Compressed Controller for Active Exoskeletons with Local Battery Modules

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Solution Overview

Problem

Existing exoskeletons with batteries located near the waist require exposed cables that introduce snag hazards, are cumbersome, and cause power losses and radio interference, while those with local batteries face issues like excess radio emissions and voltage drops during high current peaks.

Innovation Solution

A battery-powered active exoskeleton with a local battery module positioned below the knee, integrated into the exoskeleton, eliminating the need for external cables and minimizing mass and interference, using a battery management system to optimize power delivery and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a battery is located near the waist of the exoskeleton, then power can be supplied to the system, but exposed cables are required which create snag hazards and radio interference

Engineering Contradiction:

Improvepower supplyVSAvoidsnag hazards and radio interference

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The battery system is segmented into modular battery packs that can be distributed at different locations on the exoskeleton (waist, thigh, shank), allowing power supply functionality to be divided into separate units that can be optimally positioned without requiring long exposed cables

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Wireless communication and power transmission technologies serve as intermediaries between the battery system and the exoskeleton controller, eliminating the need for exposed physical cables while maintaining power supply and data communication functionality

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If exposed cables are used to connect the battery to the exoskeleton, then power can be transmitted, but power losses and radio interference occur

Engineering Contradiction:

Improvepower transmissionVSAvoidpower losses

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The mechanical cable-based power and data transmission system is replaced with wireless transmission technologies (such as inductive coupling or radio frequency communication), eliminating the physical cable that causes power losses through resistance and radio interference through electromagnetic radiation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Electromagnetic fields serve as an intermediary medium for power and data transmission between the battery system and exoskeleton, replacing the need for physical cable connections and eliminating the associated power losses and interference issues

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If local batteries are positioned near the exoskeleton actuators, then cable-related issues are eliminated, but voltage drops occur during high current peaks

Engineering Contradiction:

Improvecable-related issuesVSAvoidvoltage stability

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

Different battery packs are positioned locally near specific exoskeleton actuators (waist battery near hip joints, thigh battery near knee joints, shank battery near ankle joints), allowing each local battery to independently power nearby actuators and minimize voltage drops by reducing current travel distance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The power supply system is segmented into multiple distributed battery packs, each serving specific regions of the exoskeleton, which allows high current demands to be met locally without requiring long cable runs that cause voltage drops

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The local battery design reduces snag hazards, power losses, and radio interference, providing efficient and reliable power to the exoskeleton without adding significant weight or bulk, enhancing user mobility and safety.

Implementation Method 1

an electric motor that generates torque about an axis of rotation of an ankle joint of the user

Methodology Applied

Scientific EffectElectromagnetic interaction: Electromagnetic Induction

Implementation Method 2

A battery-powered active exoskeleton with a local battery module positioned below the knee

Methodology Applied

Scientific EffectElectrical energy storage: Battery (electricity)

Data Source

PatentUS12427079B2Systems and methods for a compressed controller for an active exoskeleton

Publication Date: 2025.09.30 DEPHY INC

AI summary

A system to augment motion via a battery-powered active exoskeleton boot is provided. The system can include a controller and an electric motor that generates torque about an axis of rotation of an ankle joint of the user. The controller can receive sensor data associated with activity of the exoskeleton boot during a first time interval. The controller can determine, based on the sensor data input into a model trained via a machine learning technique associated with one or more users performing one or more physical activities, one or more commands for a second time interval. The controller can transmit the one or more commands generated based on the model to the electric motor to cause the electric motor to generate torque about the axis of rotation of the ankle joint of the user in the second time interval.