the dedicated mechanism is a newly developed optical encoder for the output. In some embodiments, the information provided by encoder 508b, together with the information provided by the single-turn absolute encoder 508a in the electric motor, provides the precise position of the output without the need for a homing procedure. Figure 5c Output encoder 508b and output encoder instrument 512 are shown in FIG.

[0197] Reference now Figure 5b , Figure 5b A schematic cross-sectional representation of a hip actuator of an exemplary exoskeleton according to some embodiments of the present invention is shown. Figure 5b A high torque motor 302 is shown including a motor stator 502 and a motor rotor 504 . Figure 5b Also shown are the input pulley 102 , the intermediate pulley 106 , and the output pulley 110 .

[0198] Exemplary Belt Tensioning Mechanism

[0199] Reference now Figures 6a to 6d , Figures 6a to 6d Schematic diagram of an exemplary belt tensioning mechanism according to some embodiments of the present invention is shown. In some embodiments, the actuator includes a mechanism that allows the user to tension the belt. In some embodiments, the mechanism is an eccentric belt tensioner that allows the initial belt tension to be adjusted with minimal space. In some embodiments, as Figure 6a As schematically shown in FIG. 6 , the tensioner consists of a ball bearing element 602 that rotates eccentrically about a bolt 604 and can be fixed in three different positions 606 , 608 , 610 by inserting pins into the required holes. Figure 6a The numbers provided in are exemplary numbers. Other sizes of the ball bearing elements are also possible. Figure 6b , Figure 6c and Figure 6d Schematically shows how the belt is tensioned after each rotation of the ball bearing element, for example, an exemplary nominal length of the timing belt is about 425 mm. Figure 6b In the embodiment, the ball bearing element 602 is fixed in the first position 606 - low tension, so that the length of the belt reaches about 425.09 mm; Figure 6c In the embodiment, the ball bearing element 602 is fixed in the second position 608 - medium tension, so that the length of the belt reaches about 425.43 mm; and Figure 6d , the ball bearing element 602 is secured in a third position 610 - high tension, resulting in a belt length of approximately 426.01 mm.

[0200] Exemplary Configurable Thigh Segment of Exoskeleton

[0201] Reference now Figure 7 , Figure 7 A schematic diagram of an exemplary configurable thigh segment of an exoskeleton according to some embodiments of the present invention is shown. In some embodiments, the length of the thigh segment of the exoskeleton can be modified according to the needs of the user. For example, in Figure 7 , a thigh section having a minimum dimension L is shown, which is suitable for people of shorter stature. A thigh section which has been extended by a certain length X is also shown, so that the total length of the thigh section reaches L+X, which is suitable for people of taller stature.

[0202] Example Circuit

[0203] In some embodiments, the actuator includes circuitry configured to control the activity of the actuator. In some embodiments, an external circuit (eg, incorporated in an exoskeleton) is connected to the actuator and configured to control the action of the actuator.

[0204] Exemplary principle of the relationship between back-driving capability and efficiency of an actuator

[0205] Without being bound by theory, the efficiency of a motor is generally considered to be the relationship between the output mechanical power (T*ω) and the input electrical power (V*I). Efficiency has different values ​​for each operating condition (specific speed and torque), and the efficiency can range from 0 (when the output speed is 0) to a maximum value (usually designated as the "efficiency of the actuator"). On the other hand, without being bound by theory, back-drive capability is considered to be the mechanical efficiency of the actuator between the output shaft and the electric motor. In addition, back-drive capability refers to the ease with which the actuator can be moved from its output rotor. In other words, back-drive capability refers to the torque required to move the output rotor. The difference between these two concepts should be noted. Some motors may be highly efficient but cannot be back-driven, for example, a 1:5 worm gear has an efficiency of 95% and a back-drive of 0%.

[0206] As described above, the actuator of the present invention includes low back-drive torque (meaning includes high back-drive capability). In some embodiments, a potential advantage of having an actuator that includes high back-drive capability is that it potentially allows control techniques to be implemented that would be extremely difficult to implement with conventional motors, at least not without adding additional sensors.

[0207] Again, without being bound by theory, the following calculations illustrate a simplified method of estimating backdrive torque.

[0208]

[0209] in:

[0210] Cogging torque: The rotational resistance provided by the electric actuator multiplied by the reduction ratio. Typically, cogging torque is the primary contributor to back-drive capability. In some embodiments, the actuator of the present invention includes a low to medium reduction ratio.

[0211] Bearing friction loss (Simplified method): Multiply the friction coefficient by the radial force on the bearing.

[0212] Inertial contribution: The moment of inertia is multiplied by the angular acceleration. In some embodiments, the inertial contribution is ignored due to the lack of rapid acceleration performed by the system.

[0213] Mechanical transmission efficiency: Characteristics of synchronous belts. The mechanical efficiency of synchronous belts is generally between 95% and 98% of the maximum mechanical efficiency. In some embodiments, since the actuator includes two synchronous belts in series, the overall efficiency is in the range of about 90% to 96% of the maximum mechanical efficiency.

[0214] In some embodiments, an exemplary reduction ratio of the system is 1:17.96 (as an example of calculation only), which provides a theoretical reverse drive torque of about 1.7 Nm. The contribution of each element to the reverse drive capability, excluding the inertial contribution, is, for example, Figure 8a Theoretical calculations match experimental testing performed, which shows a reverse drive torque from about 1.7 Nm to about 1.98 Nm using an exemplary reduction ratio of 1:17.96. In some embodiments, the reverse drive torque is about 1.2 Nm to about 2.0 Nm, optionally about 0.5 Nm to about 2.5 Nm. In some embodiments, the nominal torque is about 20 Nm to about 40 Nm, optionally about 10 Nm to about 100 Nm.

[0215] As a mere example to highlight the potential advantages of the actuator of the present invention, the following comparison shows the differences between the present invention and known motors:

[0216]

[0217] It should be noted that the actuator of the present invention provides low to moderate back-drive torque with high nominal torque when compared to known motors.

[0218] Reference now Figure 8b , Figure 8bA graph is shown representing an exemplary comparison of Joule power losses between known systems and the present system according to some embodiments of the present invention. In some embodiments, in order to provide the system with higher back-drive capability performance, the actuator includes a lower reduction ratio compared to a parallel system configured to provide similar output torque. In some embodiments, in order to compensate for the relatively low reduction ratio, the motor of the system is configured to compensate by delivering a higher torque. In some embodiments, delivering higher torque means higher current and / or higher phase resistance. In some embodiments, the combination of these two facts results in higher Joule losses (e.g., in the form of heat) compared to other known actuators with high reduction ratios. Figure 8b This tradeoff is illustrated in the graph shown in , from which it can be seen that actuators according to some embodiments of the present invention consume 2.5 to 5 times more power at the same torque (36 Nm) relative to other actuators.

[0219] Exemplary Additional Information Regarding Integration of Exemplary Actuators into Exoskeletons

[0220] Reference now Fig. 9 , Fig. 9 A schematic diagram of an exemplary actuator according to some embodiments of the present invention is shown as being integrated into an exoskeleton. In some embodiments, one or more actuators 902 are enclosed in a housing 904. In some embodiments, an exemplary exoskeleton may include a belt or hip holder 906 and a back element 908, which optionally includes a power supply and main electronics. In some embodiments, the portion of the exoskeleton that includes the actuator is a thigh element, wherein an upper actuator located near the hip is configured to assist the movement of the thigh itself from the hip, and a lower actuator located near the knee is configured to assist the movement of the calf by moving the calf element 910, the lower actuator being reversibly attached to the calf and optionally also attached to the foot. In some embodiments, the element actuated by the actuator is referred to as an actuation applying portion, and is an element attached to the user's body. In some embodiments, the actuation applying portion may be attached to one or more of the hip, knee, foot, ankle, wrist, and elbow. In some embodiments, there is a rigid element (eg, portion), optionally made of plastic, that is coupled to the actuator / device by means of an adjustable mechanism (fixed or rotational) or is bolted directly to the actuator / device.

[0221] Exemplary Beltless Actuator

[0222] Reference now Fig.10 , Fig.10A schematic diagram of an exemplary beltless actuator according to some embodiments of the present invention is shown. In some embodiments, the actuator is not driven by a belt connected between pulleys, but is directly driven by gear teeth. In some embodiments, motor 1002 provides speed and force to input gear 1004. In some embodiments, the upper portion of intermediate gear 1006 meshes with (is directly connected to) first gear 1004. In some embodiments, the bottom portion 1008 of second gear 1006 meshes with (is directly connected to) output gear 1010. In some embodiments, the beltless actuator is provided with lubricating material between the teeth of the gears to assist the rotation of the gears and avoid destructive friction.

[0223] Example use of a Bowden cable in an exoskeleton including an actuator

[0224] Reference now Fig.11a , Fig.11a A schematic diagram of an exemplary use of an exemplary actuator with a Bowden cable system according to some embodiments of the present invention is shown. In some embodiments, the actuator allows the actuator to be placed anywhere on the human body (e.g., near the center of mass or other proximal region of the human body) and the movement is transmitted to a desired joint (e.g., distal region of the body) via, for example, a Bowden cable. For example, Fig.11a As shown, as described above, the actuator includes one or more motors 1102 (one motor 1102 is shown) connected to the system 1104. For ease of explanation, a simplification of the system is disclosed. In some embodiments, one or more cables 1106 leave the deceleration system and enter the hollow outer cable housing of the Bowden cable system 1108. In some embodiments, there is an output pulley 1110 (schematically shown) at the other end of the hollow outer cable housing of the Bowden cable system, which is configured to provide the movement of the actuator outside to the relevant body part. In some embodiments, the potential advantage of using the Bowden cable system is that it allows the use of cable-driven actuators in exoskeletons, which have a non-rigid mechanical structure made of a fabric portion (fabric harness), also referred to as a soft exoskeleton or exoskeleton suit. This exoskeleton overcomes the movement limitations of a rigid exoskeleton system, minimizes the limitations of movement, and reduces the weight of the device (the load-bearing depends only on the user's bone structure), which is particularly useful for people with mild movement disorders.

[0225] Reference now Fig.11b, a schematic diagram showing an exemplary use of an exemplary cable-driven actuator in a soft exoskeleton according to some embodiments of the present invention. As previously described, for example, an actuator including one or more motors 1102 is placed inside a rear module 1112. In some embodiments, from inside the rear module 1112, actuation can be delivered by an output pulley 1110 to one or more limbs, for example to a thigh 1114, to a knee 1116, and / or to an ankle 1118. In some embodiments, in addition, the one or more limbs are one or more of a shoulder, an elbow, and a wrist.

[0226] Reference now Fig.11c , Fig.11c A schematic diagram showing an exemplary use of an exemplary cable driven actuator in a soft exoskeleton according to some embodiments of the present invention. In some embodiments, the cable driven actuator is used without using an output pulley 1110 by attaching the ends of the Bowden cables to the foot segments 1118 (one near the toe and the other near the heel). Fig.11a and Fig.11b The described actuation mechanism. In some embodiments, release of the cable allows the ankle to move freely, while tension in the cable prevents movement of the ankle.

[0227] Reference now Fig.11d , Fig.11d A schematic diagram of an exemplary use of an exemplary cable driven actuator in a rigid exoskeleton according to some embodiments of the present invention is shown. In some embodiments, the actuator mechanism and motor 1102 are located at the rear module 1112. In some embodiments, the cable is then redirected to the hip joint. In some embodiments, a potential advantage of redirecting the cable is that it potentially reduces weight in the distal section, which is potentially useful for people with little residual motor function in the lower extremities.

[0228] Exemplary Uses of Actuators

[0229] In some embodiments, as previously disclosed, the actuators can be used for actuation of an exoskeleton. It should be understood that the actuators can be used for other purposes, such as for robotic machines, industrial robots, vehicles, toys, etc. For example, referring to Fig.12a and Figure 12b , Fig.12a A schematic diagram of an industrial robot or collaborative robot including an actuator according to some embodiments of the present invention is shown, and Figure 12b A schematic diagram of a quadruped robot including eight actuators according to some embodiments of the present invention is shown.

[0230] Exemplary Recharging

[0231] In some embodiments, the exoskeleton includes a battery configured to provide power to the entire system, such as to actuators, electrical components, etc. In some embodiments, the battery is a rechargeable battery. In some embodiments, the back-drivable actuator is configured to utilize momentum from the movement of the patient wearing the exoskeleton in order to recharge the battery. For example, the motor is configured to provide speed and force to the pulley in order to move the output element, in which case the output element will move the body member of the patient wearing the exoskeleton. In some embodiments, the system is configured to detect when forces are applied to the system, either through momentum provided by the patient's movement or by actively moving the output element, and utilize those forces to recharge the battery by converting those forces into energy.

[0232] In some embodiments, recharging of the battery can be accomplished by providing the exoskeleton with a spring mechanism in the foot that utilizes the stepping motion performed by the user during walking in order to actuate the recharging mechanism. Similar to what was explained above, the system utilizes the force of the pointing system to convert the force of the pointing system into energy to recharge the battery.

[0233] Exemplary general information

[0234] In some embodiments, the actuator is an electric powered actuator. In some embodiments, the actuator is pneumatically powered and / or hydraulically powered. In some embodiments, a potential advantage of using an electric powered actuator is that the battery is quite compact compared to other power sources such as pneumatic compressors.

[0235] In some embodiments, the size of the actuator is smaller than known actuators, for example, about 10% to about 50% smaller than known actuators. Alternatively, about 5% to about 60% smaller than known actuators. Alternatively, about 1% to about 70% smaller than known actuators. In some embodiments, the actuator comprises an outer diameter of about 50mm to about 200mm, optionally about 40mm to about 250mm, optionally about 30mm to about 275mm. In some embodiments, the actuator comprises an outer diameter of less than 100mm. In some embodiments, a potential advantage of having a smaller actuator is that it provides a smaller system to the user. In some embodiments, the actuator follows the shape of a person's leg. In some embodiments, the actuator comprises a small form factor.

[0236] In some embodiments, an exemplary actuator provides one or more of the following parameters.

[0237] 1. The nominal output torque is about 36 Nm, optionally about 20 Nm to about 40 Nm, optionally about 10 Nm to about 80 Nm.

[0238] 2. The maximum output peak torque is about 60 Nm, optionally about 40 Nm to about 70 Nm, optionally about 10 Nm to about 100 Nm.

[0239] 3. The maximum output speed is about 80 rpm, optionally about 70 rpm to about 90 rpm, optionally about 50 rpm to about 100 rpm.

[0240] 4. Low to medium reverse drive torque is about 1.7 Nm, optionally about 1 Nm to about 2 Nm, optionally about 0.5 Nm to about 2.5 Nm.

[0241] In some embodiments, the motor is "sensitive" enough to sense the force from the output element in the exoskeleton from the current drawn in the motor. For example, the user begins a movement of extending the leg. The movement of the leg will actuate the mechanism of the actuator in the opposite direction, meaning that it is not the motor driving the movement of the actuator, but the movement performed by the user that causes the movement of the actuator. In some embodiments, the motor can "sense" this movement and begin assisting the user by actuating the actuator in the same direction. In some embodiments, since the actuator includes a high back-drive capability, this feedback mechanism using the current drawn by the motor is very useful in partially assisting the user in using the exoskeleton.

[0242] In some embodiments, the actuator is configured to deliver high torque relative to angular velocity. In some embodiments, the actuator delivers a torque (Nm) / angular velocity (RPMs) of about 0.4Nm / RPM to about 1.6Nm / RPM of maximum torque / maximum value. For example, the motor provides 60Nm and 83RPM, which is equivalent to 0.7Nm / RPM. In some embodiments, the requirement of the device including the actuator is to interact with the environment (for example, the exoskeleton interacts with the patient and / or the environment, the industrial robot interacts with the operator, the quadruped robot interacts with the ground and obstacles and / or other machines), so the device is equipped with a reversibly drivable actuator realized by a reversible motor. In some embodiments, the actuator includes a reversible torque of less than 5%, ideally less than 2.5%, and a ratio of maximum torque to reversible torque, for example, the actuator includes a reversible torque of 1.55Nm and provides a maximum value of 60Nm, which is equivalent to a reversible torque / maximum torque ratio of 2.5%.

[0243]

[0046] Various embodiments and aspects of the present invention as delineated hereinabove and as claimed in the claims section below find experimental support in the following exemplary embodiments.

[0244] Exemplary Embodiments

[0245] Reference is now made to the following exemplary embodiments, which together with the above descriptions illustrate some embodiments of the invention in a non-limiting fashion.

[0246] In the following sections, an exemplary belt actuator is presented along with design specifications and tests performed, including the following:

[0247] 1. General notes related to the system;

[0248] 2. Frameless test: Test performed with the "electrical part" of the actuator;

[0249] 3. Whole system durability testing: Actuator fatigue performance testing, highlighting the number of cycles at maximum torque, motor synchronicity and maximum temperature reached.

[0250] 1. General notes related to the system

[0251] In some embodiments, an exemplary main feature of the belt actuator is a combination of a torque motor and a low reduction ratio transmission. In some embodiments, the torque motor used is a large diameter flat brushless motor with a large pole number and a very high Kt (torque current constant). In some embodiments, for the reduction system, a commercial high torque drive (HTD) synchronous belt is used. More specifically, the use of a high power (HP) belt is due to the low permanent elastic stretch of the high power (HP) belt line, the friction and wear resistant fabric with high shear strength, and the good resistance and smooth operation, low shock loads and medium shock loads. In some embodiments, in order to obtain the desired reduction ratio, for example, Figure 1b and Figure 2 As shown, a two-stage timing belt system has been designed.

[0252] Figure 5a and Figure 5b A cross-sectional view of a knee actuator and a hip actuator is shown. In some embodiments, both systems use exactly the same components, except for an emergency brake that is optionally placed only in the knee actuator.

[0253] Exemplary Safety Features :

[0254] In some embodiments, as described above, the system integrates a safety magnetic brake and output encoder. In some embodiments, a normally closed brake (a normally closed brake brakes when power is released) adds a layer of safety to the device that will still support the weight of the user in the event of a power loss. In addition, it increases the efficiency of the exoskeleton because the motor does not consume any energy when standing still (one of the situations where the user spends most of the time). In some embodiments, an exemplary brake is the 03.P1.310-400 brake from the manufacturer KEB. This 11W and 24Vdc brake can provide a constant braking torque of 2Nm in the input, which translates to a braking torque of 36Nm in the knee.

[0255] On the other hand, in some embodiments, in order to always know the location of the output, for example Figure 5d As shown, an optical encoder for the output has been included. In some embodiments, the information given by this encoder together with the information given by the single-turn absolute encoder in the electric motor gives the precise position of the output without the need for a homing procedure.

[0256] 2. No framework testing :

[0257] For example Fig.13a As shown, the frameless motor consists of a rotor (magnetic ring) and a stator (soft iron core with copper coils) bonded to a machined structure that transmits the torque generated by the motor. In order to obtain the motor constants and its thermal behavior, a Fig.13b Test bench shown: The test bench consists of a custom machined structure for the frameless motor, torque sensor, and disc brake. The test bench is then connected to a 32-bit based The drive is controlled by a microcontroller that reads and stores data from different sensors.

[0258] The drive configuration used in the tests included the following parameters:

[0259] Ip=15[A];t_peak=2000[ms];Imax=15[A];V_max=20[rev / s];In=5[A];Number of pole pairs=21;

[0260] R_ntc=10000[Ω];β=3984[K];Tmax=100[℃];encoder=4096[CPR];Ph_acc=120[m°];fpwm=50[kHz].

[0261] Current circulation: Kp = 2.02; Ki = 1739.2

[0262] Speed ​​loop (for torque and speed testing): Kp=2; Ki=4.

[0263] Test Results

[0264] Encoder linearity test

[0265] The encoder linearity test provides a measure of the coaxiality between the motor and the encoder. This is particularly relevant because, depending on the misalignment, the effective output torque can be equal to or lower than expected. The test is performed under two conditions: half the nominal current and nominal current. In both cases, two full mechanical rotations in opposite directions (to account for friction) are performed. The test parameters are: Data sampling rate: 100Hz; Drive: Everest XCR; Number of steps: 12600 (increments of 0.03 mechanical degrees).

[0266] exist Fig.13c On the graph in , the error is reported in mechanical degrees and, knowing that the number of poles of the motor is 21, it is converted into electrical degrees. It can be seen that the encoder performs a maximum error of 7 electrical degrees, corresponding to a torque ripple of 1.5%. This small torque loss is considered acceptable as it does not affect the functionality of the device.

[0267] Torque constant

[0268] In some embodiments, the torque constant determines the relationship between the quadrature current applied to the motor coils and the torque delivered by the actuator. The torque constant is sometimes an important parameter because it gives information about how much torque is applied to the patient's leg. In some embodiments, to measure the torque constant, several tests are performed to record the torque output of the motor when it is stalled at different currents. In other words, while the torque sensor is recording the torque applied by the actuator, the motor is completely stopped by the disc brake. The results can be seen in Fig.13d As seen in the graph shown, where torque is plotted against current, this results in: Kt = 0.3159.

[0269] Temperature Model

[0270] In some embodiments, the purpose of this test is to determine the relationship between the torque delivered by the motor and the time required to reach the maximum temperature of the stator coil. To do this, the motor is excited at different temperatures while measuring the time to reach 100°C, always starting from 24°C. The test parameters are: data sampling rate: 100Hz; driver: Everest XCR; thermistor model: NTCLE305E4103SB; ambient temperature: 24°C; number of test currents: 4 (3A, 5A, 10A and 15A). The results are reported in Fig.13e In the graph shown, Fig.13e From the graph shown it can be seen that the relationship follows an exponential curve.

[0271] Full system durability

[0272] Experimental protocol

[0273] Once the "electrical part" of the actuator has been tested, it is possible to check whether the entire system consisting of the electric motor, the reduction system and the housing can withstand the forces for a long time. For this purpose, a test bench was built: the test bench connects the actuator to a resistive motor that replicates the load applied by the patient. As mentioned above, the exemplary motors used by the actuator and for testing are the electric frameless motor, the T-motor U10 Kv50, and the RMB20 rotary magnetic encoder module.

[0274] Reduction system: A two-stage synchronous belt reduction system was used, which had a reduction ratio i = 16.68. The first stage included an Optibelt Omega HP 5MHP 425x9 belt, while the second stage included an Optibelt Omega HP 5MHP 475x25 belt.

[0275]

[0276]

[0277] Main features of the motor:

[0278] Maximum current 25.0A Nominal torque 33.37Nm Maximum Torque 75.08Nm Maximum speed 71.93rpm

[0279] Test parameters:

[0280] Data acquisition rate: 33Hz; Set point update rate: 1000Hz; Driver 1: Everest XCR; Driver 2: Everest XCR; Thermistor: NTCLE305E4103SB.

[0281] Monitoring parameters:

[0282] Orthogonal current; speed; position; temperature.

[0283] One run is:

[0284] - 10 walking curves, with a peak position of 70 degrees and a peak torque of 57NM;

[0285] -1 sit-to-stand curve with a peak position of 70 degrees and a peak torque of 48.6Nm;

[0286] -1 standing to sitting curve with a peak position of 70 degrees and a peak torque of 48.6Nm;

[0287] - 12 cycles in total;

[0288] - Each loop lasts 1 second.

[0289] An exemplary graph showing the test results can be found at Fig.13f Seen in.

[0290] Exemplary resistance motor features are Figure 13g shown.

[0291] Fig.13h The main components of the test bench are shown (actuator and resistance motor) as well as the mechanical coupling consisting of a 1:2 timing belt. The timing belt (8M 720x35) has been oversized to ensure that it interferes with the results as little as possible.

[0292] Fig.13i A graph showing position, velocity and current curves for 12 cycles (1 sit, 1 stand and 10 steps) is shown.

[0293] Test Results

[0294] Cycle times

[0295] In many cases it is important to know the life expectancy of an actuator, for example, by knowing the maximum number of cycles the actuator can withstand and the expected number of cycles per year, the life expectancy of a motor can be determined.

[0296] It is nearly impossible to determine the average load that the motor will be subjected to, as each user will load the unit differently depending on their impairments, weight, abilities, etc. Therefore, the motor is loaded at its absolute maximum operating conditions. This will result in a theoretical life expectancy that is shorter than the actual life expectancy.

[0297] The test ran smoothly for 508,000 cycles at maximum torque. At this point, the motor began to ratchet (tooth jump). Ratcheting is the safest type of failure because it does not imply a mechanical disconnect between the input and output. In other words, the motor always supported the patient.

[0298]

[0299]

[0300] Fig.13j Shown is the uncovered actuator after all fatigue tests have been performed. The first thing you can see is some rubber fragments all over the motor. These fragments came from the timing belt, and most of them were released during the last few cycles of the test.

[0301] Figure 13k Shows how a timing belt is affected by a skipped tooth. Some teeth are damaged and only partially attached to the belt line. Also, part of the belt line is damaged.

[0302] Motor synchronization

[0303] Motor synchronicity is defined as the error between the input rotor angle and the angle of the human leg. This parameter shows how closely the human leg will follow the desired trajectory imposed on the motor. In some cases, the goal is to have the smallest possible error, and perhaps more importantly, to have a constant error over all the expected life of the actuator. Figure 13l The graph in shows the evolution of the input-output error during the entire fatigue test. It can be seen that the error does not increase over time, so the motors remain synchronized over time.

[0304] Motor current

[0305] The motor current gives information about the actual torque delivered by the system. By examining the current data, the severity of the test can be checked. Figure 13m The graph in shows that the motor is working as hard as it can during the fatigue test. It can be seen that the RMS current is equal to the nominal current and the peak current is always reached in each cycle.

[0306] Maximum temperature

[0307] Regarding the temperature data, it is important to check whether the fact of enclosing the frameless motor inside the actuator changes the thermal behavior of the system. To this end, the temperature of the stator coils was measured during the entire experiment.

[0308] Fig.13n The graph in Figure 2 shows that the temperature never reaches 100°C, which is the maximum operating temperature specified by the manufacturer (T-type motor). As can be seen from the graph, the temperature fluctuates periodically. This temperature variation is caused by the room temperature changes during the day and night.

[0309] Exemplary Methods

[0310] In some embodiments, an exoskeleton and / or exemplary method of transmitting power in an exoskeleton is provided, the exoskeleton comprising an actuator comprising one or more of:

[0311] 1. At least one motor, the at least one motor is used to provide a first speed and a first force to at least one reduction gear assembly;

[0312] 2. At least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly is configured to perform a first speed reduction and a force amplification of a force received from at least one motor;

[0313] 3. wherein at least one motor, at least one input pulley and at least one output pulley are located internally of each other in the actuator, thereby allowing the actuator to comprise a width of up to 10 cm;

[0314] 4. wherein the two-stage reduction assembly provides a reduction ratio of about 1:10 to about 1:50;

[0315] 5. wherein the actuator is characterized by having a low to medium back-drive torque of about 0.5 Nm to about 2.5 Nm and a nominal torque of about 10 Nm to about 100 Nm;

[0316] 6. Wherein, at least one motor and at least one two-stage reduction assembly are configured to provide the actuator with a capability to deliver a maximum torque / weight ratio of about 40 Nm / Kg to about 100 Nm / Kg.

[0317] 7. Wherein, at least one motor, at least one input pulley and at least one output pulley are coaxially located in the same plane within the actuator.

[0318] 8. Wherein, at least one motor and at least one two-stage reduction assembly are configured to provide this performance to the actuator without compromising the back-drivability performance of the back-drivable motor.

[0319] 9. Wherein, at least one reduction assembly comprises: at least one input pulley and at least one additional pulley; at least one input pulley is operably connected to at least one motor; a first belt, the first belt is positioned between the at least one input pulley and the at least one additional pulley; the first belt is configured to transmit speed and force to the at least one additional pulley; at least one output pulley; a second belt, the second belt is positioned between the at least one additional pulley and the at least one output pulley; the second belt is configured to transmit speed and force to the at least one output pulley.

[0320] 10. Wherein the at least one additional pulley is external to the at least one motor, the at least one input pulley and the at least one output pulley, but is on the same plane as the at least one motor, the at least one input pulley and the at least one output pulley.

[0321] 11. Wherein the at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:6.

[0322] 12. Wherein the at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:6.

[0323] 13. Wherein: at least one reduction gear assembly does not include a belt; at least one input pulley is an input gear meshing with at least one additional gear; and at least one additional gear meshes with an output gear.

[0324] 14. At least one energy source configured to provide energy to the actuator.

[0325] 15. At least one encoder configured to provide real-time information about the position of at least one input pulley and at least one output pulley of an input.

[0326] 16. At least one brake configured to lock the actuator in an emergency situation.

[0327] The method comprises providing an actuator as described above within the exoskeleton and actuating the exoskeleton accordingly.

[0328] As used herein, with respect to an amount or value, the term "about" means "within ±20%."

[0329] The terms "comprises," "comprising," "includes," "including," "has," "having" and their cognates mean "including but not limited to."

[0330] The term "consisting of" means "including and limited to."

[0331] The term "consisting essentially of" means that a composition, method, or structure may include additional ingredients, steps, and / or parts, but only when the additional ingredients, steps, and / or parts do not materially change the basic and novel characteristics of the claimed composition, method, or structure.

[0332] Throughout this application, embodiments of the present invention may be presented with reference to range format. It should be understood that the description in range format is only for convenience and brevity and should not be interpreted as an unchangeable limitation to the scope of the present invention. Therefore, the description of the scope should be considered to have specifically disclosed all possible sub-ranges and single numerical values ​​within the scope. For example, the description of a scope such as "from 1 to 6" should be considered to have specifically disclosed sub-ranges, such as "from 1 to 3", "from 1 to 4", "from 1 to 5", "from 2 to 4", "from 2 to 6", "from 3 to 6" etc., and single digits within the scope, such as 1, 2, 3, 4, 5 and 6. No matter how wide the scope is, this applies.

[0333] Whenever a numerical range is indicated herein (e.g., "10-15," "10 to 15," or any pair of numbers linked by these other such range indications), it is intended to include any number (fractional or integer) within the indicated range limits, including the range limits, unless the context clearly dictates otherwise. The phrases "range between a first indicated number and a second indicated number" and "range from a first indicated number "to," "up to," "until," or "up to" (or another such range indicating term) the second indicated number" are used interchangeably herein and are intended to include the first indicated number and the second indicated number and all fractions and integers therebetween.

[0334] Unless otherwise indicated, the numbers used herein and any numerical ranges based thereon are approximations within reasonable measurement precision and rounding errors as understood by those skilled in the art.

[0335] It should be understood that, for the sake of clarity, certain features of the invention described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, for the sake of brevity, various features of the invention described in the context of a single embodiment may also be provided individually or in any suitable sub-combination, or suitable for provision in any other described embodiment of the invention. Certain features described in the context of various embodiments are not considered essential features of those embodiments, unless the embodiment does not function without those elements.

[0336] Although the present invention has been described in conjunction with specific embodiments of the present invention, it is apparent that many alternatives, modifications and variations will be apparent to those skilled in the art. Therefore, the present invention is intended to encompass all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

[0337] The applicant's intention is to incorporate all publications, patents and patent applications mentioned in this specification into this specification by reference in their entirety, just as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference when cited. In addition, the citation or identification of any reference in this application should not be interpreted as an admission that the reference can be used as prior art of the present invention. In terms of the use of section headings, they should not be interpreted as necessary limitations. In addition, any priority document of the application is incorporated herein by reference in its entirety.

Claims

1. An actuator, comprising: a. at least one motor, the at least one motor being configured to provide a first speed and a first force to at least one reduction assembly; b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force amplification of the force received from the at least one motor; Wherein, the at least one motor, the at least one input pulley and the at least one output pulley are located inside the actuator with respect to each other.

2. The actuator according to claim 1, wherein: The at least one motor, the at least one input pulley, and the at least one output pulley are coaxially positioned and lie in a same plane within the actuator.

3. An actuator according to claim 1 or claim 2, wherein: The at least one reduction assembly performs a reduction from about 1:10 to about 1:

50.

4. The actuator according to any one of claims 1 to 3, wherein: The at least one speed reduction assembly comprises: a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor; b. a first belt, the first belt being positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley; c. said at least one output pulley; d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

5. The actuator according to claim 4, wherein: The at least one additional pulley is external to, but on the same plane as, the at least one motor, the at least one input pulley, and the at least one output pulley.

6. The actuator according to claim 4, wherein: The at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:

6.

7. The actuator according to claim 4, wherein: The at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:

6.

8. The actuator according to any one of claims 1 to 7, wherein: The at least one motor is a high torque motor.

9. The actuator according to any one of claims 1 to 8, wherein: The actuator is characterized by having a low to medium back-drive torque from about 0.5 Nm to about 2.5 Nm, and the actuator is configured to provide a high nominal torque from about 10 Nm to about 100 Nm.

10. The actuator according to any one of claims 1 to 9, wherein: The actuator is configured to allow the motor to be back driven.

11. The actuator according to any one of claims 1 to 10, wherein: The motor is configured to allow back driving of the actuator.

12. An actuator according to any one of claims 1 to 11, wherein: The motor is a back-drivable motor.

13. An actuator according to any one of claims 1 to 12, wherein: a. The at least one deceleration assembly does not include a belt; b. said at least one input pulley is an input gear meshing with at least one additional gear; and c. The at least one additional gear meshes with the output gear.

14. The actuator according to any one of claims 1 to 13, further comprising at least one energy source configured to provide energy to the actuator.

15. The actuator of any one of claims 1 to 14, further comprising at least one encoder configured to provide real-time information about the positions of the at least one input pulley and the at least one output pulley of the input.

16. The actuator according to any one of claims 1 to 15, further comprising at least one brake configured to lock the actuator in an emergency situation.

17. An actuator according to any one of claims 1 to 16, wherein: The at least one motor and the at least one two-stage reduction assembly are configured to provide the actuator with a capability to deliver a maximum torque / weight ratio from about 40 Nm / Kg to about 100 Nm / Kg.

18. An actuator comprising: a. at least one motor, the at least one motor being configured to provide a first speed and a first force to at least one reduction assembly; b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force amplification of the force received from the at least one motor; The two-stage reduction assembly provides a reduction ratio of about 1:10 to about 1:50; Wherein, the at least one motor is a back-drivable motor having a back-drive torque of about 0.5 Nm to about 2.5 Nm and a nominal torque of about 10 Nm to about 100 Nm.

19. The actuator according to claim 18, wherein: The at least one motor, the at least one input pulley, and the at least one output pulley are located internally to each other in the actuator.

20. The actuator according to claim 18, wherein: The at least one motor, the at least one input pulley, and the at least one output pulley are coaxially positioned and lie in a same plane within the actuator.

21. An actuator according to any one of claims 18 to 20, wherein: The at least one speed reduction assembly comprises: a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor; b. a first belt, the first belt being positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley; c. said at least one output pulley; d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

22. The actuator according to claim 21, wherein: The at least one additional pulley is external to, but on the same plane as, the at least one motor, the at least one input pulley, and the at least one output pulley.

23. The actuator according to claim 21, wherein: The at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:

6.

24. The actuator according to claim 21, wherein: The at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:

6.

25. An actuator according to any one of claims 18 to 24, wherein: a. The at least one deceleration assembly does not include a belt; b. said at least one input pulley is an input gear meshing with at least one additional gear; and c. The at least one additional gear meshes with the output gear.

26. An actuator according to any one of claims 18 to 25, further comprising at least one energy source configured to provide energy to the actuator.

27. An actuator according to any one of claims 18 to 26, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

28. An actuator according to any one of claims 18 to 27, further comprising at least one brake configured to lock the actuator in an emergency situation.

29. An actuator comprising: a. at least one motor, the at least one motor being configured to provide a first speed and a first force to at least one reduction assembly; b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force amplification of the force received from the at least one motor; Wherein, the at least one motor and the at least one two-stage reduction assembly are configured to provide the actuator with a capability for delivering a maximum torque / weight ratio of about 40 Nm / Kg to about 100 Nm / Kg.

30. The actuator of claim 29, wherein: The at least one motor is a high torque motor.

31. The actuator of claim 29, wherein: The at least one motor and the at least one two-stage reduction assembly are configured to provide the performance to the actuator without compromising the back-driving capability performance of the actuator.

32. An actuator according to any one of claims 28 to 31, wherein: The at least one motor, the at least one input pulley, and the at least one output pulley are located internally to each other in the actuator.

33. An actuator according to any one of claims 28 to 31, wherein: The at least one motor, the at least one input pulley, and the at least one output pulley are coaxially positioned and lie in a same plane within the actuator.

34. An actuator according to any one of claims 28 to 33, wherein: The at least one reduction assembly performs a reduction from about 1:10 to about 1:

50.

35. An actuator according to any one of claims 28 to 34, wherein: The at least one speed reduction assembly comprises: a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor; b. a first belt, the first belt being positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley; c. said at least one output pulley; d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

36. An actuator according to claim 35, wherein: The at least one additional pulley is external to, but on the same plane as, the at least one motor, the at least one input pulley, and the at least one output pulley.

37. An actuator according to claim 35, wherein: The at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:

6.

38. The actuator of claim 35, wherein: The at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:

6.

39. An actuator according to any one of claims 28 to 38, wherein: The motor is characterized as having a low to medium reverse drive torque of about 0.5 Nm to about 2.5 Nm, and the motor is configured to provide a high nominal torque of about 10 Nm to about 100 Nm.

40. An actuator according to any one of claims 28 to 39, wherein: a. The at least one deceleration assembly does not include a belt; b. said at least one input pulley is an input gear meshing with at least one additional gear; and c. The at least one additional gear meshes with the output gear.

41. An actuator according to any one of claims 28 to 40, further comprising at least one energy source configured to provide energy to the actuator.

42. An actuator according to any one of claims 28 to 41, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

43. An actuator according to any one of claims 28 to 42, further comprising at least one brake configured to lock the actuator in an emergency situation.

44. An actuator comprising: a. at least one motor, the at least one motor being configured to provide a first speed and a first force to at least one reduction assembly; b. at least one two-stage reduction assembly, the at least one two-stage reduction assembly comprising at least one input pulley and at least one output pulley; the at least one two-stage reduction assembly being configured to perform a reduction in the first speed and a force amplification of the force received from the at least one motor; wherein the at least one motor, the at least one input pulley and the at least one output pulley are located internally of each other in the actuator, thereby allowing the actuator to comprise a width of up to 10 cm; wherein the two-stage reduction assembly provides a reduction ratio of about 1:10 to about 1:50; wherein the actuator is characterized by having a low to medium back-drive torque of about 0.5 Nm to about 2.5 Nm and a nominal torque of about 10 Nm to about 100 Nm; Wherein, the at least one motor and the at least one two-stage reduction assembly are configured to provide the actuator with a capability for delivering a maximum torque / weight ratio of about 40 Nm / Kg to about 100 Nm / Kg.

45. An actuator according to claim 44, wherein: The at least one motor, the at least one input pulley, and the at least one output pulley are coaxially positioned and lie in a same plane within the actuator.

46. ​​An actuator according to claim 44 or 45, wherein: The at least one motor and the at least one two-stage reduction assembly are configured to provide the performance to the actuator without compromising the back-drive capability performance of the motor.

47. An actuator according to any one of claims 44 to 46, wherein: The at least one speed reduction assembly comprises: a. said at least one input pulley and at least one additional pulley; said at least one input pulley being operably connected to said at least one motor; b. a first belt, the first belt being positioned between the at least one input pulley and the at least one additional pulley; the first belt being configured to transmit speed and force to the at least one additional pulley; c. said at least one output pulley; d. A second belt positioned between the at least one additional pulley and the at least one output pulley; the second belt being configured to transmit velocity and force to the at least one output pulley.

48. An actuator according to claim 47, wherein: The at least one additional pulley is external to, but on the same plane as, the at least one motor, the at least one input pulley, and the at least one output pulley.

49. An actuator according to claim 47, wherein: The at least one input pulley and the at least one additional pulley provide a reduction from about 1:3 to about 1:

6.

50. The actuator of claim 47, wherein: The at least one additional pulley and the at least one output pulley provide a reduction from about 1:2 to about 1:

6.

51. An actuator according to any one of claims 44 to 50, wherein: a. The at least one deceleration assembly does not include a belt; b. said at least one input pulley is an input gear meshing with at least one additional gear; and c. The at least one additional gear meshes with the output gear.

52. An actuator according to any one of claims 44 to 51, further comprising at least one energy source, the at least one energy source being configured to provide energy to the actuator.

53. An actuator according to any one of claims 44 to 52, further comprising at least one encoder configured to provide real-time information about the position of the at least one input pulley and the at least one output pulley of the input.

54. An actuator according to any one of claims 44 to 53, further comprising at least one brake configured to lock the actuator in an emergency situation.

55. An exoskeleton comprising: a. at least one actuating portion; b. At least one actuator according to claim 1 or claim 18 or claim 29 or claim 44.

56. An exoskeleton according to claim 55, wherein: The at least one actuation applying portion is attached to one or more sections selected from the group consisting of a thigh, a calf, a foot, a torso, a forearm, an upper arm, and a hand.

57. An exoskeleton according to claim 55 or claim 56, further comprising at least one circuit configured to control the motor of the at least one actuator.

58. An exoskeleton according to any one of claims 55 to 57, wherein: At least one output unit provides an output range of motion (ROM) of about 45° to about 180° to the at least one actuation applying portion.

59. An exoskeleton according to any one of claims 55 to 58, wherein: The at least one actuator is located inside a dedicated unit in the exoskeleton, and wherein the dedicated unit is located on one or more segments selected from the group consisting of a thigh, a calf, a foot, a torso, a forearm, an upper arm, and a hand.

60. The exoskeleton of claim 59, wherein: The at least one output unit is located outside the dedicated unit.

61. The exoskeleton of claim 58, wherein: The at least one output unit is located at the location of the at least one actuation applying portion.

62. An exoskeleton according to any one of claims 55 to 61, further comprising at least one energy source configured to provide energy to the exoskeleton.

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