Trunk-supporting exoskeleton with one powered actuator

Abstract

Some embodiments described herein are directed to a trunk support exoskeleton for reducing muscle force on a wearer's back during lumbar forward bending. The trunk support exoskeleton may include a trunk support frame, a first thigh link, a second thigh link, an actuator, a shaft pulley, a housing pulley, a shaft line, and a housing line. The actuator may include an actuator housing and an actuator shaft. When the wearer is bending forward in the sagittal plane relative to a vertical line of gravity, the actuator may generate an actuator resistance torque between the actuator housing and the actuator shaft. The actuator resistance torque between the actuator housing and the actuator shaft may generate a tension force in the housing line and the shaft line, thereby generating an extension torque between the respective first and second thigh links and the trunk support frame.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 362,778, filed April 11, 2022, and U.S. Provisional Patent Application No. 63 / 362,779, filed April 11, 2022, each of which is incorporated by reference in its entirety herein.

[0002] The unnumbered international application filed on the same day herewith ("AN ACTUATOR FOR AN EXOSKELETON", Inventors Wayne TUNG et al., Attorney Docket No. 5085.004PC03) is hereby incorporated by reference in its entirety.

[0003] The present disclosure relates generally to exoskeleton systems, and more particularly to core support exoskeleton systems. [Background technology]

[0004] It may be desirable to reduce the forces exerted on the wearer's back during lumbar flexion (eg, while bending or crouching). Summary of the Invention

[0005] Some embodiments described herein are directed to a trunk support exoskeleton for reducing muscle forces on a wearer's back during lumbar forward bending. The trunk support exoskeleton may include a trunk support frame, a first thigh link, a second thigh link, an actuator, a shaft pulley, a housing pulley, a shaft line, and a housing line. The trunk support frame may be configured to be coupled to a trunk of the wearer. The first thigh link may be configured to be coupled to one of the wearer's thighs. The second thigh link may be configured to be coupled to the other of the wearer's thighs. Each of the first thigh link and the second thigh link may be rotatably coupled to the trunk support frame such that the respective first thigh link or second thigh link may flex or extend relative to the trunk support frame. The actuator may be coupled to the trunk support frame. The actuator may include an actuator housing and an actuator shaft. The actuator shaft and the actuator housing may be rotatable relative to the trunk support frame. The shaft pulley may be coupled to the actuator shaft. The housing pulley may be coupled to the actuator housing. The shaft line may have a first end wound around the shaft pulley and a second end coupled to the first thigh link. The housing line may have a first end wound around the housing pulley and a second end coupled to the second thigh link. When the wearer is bending forward with respect to the vertical line of gravity in the sagittal plane, the actuator may generate an actuator resistance torque between the actuator housing and the actuator shaft. The actuator resistance torque between the actuator housing and the actuator shaft may generate a tensile force in the housing line and the shaft line, thereby generating an extension torque between the respective first and second thigh links and the trunk support frame.

[0006] In some embodiments, the first thigh link can include a first thigh link pulley. In some embodiments, the second thigh link can include a second thigh link pulley. In some embodiments, the second end of the shaft line is wrapped around the first thigh link pulley such that tension in the shaft line provides an extension torque between the first thigh link and the trunk support frame. In some embodiments, the second end of the housing line is wrapped around the second thigh pulley such that tension in the housing line provides an extension torque between the second thigh link and the trunk support frame.

[0007] In some embodiments, when the wearer is not bending forward relative to the vertical line of gravity, the actuator does not create an actuator resistance torque between the actuator housing and the actuator shaft.

[0008] In some embodiments, when the wearer is not bending forward relative to the vertical line of gravity, the actuator generates a substantially small actuator resistance torque between the actuator housing and the actuator shaft that allows substantially free movement of the thigh link.

[0009] In some embodiments, when the wearer is not bending forward relative to the vertical line of gravity and the thigh link is in a reciprocating mode indicative of walking, the actuator generates a substantially small actuator resistance torque that allows substantially free movement of the thigh link.

[0010] In some embodiments, the shaft line and the housing line each comprise an element or combination of elements selected from the group consisting of wire, cable, belt, fabric rope, plastic rope, cord, twine, chain, wire rope, and string.

[0011] In some embodiments, the actuator comprises an element or combination of elements selected from the group consisting of an AC (alternating current) motor, a brushed DC (direct current) motor, a brushless DC motor, an electronically commutated motor (ECM), a stepper motor, and combinations thereof.

[0012] In some embodiments, the actuator comprises a transmission system.

[0013] In some embodiments, the transmission system includes an element or combination of elements selected from the group consisting of a harmonic drive, a planetary gear, a ball screw mechanism, a lead screw mechanism, a worm gear, and combinations thereof.

[0014] In some embodiments, the transmission system includes an element or combination of elements selected from the group consisting of gears, worm gears, gear trains, pulleys, lines, belts, toothed belts, toothed pulleys, planetary gears, harmonic drives, spur gears, flexible belts, wire ropes, ropes, ball screw mechanisms, and lead screw mechanisms.

[0015] In some embodiments, the trunk support exoskeleton includes a controller that sends a signal to the actuator to generate an actuator resistance torque between the actuator housing and the actuator shaft when the wearer is bending forward relative to the vertical line of gravity.

[0016] In some embodiments, the actuator resistance torque is a function of how far the wearer is leaning forward relative to the vertical line of gravity.

[0017] In some embodiments, the actuator resistance torque increases as the angle of the trunk support frame relative to the vertical line of gravity increases.

[0018] In some embodiments, the actuator resistance torque decreases as the angle of the trunk support frame relative to the vertical line of gravity decreases.

[0019] In some embodiments, the actuator resistance torque is a function of the angular velocity of the trunk support frame in the sagittal plane.

[0020] In some embodiments, the actuator resistance torque decreases as the forward angular velocity of the trunk support frame in the sagittal plane increases.

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

[0022] In some embodiments, the actuator resistance torque decreases as the posterior angular velocity of the trunk support frame in the sagittal plane increases.

[0023] In some embodiments, the actuator resistance torque increases as the posterior angular velocity of the trunk support frame in the sagittal plane decreases.

[0024] In some embodiments, the controller sends a signal to the actuator to generate a substantially small actuator resistance torque between the actuator housing and the actuator shaft when the wearer is not bending forward relative to the vertical line of gravity.

[0025] In some embodiments, the trunk support exoskeleton includes a tilt sensor and a controller. In some embodiments, the tilt sensor generates a tilt signal indicative of an angle of the trunk support frame relative to a vertical line of gravity in a sagittal plane. In some embodiments, the controller sends a signal to the actuator to generate an actuator resistance torque between the actuator housing and the actuator shaft when the tilt signal indicates an angle of the trunk support frame relative to the vertical line of gravity that is greater than a predetermined angle.

[0026] In some embodiments, the tilt sensor comprises an element or combination of elements selected from the group consisting of an inertial measurement unit (IMU), an inclinometer, an encoder, and an angle sensor.

[0027] In some embodiments, the actuator resistance torque is a function of the tilt signal.

[0028] In some embodiments, the controller sends a signal to the actuator to generate a substantially small actuator resistance torque between the actuator housing and the actuator shaft when the tilt signal indicates that the wearer is not leaning forward relative to the vertical line of gravity.

[0029] In some embodiments, the core support exoskeleton includes a shaft line jacket surrounding the shaft line, hi some embodiments, the shaft line jacket is secured to the core support frame to facilitate adjusting the size of the core support frame without adjusting the size of the shaft line.

[0030] In some embodiments, the core support exoskeleton includes a housing line jacket surrounding the housing line, in some embodiments, the housing line jacket is secured to the core support frame to facilitate size adjustment of the core support frame without adjusting the size of the housing line.

[0031] In some embodiments, the actuator generates the actuator resistance torque by using electrical power.

[0032] In some embodiments, the actuator includes an actuator spring. In some embodiments, a first end of the actuator spring is coupled to an actuator shaft. In some embodiments, a second end of the actuator spring is free within a first range of rotation of the actuator shaft relative to the actuator housing. In some embodiments, the second end of the actuator spring is constrained by the actuator housing within a second range of rotation of the actuator shaft relative to the actuator housing. In some embodiments, in the first range of rotation, the actuator generates an actuator resistance torque by using electrical power. In some embodiments, in the second range of rotation, the spring generates at least a portion of the actuator resistance torque.

[0033] In some embodiments, the actuator spring comprises an element or combination of elements selected from the group consisting of coil springs, leaf springs, bungee cords, rotational springs, elastomeric cords, elastic cords, fabric cords, plastic cords, cords, twine, wire rope elastomers, and string.

[0034] In some embodiments, in a first range of rotation of the actuator shaft relative to the actuator housing, the actuator generates an actuator resistance torque by using electrical power, in some embodiments, in a second range of rotation of the actuator shaft relative to the actuator housing, the actuator resistance torque is the sum of the torque generated by the spring and the torque generated by using electrical power.

[0035] In some embodiments, the trunk support frame is configured to partially surround the wearer's trunk and includes a lower frame portion coupled to a first thigh link and a second thigh link on either side of the wearer.

[0036] In some embodiments, the trunk support frame includes a spinal frame portion coupled to a lower frame portion.

[0037] In some embodiments, the spinal frame portions are adjustable in length to accommodate wearers of various heights.

[0038] In some embodiments, the lower frame portion is width adjustable to accommodate wearers of various width sizes.

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

[0040] In some embodiments, the core support frame includes an upper frame portion coupled to the spine frame portion and configured to apply core support to the wearer's core and thoracic region.

[0041] In some embodiments, the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to the wearer's spine.

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

[0043] In some embodiments, the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to one of a medial-lateral flexion and extension axis of the wearer's lumbar spine.

[0044] Some embodiments described herein are directed to a trunk support exoskeleton for reducing muscle forces on a wearer's back during lumbar forward bending. The trunk support exoskeleton may include a trunk support frame, a first thigh link, a second thigh link, and an actuator. The trunk support frame may be configured to be coupled to a trunk of the wearer. The first thigh link may be configured to be coupled to one of the wearer's thighs. The second thigh link may be configured to be coupled to the other of the wearer's thighs. Each of the first thigh link and the second thigh link may be rotatably coupled to the trunk support frame such that the respective first thigh link or second thigh link may flex or extend relative to the trunk support frame. The actuator may be coupled to the trunk support frame. The actuator may include an actuator housing and an actuator shaft. The actuator may be freely rotatable relative to the trunk support frame. The actuator shaft may be coupled to the first thigh link, and the actuator housing may be coupled to the second thigh link. When the wearer bends forward in the sagittal plane, the actuator generates an actuator resistance torque between the actuator housing and the actuator shaft, thereby generating an extension torque between each of the first and second thigh links and the trunk support frame.

[0045] In some embodiments, the trunk support exoskeleton includes a shaft pulley, a housing pulley, a shaft line, and a housing line. In some embodiments, the shaft pulley is coupled to the actuator shaft. In some embodiments, the housing pulley is coupled to the actuator housing. In some embodiments, the shaft line has a first end wrapped around the shaft pulley and a second end coupled to the first thigh link. In some embodiments, the housing line has a first end wrapped around the housing pulley and a second end coupled to the second thigh link. In some embodiments, the actuator resistance torque can generate a tension force on the housing line and the shaft line, thereby generating an extension torque between the respective first and second thigh links and the trunk support frame.

[0046] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate the present disclosure and, together with the description, further serve to explain its principles and enable one skilled in the art to make and use the same. [Brief description of the drawings]

[0047] [Figure 1] FIG. 1 shows a perspective view of a person wearing a trunk support exoskeleton. [Diagram 2] FIG. 2 shows a perspective view of the trunk support exoskeleton of FIG. [Diagram 3] 2 illustrates another perspective view of the trunk support exoskeleton of FIG. 1. [Figure 4] FIG. 2 shows a side view of a person wearing the trunk support exoskeleton of FIG. 1, in which the person is bending forward in the sagittal plane. [Diagram 5] FIG. 2 shows a perspective view of an actuator with a housing pulley and a shaft pulley for the trunk support exoskeleton of FIG. [Figure 6] FIG. 6 shows a cross-sectional view of the actuator of FIG. [Figure 7] FIG. 6 shows a perspective view of the actuator of FIG. 5 with the shaft pulley removed for illustrative purposes. [Figure 8]FIG. 6 shows a cross-sectional view of the actuator of FIG. 5 with the shaft pulley removed for illustrative purposes. [Figure 9] FIG. 6 shows a perspective view of the actuator of FIG. 5 with the housing pulley and shaft pulley removed for purposes of illustration. [Figure 10] FIG. 6 shows a cross-sectional view of the actuator of FIG. 5 with the housing pulley and shaft pulley removed for purposes of illustration. [Figure 11] 2 shows an enlarged view of a portion of the trunk support exoskeleton of FIG. 1. [Figure 12] FIG. 13 shows a close-up view of a portion of the trunk support exoskeleton showing an alternative connection between the shaft line and the thigh link. [Figure 13] FIG. 2 is a schematic diagram showing how a resistance torque between the housing and shaft of an actuator of the trunk support exoskeleton of FIG. 1 generates an extension torque between the thigh link of the trunk support exoskeleton and the trunk support frame. [Figure 14] This diagram shows the forces acting on a person's back when bending forward in the sagittal plane. [Figure 15] 1 shows a flow chart of a control algorithm for controlling a trunk support exoskeleton. [Figure 16] 2 shows an enlarged view of a portion of the trunk support exoskeleton of FIG. 1. [Figure 17] 2 shows an enlarged view of a portion of the trunk support exoskeleton of FIG. 1. [Figure 18] 2 shows an enlarged view of a portion of the trunk support exoskeleton of FIG. 1. [Figure 19] FIG. 2 shows a cross-sectional view of an actuator for the trunk support exoskeleton of FIG. [Figure 20] 2A-2C show cross-sectional views of an actuator for the trunk support exoskeleton of FIG. 1, illustrating alternative configurations of the actuator springs. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] A trunk support exoskeleton can be used to reduce muscle strength in the wearer's back during lumbar flexion that occurs during activities such as leaning forward and bending. A person may want to wear the exoskeleton to provide support during these activities, and continue to wear the exoskeleton (e.g., for convenience) during other activities, including walking, climbing hills, or climbing stairs or ladders. Some embodiments of the present invention provide an exoskeleton that reduces muscle strength in the wearer's back during leaning forward and bending, while also allowing the wearer to comfortably walk, climb hills, or climb stairs or ladders.

[0049] In some embodiments, the exoskeleton includes a trunk support frame, a first thigh link and a second thigh link, and an actuator that creates an extension torque between the thigh links and the trunk support frame to support the wearer while crouching or bending.

[0050] In some embodiments, the actuator generates an extension torque between the first and second thigh links and the trunk support frame only when the wearer is bending forward in the sagittal plane. In some embodiments, the actuator does not generate an extension torque between the first and second thigh links and the trunk support frame when the user is walking, climbing, or ascending.

[0051] In some embodiments, the actuator generates a torque between the actuator housing and the actuator shaft, which generates an extension torque between the thigh link and the trunk support frame. In some embodiments, the torque generated by the actuator between the actuator housing and the actuator shaft is transferred through a system of pulleys and lines to generate an extension torque between the thigh link and the trunk support frame.

[0052] In some embodiments, the actuator housing and the actuator shaft can rotate relative to one another (e.g., in response to non-reciprocating motion of a thigh link coupled to the actuator housing and the actuator shaft, which occurs, for example, when the wearer's legs do not move in opposite directions at the same speed). Non-reciprocating motion occurs naturally during activities such as walking, climbing, and climbing. For example, during some stages of a walking cycle, both of a person's legs move in the same direction.

[0053] In some embodiments, movement of the first and second thigh links relative to the trunk support frame (e.g., movement while the wearer walks while wearing the trunk support exoskeleton) can transmit forces to the actuator housing and actuator shaft via a system of lines and pulleys. In embodiments in which the actuator housing and actuator shaft can rotate relative to one another, these forces can cause the actuator housing and actuator shaft to rotate relative to one another (e.g., in response to non-reciprocating movement of the thigh links, which occurs, for example, when the wearer's legs do not move in opposite directions at the same speed) if they are other than equal and opposite. Allowing the actuator housing and actuator shaft to rotate relative to one another in response to non-reciprocating movement of the thigh links can allow the wearer to feel more comfortable when walking, climbing, or otherwise while wearing the trunk support exoskeleton. If the actuator housing and actuator shaft could not rotate relative to one another in response to non-reciprocating motion of the thigh link, tension in the lines connecting the actuator housing and actuator shaft to the first and second thigh links could interfere with that non-reciprocating motion, making walking, lifting, or climbing uncomfortable or impossible for the user.

[0054] In some embodiments, the actuator can rotate relative to the trunk support frame (eg, in response to non-reciprocating motion of a thigh link coupled to the actuator housing and actuator shaft).

[0055] Allowing the actuator to rotate relative to the trunk support frame in response to non-reciprocating motion of the thigh link may allow the wearer to feel more comfortable when walking, climbing, or climbing while wearing the trunk support exoskeleton. If the actuator cannot rotate relative to the trunk support frame in response to non-reciprocating motion of the thigh link, tension in the actuator housing and lines connecting the actuator shaft to the first and second thigh links may impede that non-reciprocating motion, making walking, climbing, or climbing uncomfortable or impossible for the user.

[0056] These and other embodiments are described in further detail below with reference to the figures.

[0057] 1-4 show an embodiment of a trunk supporting exoskeleton 100. As described below, the trunk supporting exoskeleton 100 can be worn by a wearer 200 to reduce the wearer's back muscle force during lumbar forward bending that occurs during movements such as bending and bending. FIG. 1 shows a perspective view of the trunk supporting exoskeleton 100 worn by a wearer 200. FIG. 2 shows a perspective view of the trunk supporting exoskeleton 100 with the wearer 200 removed to further show the components of the trunk supporting exoskeleton 100. FIG. 3 shows another perspective view of the trunk supporting exoskeleton 100. FIG. 4 shows the wearer 200 wearing the trunk supporting exoskeleton 100 and bending forward in the sagittal plane. In this position, a lumbar forward bending is occurring. Angle 240 represents how much the wearer 200 has bent along the forward direction.

[0058] For example, as shown in FIG. 1 , the trunk support exoskeleton 100 may include a trunk support frame 102 configured to be coupled to a wearer's trunk 202, a first thigh link 104 and a second thigh link 106 configured to be coupled to thighs 204 and 206 of the wearer 200, respectively, and an actuator 118 that generates extension torque between the first thigh link 104 and the trunk support frame 102, and between the second thigh link 106 and the trunk support frame 102.

[0059] As used herein and elsewhere in this disclosure, the wearer's torso 202 may include the wearer's chest, abdomen, pelvis, and back. The wearer's torso 202 may be, for example, the wearer's body excluding the head and limbs, or the central portion of the wearer from which the neck and limbs extend.

[0060] As described above, the trunk support exoskeleton 100 may include a first thigh link 104 and a second thigh link 106 configured to be coupled to respective thighs 204 and 206 of a wearer 200. When the first thigh link 104 and the second thigh link 106 are coupled to the respective thighs 204 and 206, the first thigh link 104 and the second thigh link 106 move in concert with the wearer's thighs 204 and 206, respectively, such that the first thigh link 104 and the second thigh link 106 respectively flex and extend relative to the trunk support frame 102.

[0061] In some embodiments, the first thigh link 104 and the second thigh link 106 are rotatably coupled to the trunk support frame 102 such that the first thigh link 104 and the second thigh link 106 can flex or extend relative to the trunk support frame 102. As shown by arrow 220 in FIG. 4, flexion of the first thigh link 104 relative to the trunk support frame 102 occurs when the first thigh link 104 and the trunk support frame 102 rotate toward each other. Similarly, flexion of the second thigh link 106 relative to the trunk support frame 102 occurs when the second thigh link 106 and the trunk support frame 102 rotate toward each other. As shown by arrow 222 in FIG. 4, extension of the first thigh link 104 relative to the trunk support frame 102 occurs when the first thigh link 104 and the trunk support frame 102 rotate away from each other. Similarly, extension of the second thigh link 106 relative to the trunk support frame 102 occurs when the second thigh link 106 and the trunk support frame 102 rotate away from each other.

[0062] 1 and 2, the trunk support exoskeleton 100 can include an actuator 118. In some embodiments, as described below, the actuator 118 can generate extension torques between the first thigh link 104 and the trunk support frame 102 and between the second thigh link 106 and the trunk support frame 102 to support the wearer during lumbar flexion. In some embodiments, as described below, the actuator 118 is coupled to the trunk support frame 102 but is free to rotate relative to the trunk support frame 102.

[0063] The actuator 118 is described below with reference to Figures 1 and 5-10. As shown in Figures 5 and 6, in some embodiments, the actuator 118 includes an actuator housing 120, a housing pulley 124, a housing line 128 (shown in Figure 7), an actuator shaft 122, a shaft pulley 126, and a shaft line 130. In Figures 7 and 8, the actuator 118 is shown with the shaft pulley 126 removed for illustration purposes. In Figures 9 and 10, the actuator 118 is shown with the housing pulley 124 and the shaft pulley 126 removed for illustration purposes.

[0064] In some embodiments, the actuator housing 120 and the actuator shaft 122 can rotate relative to one another along axis 243. The actuator 118 can be coupled to the trunk support frame 102 at any point, however, both the actuator housing 120 and the actuator shaft 122 can rotate freely relative to the trunk support frame 102.

[0065] In some embodiments, the actuator 118 can generate a torque between the actuator housing 120 and the actuator shaft 122 .

[0066] 5 and 6, the shaft pulley 126 is coupled to the actuator shaft 122 and may rotate with the actuator shaft 122 (e.g., when the actuator 118 generates a torque between the actuator housing 120 and the actuator shaft 122). Any suitable method may be used to couple the shaft pulley 126 to the actuator shaft 122 such that the shaft pulley 126 and the actuator shaft 122 rotate together. For example, a fastener may be used to couple the shaft pulley 126 to the actuator shaft 122.

[0067] 7 and 8, the housing pulley 124 is coupled to the actuator housing 120 and may rotate with the actuator housing 120 along axis 243 (e.g., when the actuator 118 generates a torque between the actuator housing 120 and the actuator shaft 122). Any suitable method may be used to couple the housing pulley 124 to the actuator housing 120 such that the housing pulley 124 and the actuator housing 120 rotate together. For example, fasteners may be used to couple the housing pulley 124 to the actuator housing 120.

[0068] In some embodiments, a first end of the shaft line 130 can be coupled to the shaft pulley 126 (e.g., wrapped around the shaft pulley 126) and a second end of the shaft line 130 can be coupled to the first thigh link 104, such that a pulling force on the shaft line 130 (e.g., generated by a torque generated by the actuator 118 between the actuator housing 120 and the actuator shaft 122) generates an extension torque between the first thigh link 104 and the trunk support frame 102.

[0069] The shaft line 130 may be or include any device or combination of devices capable of performing the indicated functions. Examples of the shaft line 130 include, but are not limited to, wire, cable, belt, fabric rope, plastic rope, cord, twine, chain, bicycle-type chain, wire rope, string, and combinations thereof. In some embodiments, the shaft line 130 comprises a multi-strand wire rope having a maximum strength of about 200 pounds.

[0070] In some embodiments, a first end of the housing line 128 can be coupled to the housing pulley 124 (e.g., wrapped around the housing pulley 124) and a second end of the housing line 128 can be coupled to the second thigh link 106, such that a pulling force on the housing line 128 (e.g., generated by a torque generated by the actuator 118 between the actuator housing 120 and the actuator shaft 122) generates an extension torque between the second thigh link 106 and the trunk support frame 102.

[0071] The housing line 128 may be or include any device or combination of devices capable of performing the indicated functions. Examples of the housing line 128 include, but are not limited to, wire, cable, belt, fabric rope, plastic rope, cord, twine, chain, bicycle-type chain, wire rope, string, and combinations thereof. In some embodiments, the housing line 128 comprises a multi-strand wire rope having a maximum strength of about 200 pounds.

[0072] In some embodiments, the first thigh link 104 includes a first thigh link pulley 108 that rotates with the first thigh link 104 about an axis 158 relative to the trunk support frame 102, as shown for example in FIG. 11 . In some embodiments, the second end of the shaft line 130 is coupled (e.g., wrapped) around the first thigh link pulley 108 such that pulling force in the shaft line 130 generates an extension torque between the first thigh link 104 and the trunk support frame 102. In some embodiments, the second end of the shaft line 130 is directly connected to the first thigh link 104 such that pulling force in the shaft line 130 generates a torque about the axis 158, as shown for example in FIG. 12 .

[0073] In some embodiments, the second thigh link 106 includes a second thigh link pulley 110 that rotates with the second thigh link 106 about an axis 160 relative to the trunk support frame 102. In some embodiments, the second end of the housing line 128 is coupled (e.g., wrapped) to the second thigh link pulley 110 such that pulling force on the housing line 128 generates an extension torque between the second thigh link 106 and the trunk support frame 102. In some embodiments, the second end of the housing line 128 is directly connected to the second thigh link 106 such that pulling force on the housing line 128 generates a torque about the axis 160.

[0074] As mentioned above, in some embodiments, the actuator 118 can generate a torque between the actuator housing 120 and the actuator shaft 122. FIG. 13 shows a schematic of how this torque can be transmitted through the system of pulleys and lines described above. In FIG. 13, the system is expanded into a two-dimensional schematic to show the torque transmission. As shown in FIG. 13, when the actuator 118 generates a resistive torque between the actuator housing 120 and the actuator shaft 122, the torque is transmitted to the housing pulley 124 (coupled to and rotating with the actuator housing 120) and the shaft pulley 126 (coupled to and rotating with the actuator shaft 122). The torque transmitted to the housing pulley 124 and the shaft pulley 126 then generates tension forces in the housing line 128 and the shaft line 130. These tension forces result in an extension torque in the direction of the arrow 222 between the thigh links 104 and 106 and the trunk support frame 102.

[0075] In Figs. 5 and 6, the shaft pulley 126 and the housing pulley 124 have equal diameters. However, in other embodiments (e.g., as shown in Fig. 13), the shaft pulley 126 and the housing pulley 124 may have unequal diameters. In the embodiment illustrated in Figs. 1-4, the first thigh link pulley 108 and the second thigh link pulley 110 have equal diameters. However, in other embodiments, the first thigh link pulley 108 and the second thigh link pulley 110 may have unequal diameters. In an embodiment in which the shaft pulley 126 and the housing pulley 124 have equal diameters and the first thigh link pulley 108 and the second thigh link pulley 110 have equal diameters, the torque between the actuator housing 120 and the actuator shaft 122 is transmitted equally to the thigh links 104 and 106. As a result, the extension torque between the trunk support frame 102 and the thigh links is equal to twice the torque generated by the torque actuator 118. However, in embodiments in which the diameters of the shaft pulley 126 and the housing pulley 124 are not equal, or the diameters of the first thigh link pulley 108 and the second thigh link pulley 110 are not equal, unequal torques may be transmitted to the thigh links 104 and 106.

[0076] Returning to FIG. 4, during operation, when the wearer 200 bends forward in the sagittal plane such that a predetermined portion 147 of the trunk support frame 102 passes beyond a predetermined angle 242 from the vertical line of gravity 244, the actuator 118 can generate a resistance torque between the actuator housing 120 and the actuator shaft 122. As explained, this resistance torque can cause a pulling force on the housing line 128 and the shaft line 130 (e.g., by a torque generated between the housing pulley 124 and the shaft pulley 126), which can cause an extension torque between the trunk support frame 102 and the first thigh link 104 and the second thigh link 106. The extension torque between the thigh link 104 and the trunk support frame 102 can attempt to rotate the first thigh link 104 and the trunk support frame 102 away from each other. Similarly, an extension torque between the second thigh link 106 and the trunk support frame 102 can tend to rotate the second thigh link 106 and the trunk support frame 102 away from each other.

[0077] The extension torque between the trunk support frame 102 and the first thigh link 104 and the second thigh link 106 can exert a trunk support force 230 (shown in FIG. 4 ) on the wearer's trunk 202. The trunk support force 230 exerted by the trunk support frame 102 on the wearer's trunk 202 can help reduce muscle forces in the wearer's lower back in the general region of 208. In the embodiment of FIG. 4 , the trunk support force 230 is generally exerted on the wearer's chest region 210. However, the trunk support force 230 may be exerted on different portions of the wearer's trunk 202 depending on the design of the upper frame portion 306 of the trunk support frame 102. At the same time, the first thigh link 104 and the second thigh link 106 can exert a force on the wearer's thighs 204 and 206.

[0078] In some embodiments, when the wearer 200 is not bending forward in the sagittal plane (i.e., when the predetermined portion 147 of the trunk support frame 102 is not past a predetermined angle 242 from the vertical line of gravity 244), the actuator 118 does not generate a resistance torque between the actuator shaft 122 and the actuator housing 120. In such embodiments, the actuator 118 does not generate an extension torque between the trunk support frame 102 and the first thigh link 104 and the second thigh link 106. This means that the wearer 200 can walk, climb, and descend stairs and ramps without any force being applied to the wearer 200 from the trunk support frame 102 as long as the wearer 200 is not bending forward in the sagittal plane.

[0079] However, when the wearer 200 is bending forward in the sagittal plane (i.e., when a predetermined portion 147 of the trunk support frame 102 passes beyond a predetermined angle 242 from the vertical line of gravity 244, as shown in FIG. 12 ), the trunk support force 230 from the trunk support frame 102 begins to help support the wearer's trunk 202.

[0080] Examples of the predetermined angle 242 may be 5 degrees, 10 degrees, or 15 degrees. In some embodiments, the predetermined angle 242 may be zero.

[0081] In some embodiments, when the wearer 200 is not bending forward in the sagittal plane, the actuator 118 generates a substantially small resistive torque between the actuator shaft 122 and the actuator housing 120. This substantially small resistive torque generated by the actuator 118 may allow the thigh links 104 and 106 to move substantially freely relative to the trunk support frame 102. This substantially small resistive torque generated by the actuator 118 may allow the thigh links 104 and 106 to remain in contact with the wearer's thighs during walking. This substantially small resistive torque generated by the actuator 118 may be selected to be small enough so that it does not impede or interfere with the wearer during walking, but still allows the thigh links to move with the wearer's thighs.

[0082] As noted above, a person may desire to wear the exoskeleton 100 for support when bending forward in the sagittal plane as described above, and may also desire to continue wearing the exoskeleton 100 (e.g., as it is convenient) during other activities, including walking, walking up a slope, or climbing stairs or ladders. In some embodiments, the actuator housing 120 and the actuator shaft 122 may rotate relative to one another along axis 243 in response to non-reciprocating motion to allow the wearer to comfortably walk, walk up a slope, or climb stairs or ladders while wearing the exoskeleton 100. This rotation may occur, for example, when the wearer's legs do not move in opposite directions at the same speed.

[0083] In some embodiments, the actuator housing 120 and the actuator shaft 122 can rotate relative to one another in response to non-reciprocating motion of the thigh links 104 and 106 when the actuator 118 does not generate a resistive torque between the actuator housing 120 and the actuator shaft 122 (e.g., when the wearer 200 is not bending forward in the sagittal plane).

[0084] In some embodiments, the actuator housing 120 and the actuator shaft 122 can rotate relative to one another in response to non-reciprocating motion of the thigh links 104 and 106, while the actuator 118 generates a substantially small resistive torque between the actuator housing 120 and the actuator shaft 122.

[0085] In some embodiments, extension of the first thigh link 104 or the second thigh link 106 relative to the torso support frame 102 (e.g., as the wearer 200 walks) may transmit forces to the actuator shaft 122 and actuator housing 120 via the system of lines 128, 130 and pulleys 124, 126 described above. In embodiments in which the actuator housing 120 and the actuator shaft 122 can rotate relative to one another, these forces may cause the actuator housing 120 and the actuator shaft 122 to rotate relative to one another (e.g., in response to non-reciprocating motion of the wearer's legs) other than when the forces are equal and opposite. If the actuator housing 120 and the actuator shaft 122 were not able to rotate relative to one another in response to non-reciprocating motion of the person's legs, tension in the lines 128, 130 connecting the actuator housing 120 and the actuator shaft 122 to the first thigh link 104 and the second thigh link 106 could interfere with the non-reciprocating motion of the thigh links 104 and 106 relative to the trunk support frame 102, making walking, climbing, or other movements uncomfortable or impossible for the wearer.

[0086] In some embodiments, to allow a wearer to comfortably walk, walk up a slope, or climb stairs or ladders while wearing the exoskeleton 100, the actuators 118 are rotatably coupled to the trunk support frame 102 such that the actuators 118 are free to rotate relative to the trunk support frame 102. In some embodiments, there may be a friction torque that opposes the rotation of the actuators 118 relative to the trunk support frame 102.

[0087] The actuator 118 may be coupled to the trunk support frame 102 via any suitable mechanism that allows the actuator 118 to rotate relative to the trunk support frame 102. For example, in some embodiments, the actuator 118 is coupled to the trunk support frame 102 via a ball bearing mechanism. As another example, in some embodiments, a bushing may allow the actuator 118 to rotate relative to the trunk support frame 102. In the embodiment illustrated in FIGS. 1-10 , for example, an outer race 142 of a ball bearing 140 (shown in FIG. 9 ) is coupled to the trunk support frame 102 and an inner race 144 of the ball bearing 140 is coupled to the actuator housing 120. This configuration allows the actuator housing 120 to rotate relative to the trunk support frame 102.

[0088] The coupling of the actuator housing 120 to the trunk support frame 102 is not limited to the configuration shown. Rather, the actuator housing 120 may be coupled to the trunk support frame 102 via any suitable mechanism that allows the actuator housing 120 to rotate relative to the trunk support frame 102. For example, bushings may be used to allow rotation of the actuator housing 120 relative to the trunk support frame 102.

[0089] As previously mentioned, in some embodiments, the actuator 118 is rotatable relative to the trunk support frame 102, and in some embodiments, the actuator housing 120 and the actuator shaft 122 are rotatable relative to one another. In some embodiments, the actuator 118 is rotatable relative to the trunk support frame 102, and the actuator housing 120 and the actuator shaft 122 are rotatable relative to one another. That is, in some embodiments, the actuator housing 120 and the actuator shaft 122 are rotatable relative to the trunk support frame 102 and relative to one another.

[0090] In some embodiments, the trunk support exoskeleton 100 includes a controller 146 that sends signals to the actuators 118 that generate a resistive torque between the actuator housing 120 and the actuator shaft 122 (e.g., when the wearer 200 is bending forward in the sagittal plane, as described). The controller 146 may be or include any device or combination of devices capable of performing the indicated functions. Examples of the controller 146 include, but are not limited to, analog devices, analog computing modules, digital devices including, but not limited to, small scale integrated circuits, medium scale integrated circuits, and large scale integrated circuits, application specific integrated circuits, programmable gate arrays, and programmable logic arrays, and digital computing modules including, but not limited to, microcomputers, microprocessors, microcontrollers, and programmable logic controllers. In some embodiments, the controller 146 includes an element or combination of elements selected from the group consisting of an electromechanical relay or a MOSFET switch.

[0091] In some embodiments, the core support exoskeleton 100 includes a tilt sensor 150 that generates a tilt signal 156. In some embodiments, the tilt signal 156 can indicate the angle of the core support frame 102 from the vertical line of gravity 244 in the sagittal plane. This angle is shown at 240 in FIG.

[0092] Sensor 150 may be or may include any device or combination of devices capable of performing the indicated functions. Examples of tilt sensor 150 include, but are not limited to, an inertial measurement unit (IMU), an inclinometer, an encoder, and an angle sensor.

[0093] In operation, when the tilt signal 156 indicates that the wearer 200 or the trunk support frame 102 is bending forward in the sagittal plane (i.e., when the tilt signal indicates that the angle of the trunk support frame 102 from the vertical line of gravity 244 in the sagittal plane is greater than a predetermined angle 242), the controller 146 can send a signal to the actuator 118 to generate a resistive torque between the actuator housing 120 and the actuator shaft 122. As described, the resistive torque generated between the actuator housing 120 and the actuator shaft 122 can generate a tensile force in the housing line 128 and the shaft line 130, which can provide an extension torque between the trunk support frame 102 and the thigh links 104 and 106.

[0094] The following is an example of calculating the resistive torque of the actuator 118:

[0095] For context, Figure 14 shows a diagram of the forces acting on a person's back when bending forward in the sagittal plane in the absence of a trunk-supporting exoskeleton. In the static or quasi-static case, when the person is not lifting any load, the bending moment (torque) applied to L5 / S1 is [M B gl B sin(∝)], where M B represents the mass of the upper body (including the trunk, head, and arms) and the part being lifted by the arms, g represents the gravitational acceleration, and l B is the distance between the center of gravity of the upper body and the L5 / S1 point. ∝ represents the angle of the person's trunk from the vertical line of gravity 244. Bending moments increase during loading and dynamic manipulation.

[0096] As described above, when the wearer 200 wearing the trunk support exoskeleton 100 is bending forward in the sagittal plane, the actuator 118 can generate an extension torque between the trunk support frame 102 and the first thigh link 104 and the second thigh link 106. The extension torque generated by the actuator 118 can generate a trunk support force 230 in the wearer that counteracts the bending moment due to the weight of the trunk and parts. This changes the bending moment (torque) applied to L5 / S1 to a new value [(M B l B )gsin(∝)-FL], where L is the distance from the trunk support force 230 to the point L5 / S1 as shown in FIG. 14. This illustrates the basic concept of a trunk supporting exoskeleton, which reduces the bending moment at L5 / S1 and therefore reduces the chance of injury during repetitive manipulations.

[0097] Erector spinae muscle tension F M decreases as the trunk support force 230 increases. In the more general case, the erector spinae force F M teeth,

number

number

number

[0098] C is a constant,

number

number

[0099] Spine compression force F CS similarly decreases as the core support force 230 increases and can be expressed as:

number

[0100] In this analysis, F CS and F M It is assumed that the force F acts perpendicular to the trunk support force 230. In theory, if the exoskeleton support torque FL is selected as in equation (3), the force F M reduces to zero (Eq. 4), and the force F CS is substantially reduced (Eq. 5).

number

number

[0101] This means that, theoretically, by controlling the trunk support force 230 acting on the wearer 200, the erector spinae muscle force F M to zero, and the spinal compression force F CS This means that it is possible to reduce M to smaller values. However, the parameters in equation (3) can be difficult to measure or calculate accurately. For example, M B is not a known quantity, l B is only an estimate, and the measurement of ∝ is not precise. Nevertheless, any attempt to cancel the terms in equation (1) using equation (3) will result in a higher spinal compression force F CS and erector spinae strength F M In most cases, this reduces the bending acceleration. As these equations show, as the trunk support force 230 increases, the erector spinae force and the spinal compression force (F CS and F M ) decreases.

[0102] The term FL is referred to as the support torque because it supports the wearer 200 during bending and leaning forward. As can be seen from Figure 14, this support torque is an extension torque. In some embodiments, the exoskeleton support torque FL can be chosen as follows:

number

[0103] K1 and K2 are the accelerations JPEG2025514673000012.jpg22 represents an approximation of the parameters in equation (3) when it is negligible. As shown by equation (6), the exoskeleton support torque FL in some embodiments includes a torque that is a function of the angle ∝. In some embodiments, as shown by equation (6), the exoskeleton support torque FL is a function of the torque of the trunk support frame.

number

number

number

number

[0104] If the diameters of the shaft pulley 126 and the housing pulley 124 are equal, and if the diameters of the first thigh link pulley 108 and the second thigh link pulley 110 are equal, T R The resistance torque of the actuator 118, represented by:

number

[0105] In some embodiments, the resistance torque is a function of the tilt signal 156, as shown by Equation 7. In some embodiments, the resistance torque is a function of how far the wearer is bending forward in the sagittal plane. In some embodiments, the resistance torque increases as the angle of the trunk support frame 102 from the vertical line of gravity 244 increases. In some embodiments, the resistance torque decreases as the angle of the trunk support frame 102 from the vertical line of gravity 244 decreases. In some embodiments, the resistance torque is a function of the angular velocity of the trunk support frame 102 in the sagittal plane. In some embodiments, the resistance torque decreases as the forward angular velocity of the trunk support frame 102 in the sagittal plane increases. This may allow, for example, the wearer 200 to bend forward in the sagittal plane with less effort to push the trunk support frame 102. In some embodiments, the resistance torque increases as the forward angular velocity of the trunk support frame 102 in the sagittal plane decreases. In some embodiments, the resistance torque decreases as the backward angular velocity of the trunk support frame 102 in the sagittal plane increases. In some embodiments, as the rearward angular velocity of the trunk support frame 102 in the sagittal plane decreases, the resistive torque increases.

[0106] In some embodiments, the controller 146 stops sending signals to the actuator 118 to generate a resistance torque according to equation (7) when the tilt signal 156 indicates that the wearer 200 is no longer bending forward in the sagittal plane.

[0107] In some embodiments, the controller 146 sends a signal to the actuator 118 to generate a substantially small resistive torque between the actuator housing 120 and the actuator shaft 122 when the tilt signal 156 indicates that the wearer 200 is not bending forward in the sagittal plane.

[0108] In some embodiments, the controller 146 sends a signal to the actuator 118 to generate zero torque when the tilt signal 156 indicates that the wearer 200 is not bending forward in the sagittal plane.

[0109] In some embodiments, the actuator 118 generates a biased resistive torque T biased By providing a small amount of tension to the housing line 128 and the shaft line 130, T shown in Equation 8 biased provides a small initial tension force on the housing line 128 and the shaft line 130.

number

[0110] 15 shows a flow chart of the control algorithm for the exoskeleton 100. The control software can begin by reading one or more of the voltage of the battery 145, the temperature of the actuator 118 or its components (e.g., the electric motor 116), the tilt signal 156, or the rate of change of the tilt signal 156.

[0111] In embodiments in which the voltage of the battery 145 is checked, if the voltage of the battery 145 is below a minimum voltage and the calculated resistive torque is less than a threshold torque, the actuator 118 may be disabled.

[0112] In embodiments where the actuator temperature is checked, the resistive torque may be reduced if the actuator temperature is higher than an acceptable temperature.

[0113] In embodiments where the tilt signal 156 and / or the rate of change of the tilt signal 156 are read, the resistive torque of the actuator 118 may be calculated using Equation 8.

number

[0114] In some embodiments, the calculated resistive torque may be checked to see if it is negative or positive, and in some embodiments, if the calculated resistive torque is negative, the resistive torque may be set to zero.

[0115] In some embodiments, the resistive torque can be checked to see if it is greater than the maximum torque of the actuator 118 (or the maximum torque that can be generated by the electric motor 116 of the actuator 118). max The calculated resistance torque is called the maximum torque T max If the torque is greater than T, max It can be set as:

[0116] Additional aspects related to the trunk support frame 102 will now be described with reference to Figures 1 and 16-18. As shown in Figure 1, in some embodiments, the trunk support frame 102 includes a lower frame portion 302, a spine frame portion 304, and an upper frame portion 306.

[0117] 1, in some embodiments, the lower frame portion 302 is located substantially behind the wearer 200 when the trunk support exoskeleton 100 is worn. In some embodiments, the lower frame portion 302 is configured to partially surround the wearer's trunk 202 and hips. In some embodiments, the lower frame portion 302 is coupled to the first thigh link 104 and the second thigh link 106 from either side of the wearer 200.

[0118] The spine frame portion 304 can be coupled (e.g., rotatably coupled) to the lower frame portion 302. In some embodiments, the spine frame portion 304 can be rotatable about an axis 320 relative to the lower frame portion 302. This can allow, for example, the wearer 200 to freely rotate his or her upper body relative to his or her lower body. In some embodiments, the axis 320 is substantially parallel to the wearer's spine. Arrow 322 indicates the direction of rotation of the spine frame portion 304 relative to the lower frame portion 302 about the axis 320. In some embodiments, the spine frame portion 304 is located behind the wearer 200 when the trunk support exoskeleton 100 is worn.

[0119] The upper frame portion 306 can be coupled (e.g., rotatably coupled) to the spinal frame portion 304. In some embodiments, the upper frame portion 306 can be rotatable about an axis 320 relative to the spinal frame portion 304. This can allow, for example, the wearer 200 to freely rotate his / her upper body relative to his / her lower body. In some embodiments, the axis 320 is substantially parallel to the wearer's spine. Arrow 322 indicates a direction of rotation of the upper frame portion 306 relative to the spinal frame portion 304 about the axis 320. In some embodiments, the upper frame portion 306 can be rotatable about an axis 324 relative to the spinal frame portion 304. This can allow, for example, the wearer 200 to freely rotate his / her upper body relative to his / her lower body. In some embodiments, the axis 324 is substantially parallel to one of the medial-lateral flexion and extension axes of the wearer's lumbar spine. Arrow 328 indicates a direction of rotation of the upper frame portion 306 relative to the spinal frame portion 304 about the axis 324.

[0120] In some embodiments, the upper frame portion 306 is configured to contact the wearer's trunk 202 such that the upper frame portion 306 can apply a force (e.g., trunk support force 230 shown in FIG. 6 ) to the front of the wearer's trunk 202. In some embodiments, the upper frame portion 306 is configured to contact the chest region 210 of the wearer's trunk 202 such that the upper frame portion 306 can apply a force (e.g., trunk support force 230 shown in FIG. 4 ) to the chest region 210 of the wearer's trunk 202. In some embodiments, the upper frame portion 306 is configured to contact the shoulder region 218 of the wearer's trunk 202 such that the upper frame portion 306 can apply a force (e.g., trunk support force 230) to the shoulder region 218 of the wearer's trunk 202. As shown in FIGS. 2 and 3 , in some embodiments, the upper frame portion 306 includes shoulder straps 308. In some embodiments, as shown in FIGS. 2 and 3, the upper frame portion 306 includes a chest strap 310.

[0121] As previously mentioned, in some embodiments, spinal frame portion 304 is rotatable relative to lower frame portion 302, and in some embodiments, upper frame portion 306 is rotatable relative to spinal frame portion 304. In some embodiments, both upper frame portions 306 are rotatable relative to spinal frame portion 304, and spinal frame portion 304 is rotatable relative to lower frame portion 302.

[0122] In some embodiments, the height of the trunk support frame 102 is adjustable. In some embodiments, the trunk support frame 102 includes an adjustment mechanism 326 (shown in FIG. 2 ) for adjusting the height of the trunk support frame 102. For example, in some embodiments, the upper frame portion 306 is configured to slide linearly along the spine frame portion 304 to adjust the height of the trunk support frame 102. In some embodiments, the height of the trunk support frame 102 can be increased or decreased as indicated by arrows 374 and 378 in FIG. 2 .

[0123] In some embodiments, the lower frame portion 302 is adjustable in width to accommodate a variety of people. In some embodiments, the trunk support frame 102 includes an adjustment mechanism 255 (shown in FIG. 16 ) for adjusting the width of the lower frame portion 302. For example, in some embodiments, the adjustment mechanism 255 can increase or decrease the width of the lower frame portion 302, as shown by arrows 332 and 334 in FIG. 16 .

[0124] In some embodiments, the lower frame portion 302 is depth adjustable to accommodate a variety of people. In some embodiments, the trunk support frame 102 includes an adjustment mechanism 329 (shown in FIG. 17 ) for adjusting the depth of the lower frame portion 302. For example, in some embodiments, the adjustment mechanism 329 can increase or decrease the depth of the lower frame portion 302, as shown by arrows 336 and 338 in FIG. 17 .

[0125] As mentioned above, in some embodiments, the trunk support frame 102 may be adjustable in width, length, and depth to accommodate a variety of wearers. In some such embodiments, as shown in FIGS. 16 and 18, a shaft line jacket 236 surrounds the shaft line 130 and is secured to the trunk support frame 102 at locations 250 and 252. This configuration may help to facilitate size adjustment of the trunk support frame 102 without having to adjust the size of the shaft line 130. Similarly, in some embodiments, a housing line jacket 238 surrounds the housing line 128 and is secured to the trunk support frame 102. This configuration may help to facilitate size adjustment of the trunk support frame 102 without having to adjust the size of the housing line 128. FIG. 18 illustrates generally how the shaft line 130 may be surrounded by the jacket 236.

[0126] Further aspects regarding the actuator 118 will now be described with reference to FIGS.

[0127] The actuator 118 may be or include any device or combination of devices capable of performing the indicated functions. Examples of the actuator 118 include electric motors, including, but not limited to, AC (alternating current) motors, brushed DC (direct current) motors, brushless DC motors, electronically commutated motors (ECMs), stepper motors, and combinations thereof. In some embodiments, the actuator 118 comprises a transmission system such as a harmonic drive, planetary gears, ball screw mechanisms, lead screw mechanisms, worm gears, and combinations thereof. In some embodiments, the actuator 118 comprises a hydraulic actuator.

[0128] In some embodiments, the actuator 118 includes an electric motor 116 configured to generate a torque between the actuator shaft 122 and the actuator housing 120 using electrical power. The electric motor 116 may be or include any device or combination of devices capable of performing the indicated functions. Examples of electric motors include, but are not limited to, an element or combination of elements selected from the group consisting of electric motors, including, but not limited to, AC (alternating current) motors, brushed DC (direct current) motors, brushless DC motors, ECMs, stepper motors, and combinations thereof.

[0129] In some embodiments, the actuator 118 includes a transmission system for varying and adjusting the torque of the actuator 118. The transmission system may be or include any device or combination of devices capable of performing the indicated functions. Examples of transmission systems include, but are not limited to, gears, worm gears, gear trains, pulleys, lines, belts, toothed belts, toothed pulleys, planetary gears, harmonic drives, spur gears, flexible belts, wire ropes, ropes, ball screw mechanisms, and lead screw mechanisms.

[0130] In some embodiments, as shown in FIGS. 19 and 20, the actuator 118 includes an actuator spring 196 that creates a resistive torque between the actuator shaft 122 and the actuator housing 120 .

[0131] In some embodiments, the actuator 118 includes both an electric motor 116 and an actuator spring 196 to generate a resistive torque between the actuator shaft 122 and the actuator housing 120 .

[0132] 19, the actuator spring 196 can include a first end 246 and a second end 248. The first end 246 of the actuator spring 196 can be directly or indirectly coupled to the actuator shaft 122 such that when the actuator shaft 122 rotates relative to the actuator housing (e.g., in response to bending of the wearer 200 in the sagittal plane), the first end 246 of the actuator spring 196 rotates with the actuator shaft 122.

[0133] When the actuator shaft 122 is within a first range of rotation 260 of the actuator shaft 122 relative to the actuator housing 120, the second end 248 of the actuator spring 196 may be free. When the actuator shaft 122 rotates beyond the first range of rotation relative to the actuator housing 120 (e.g., by rotating in a clockwise direction relative to the actuator housing 120), the second end 248 of the actuator spring 196 may become constrained by the actuator housing 120. In other words, in this second range of rotation, the second end 248 of the actuator spring 196 may be directly or indirectly coupled to the actuator housing 120 such that the second end 248 of the actuator spring 196 rotates with the actuator housing 120. When the actuator shaft 122 is within this second range of rotation 262 in which the second end 248 of the spring 196 is constrained, further rotation of the actuator shaft 122 in the same direction (e.g., clockwise) relative to the actuator housing 120 may cause the spring 196 to deflect, thereby causing the spring 196 to exert a spring resistance torque on the actuator shaft 122. In some embodiments, the actuator housing 120 may include a housing protrusion 254 (shown in FIG. 19 ) that constrains the second end 248 of the actuator spring 196. As shown in FIG. 19 , as the actuator shaft 122 rotates relative to the actuator housing 120 (e.g., in a clockwise direction), the second end 248 comes into engagement with the housing protrusion 254. After the second end 248 engages the housing protrusion 254, the second end 248 is no longer able to rotate relative to the actuator housing 120. Further rotation of the actuator shaft 122 relative to the actuator housing 120 in the same direction causes the actuator spring 196 to bend, resisting rotation of the actuator shaft 122 relative to the actuator housing 120 .

[0134] The above-described configuration can allow for the creation of a resistive torque not only through the use of electrical power, but also through the passive use of the actuator spring 196. In operation, when the actuator shaft 122 is within a first range of rotation, the electric motor 116 can generate a resistive torque between the actuator shaft 122 and the actuator housing 120 by using electrical power. When the actuator shaft 122 is within a second range of rotation, the actuator spring 196 can provide a spring resistive torque between the actuator shaft 122 and the actuator housing 120. In some embodiments, when the actuator shaft 122 is within the second range of rotation, the electric motor 116 can also provide a motor resistive torque to the actuator shaft 122 relative to the actuator housing 120. In such embodiments, the resistive torque is the sum of both the spring torque and the torque generated by the motor 116. The technique of adding actuator spring torque in parallel with the electric motor torque described above is useful for increasing the torque capability of the actuator 118.

[0135] Examples of actuator springs 196 include, but are not limited to, coil springs, rotational springs, leaf springs, helical springs, bungee cords, elastomeric cords, elastic cords, elastic cloth cords, plastic cords, elastomeric cords, twine, wire rope elastomers, string, and combinations thereof.

[0136] In the embodiment shown in FIG. 19, the first end 246 of the spring 196 is coupled to the actuator shaft 122. However, in other embodiments, such as the embodiment shown in FIG. 20, the first end 246 of the spring 196 is instead coupled to the actuator housing 120 such that when the actuator housing 120 rotates relative to the actuator shaft 122 (e.g., in response to the wearer 200 bending in the sagittal plane), the first end 246 of the actuator spring 196 rotates with the actuator housing 120. As shown in FIG. 20, when the actuator housing 120 is within a first rotational range 260 relative to the actuator shaft 122, the second end 248 of the spring 196 is free to rotate. When the actuator housing 120 rotates beyond the first rotational range 260 relative to the actuator shaft 122 (e.g., in a clockwise direction), the second end 248 of the spring 196 may become constrained (e.g., by a shaft constraining element 234 coupled to the actuator shaft 122). Based on the two embodiments of FIG. 19 and FIG. 20, it can be seen that in general, the spring 196 includes a first end 246 and a second end 248. The first end 246 of the spring 196 can be coupled to one of the actuator shaft 122 or the actuator housing 120. When the actuator shaft 122 is within a first range of rotation relative to the actuator housing 120, the second end 248 of the spring 196 can be free. Thus, when the actuator shaft 122 is within the first range of rotation, the spring 196 does not exert a spring resistance torque on the actuator shaft 122. When the actuator shaft 122 is within a second range of rotation relative to the actuator housing 120, the second end 248 of the spring 196 can be constrained by the other of the actuator shaft 122 or the actuator housing 120. In operation, when the actuator shaft 122 is within the first range of rotation, the motor 116 can exert a motor resistance torque on the actuator shaft 122 relative to the actuator housing 120. When the actuator shaft 122 is within the second range of rotation, the spring 196 can impart a spring resistant torque to the actuator shaft 122 relative to the actuator housing 120. In some embodiments, when the actuator shaft 122 is within the second range of rotation, the motor 116 can also impart a motor resistant torque to the actuator shaft 122 relative to the actuator housing 120.

Claims

1. A trunk support exoskeleton for reducing a wearer's back muscle strength during forward lumbar bending, comprising: a trunk support frame configured to be coupled to the wearer's trunk; a first thigh link configured to be coupled to one of the wearer's thighs; a second thigh link configured to be coupled to another of the wearer's thighs, each of the first thigh link and the second thigh link being rotatably coupled to the trunk support frame such that the respective first thigh link or second thigh link can flex or extend relative to the trunk support frame; an actuator coupled to a trunk support frame, the actuator including an actuator housing and an actuator shaft, the actuator shaft and the actuator housing rotatable relative to the trunk support frame; a shaft pulley coupled to the actuator shaft; a housing pulley coupled to the actuator housing; a shaft line having a first end wrapped around the shaft pulley and a second end coupled to the first thigh link; a housing line having a first end wrapped around the housing pulley and a second end coupled to the second thigh link; Equipped with When the wearer is bending forward with respect to a vertical line of gravity in a sagittal plane, the actuator generates an actuator resistance torque between the actuator housing and the actuator shaft; the actuator resistance torque between the actuator housing and the actuator shaft generates a tension force in the housing line and the shaft line, thereby generating an extension torque between the respective first and second thigh links and the trunk support frame.

2. the first thigh link includes a first thigh link pulley; the second thigh link includes a second thigh link pulley; the second end of the shaft line is wound around the first thigh link pulley such that tension in the shaft line provides an extension torque between the first thigh link and the trunk support frame; 2. The trunk support exoskeleton of claim 1, wherein the second end of the housing line is wrapped around the second thigh link pulley such that tension in the housing line provides an extension torque between the second thigh link and the trunk support frame.

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

4. 2. The trunk support exoskeleton of claim 1, wherein the actuator generates a substantially small actuator resistance torque between the actuator housing and the actuator shaft that allows substantially free movement of the thigh link when the wearer is not bending forward relative to the vertical line of gravity.

5. 2. The trunk support exoskeleton of claim 1, wherein when the wearer is not bending forward relative to the vertical line of gravity and the thigh link is in a reciprocating mode indicative of walking, the actuator generates a substantially small actuator resistance torque that allows substantially free movement of the thigh link.

6. 10. The trunk support exoskeleton of claim 1, wherein the shaft lines and the housing lines each comprise an element or combination of elements selected from the group consisting of wires, cables, belts, fabric ropes, plastic ropes, cords, twine, chains, wire ropes, and strings.

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

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

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

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

11. 2. The trunk support exoskeleton of claim 1, further comprising a controller that sends a signal to the actuator to generate the actuator resistance torque between the actuator housing and the actuator shaft when the wearer is bending forward relative to the vertical line of gravity.

12. 12. The trunk support exoskeleton of claim 11, wherein the controller sends a signal to the actuator to generate a substantially small actuator resistance torque between the actuator housing and the actuator shaft when the wearer is not bending forward relative to the vertical line of gravity.

13. The trunk support exoskeleton of claim 1 , wherein the actuator resistance torque is a function of how far the wearer is leaning forward relative to the vertical line of gravity.

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

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

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

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

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

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

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

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

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

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

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

25. 2. The trunk support exoskeleton of claim 1, further comprising a shaft line jacket surrounding the shaft lines, the shaft line jacket being secured to the trunk support frame to facilitate adjusting a size of the trunk support frame without adjusting a size of the shaft lines.

26. 2. The trunk support exoskeleton of claim 1, further comprising a housing line jacket surrounding the housing lines, the housing line jacket being secured to the trunk support frame to facilitate adjusting a size of the trunk support frame without adjusting a size of the housing lines.

27. The core support exoskeleton of claim 1 , wherein the actuator generates the actuator resistance torque by using electrical power.

28. the actuator includes an actuator spring; a first end of the actuator spring coupled to the actuator shaft; a second end of the actuator spring is free within a first range of rotation of the actuator shaft relative to the actuator housing; a second end of the actuator spring is constrained by the actuator housing within a second range of rotation of the actuator shaft relative to the actuator housing; In the first range of rotation, the actuator generates the actuator resistance torque by using electric power; The core support exoskeleton of claim 1 , wherein in the second range of rotation, the spring generates at least a portion of the actuator resistance torque.

29. 30. The core support exoskeleton of claim 28, wherein the actuator spring comprises an element or combination of elements selected from the group consisting of coil springs, leaf springs, bungee cords, rotational springs, elastomeric cords, elastic cords, fabric cords, plastic cords, cords, twine, wire rope elastomers, and strings.

30. 2. The core support exoskeleton of claim 1, wherein in a first range of rotation of the actuator shaft relative to the actuator housing, the actuator generates the actuator resistance torque by using electrical power, and in a second range of rotation of the actuator shaft relative to the actuator housing, the actuator resistance torque is the sum of a torque generated by a spring and a torque generated by using the electrical power.

31. 2. The trunk support exoskeleton of claim 1, wherein the trunk support frame is configured to partially surround the trunk of the wearer and includes a lower frame portion coupled to the first thigh link and the second thigh link on either side of the wearer.

32. 32. The trunk support exoskeleton of claim 31 , wherein the trunk support frame includes a spinal frame portion coupled to the lower frame portion.

33. 33. The trunk support exoskeleton of claim 32, wherein the spinal frame portion is adjustable in length to accommodate wearers of various heights.

34. 32. The trunk support exoskeleton of claim 31, wherein the lower frame portion is width adjustable to accommodate wearers of various width sizes.

35. 32. The trunk support exoskeleton of claim 31, wherein the lower frame portion is depth adjustable to accommodate wearers of different depth sizes.

36. 10. The trunk support exoskeleton of claim 1, wherein the trunk support frame includes an upper frame portion coupled to a spine frame portion and configured to apply a trunk support force to a trunk and thoracic region of the wearer.

37. 37. The support stem of claim 36, wherein the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to the wearer's spine.

38. 37. The support stem of claim 36, wherein the spinal frame portion is configured to rotate relative to the lower frame portion along an axis substantially parallel to the wearer's spine.

39. 37. The support stem of claim 36, wherein the upper frame portion is configured to rotate relative to the spinal frame portion along an axis substantially parallel to one of a medial-lateral flexion axis and an extension axis of the wearer's lumbar spine.

40. A trunk support exoskeleton for reducing a wearer's back muscle strength during forward lumbar bending, comprising: a trunk support frame configured to be coupled to the wearer's trunk; a first thigh link configured to be coupled to one of the wearer's thighs, and a second thigh link configured to be coupled to the other of the wearer's thighs, each of the first thigh link and the second thigh link being rotatably coupled to the trunk support frame such that the respective first thigh link or second thigh link can flex or extend relative to the trunk support frame; an actuator coupled to the trunk support frame, the actuator including an actuator housing and an actuator shaft, the actuator being free to rotate relative to the trunk support frame, the actuator shaft being coupled to the first thigh link and the actuator housing being coupled to the second thigh link; Equipped with When the wearer bends forward in a sagittal plane, the actuator generates an actuator resistance torque between the actuator housing and the actuator shaft, thereby generating an extension torque between the first and second thigh links and the trunk support frame.

41. a shaft pulley coupled to the actuator shaft; a housing pulley coupled to the actuator housing; a shaft line having a first end wrapped around the shaft pulley and a second end coupled to the first thigh link; a housing line having a first end wrapped around the housing pulley and a second end coupled to the second thigh link; Further equipped with 41. The trunk support exoskeleton of claim 40, wherein the actuator resistance torque generates a tension force on the housing lines and the shaft lines, thereby generating an extension torque between the respective first and second thigh links and the trunk support frame.

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