Exoskeleton Joint Coupling System for Tool-Free Assembly
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Solution Overview
Problem
Existing exoskeleton joint systems are difficult to assemble and disassemble quickly and safely, and they do not allow for autonomous management by patients, limiting their usability and portability.
Innovation Solution
A modular powered exoskeleton joint with a coupling system featuring a male and female part that fit partially inside each other, allowing for easy assembly and disassembly, and incorporating a locking pin and elastic element for secure engagement without the need for tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If existing exoskeleton joint systems are used, then structural strength and stability are maintained, but assembly and disassembly operations become complex and time-consuming requiring tools
Solution Approach 1:
The coupling system is divided into distinct male and female parts with specific geometric features (truncated pyramid shapes) that enable simplified assembly. The male part includes a truncated pyramid mating end while the female part includes a corresponding recess, creating a segmented but easily connectable structure that eliminates complex fastening mechanisms
Solution Approach 2:
The male part is designed to be inserted into and nested within the female part, with the truncated pyramid mating end fitting precisely into the corresponding recess. This nesting arrangement allows compact storage and easy assembly without requiring additional fastening operations or tools
2Extent of automation
If traditional locking mechanisms are used, then connection reliability is ensured, but the system requires tools and cannot be managed autonomously by patients
Solution Approach 1:
The locking pin is designed to engage automatically with the locking housing when the male part is inserted into the female part, without requiring any manual intervention or tools. The elastic element provides the necessary force for automatic engagement, enabling patients to assemble and disassemble the system autonomously while maintaining reliable connections
Solution Approach 2:
The traditional mechanical locking system requiring tools is replaced with an elastic-powered automatic locking mechanism. The elastic element stored energy is released to drive the locking pin into the locking housing, substituting complex mechanical fastening with a simpler elastic-driven automatic system
3Adaptability or versatility
If modular design is implemented for easy assembly, then portability and usability improve, but structural stiffness and force transmission capacity may be compromised
Solution Approach 1:
The truncated pyramid geometry introduces asymmetry into the modular coupling system, with specific angular facets that provide both easy alignment during assembly and robust force transmission. The asymmetric shape prevents misalignment while maintaining structural integrity through optimized surface contact areas
Solution Approach 2:
The truncated pyramid surfaces provide curved-like contact areas that distribute forces evenly across the mating interface. The geometric surfaces are designed to maximize contact area and minimize stress concentrations, maintaining structural stiffness while enabling modular assembly
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 solution enables quick and safe assembly and disassembly of exoskeleton components, allowing patients to manage the system independently, improving usability and portability while ensuring secure mechanical and electrical connections.
Implementation Method 1
the female part comprises an elastic element configured to keep the locking pin in an engaged condition as the male part is inserted into the female part
Implementation Method 2
The female part has tapered surfaces complementary to the outer surfaces of a mating end of the male part
Data Source
AI summary
A powered exoskeleton joint includes an actuation unit and an actuation arm mounted oscillatingly onto the actuation unit. The actuation unit moves the actuation arm oscillatingly around the joint. The actuation arm is coupled to the frame of an exoskeleton by a coupling system. The coupling system includes a first part integral with the actuation arm and another part integral with the exoskeleton frame, which parts are insertable at least partially inside each other, as a male part and a female part, the male part passing from an inserted condition to an extracted condition, and vice-versa. The female part has tapered surfaces complementary to external surfaces of a male end of the male part and includes a pin for locking the male part in the inserted condition, mounted translatable according to a direction incident to the insertion direction, which engages with a corresponding locking housing provided on the male part.