Lightweight Hip Exoskeleton With Bowden Cable Torque Actuation
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Solution Overview
Problem
Existing exoskeletons are heavy, bulky, and expensive, making them impractical for home-based and long-term assistance and rehabilitation, and they often lack sufficient torque for effective hip movement support.
Innovation Solution
A lightweight, high-torque, and cost-effective hip exoskeleton design using 3D printed components made from materials like PLA, TPU, and PETG, with a Bowden cable and pulley system for actuation, and a semi-rigid knee chain for enhanced flexibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional exoskeleton designs are used, then torque for hip movement is sufficient, but weight becomes excessive and device complexity increases
Solution Approach 1:
The exoskeleton is divided into separate functional modules: a hip joint mechanism with independent actuation, a knee joint mechanism, and a thigh support structure. Each module can be optimized independently for weight and torque requirements. The hip joint mechanism uses a motor coupled to a gear system that provides sufficient torque while keeping individual component weights minimal.
Solution Approach 2:
The patent replaces heavy conventional mechanical actuation systems with a more efficient motor-gear coupling system. The motor is directly coupled to the gear mechanism through a coupling device, eliminating the need for heavy intermediate transmission components while maintaining sufficient torque output for hip movement support.
2Force
If conventional exoskeleton designs are used, then torque for hip movement is sufficient, but device complexity and cost increase
Solution Approach 1:
The hip joint mechanism and knee joint mechanism share common structural elements and control systems. The motor support structure serves both joints, and the gear mechanisms are integrated in a way that reduces overall component count. This merging approach maintains sufficient torque for hip movement while reducing device complexity and manufacturing cost.
Solution Approach 2:
The exoskeleton design uses universal components that serve multiple functions. The gear mechanism not only provides torque multiplication for the hip joint but also enables controlled movement for the knee joint. The motor support structure provides both structural support and actuation functionality, reducing the need for separate dedicated components.
3Weight of moving object
If lightweight materials are used, then exoskeleton weight is reduced, but structural strength may be compromised
Solution Approach 1:
The exoskeleton employs composite material construction, particularly in the gear mechanisms and structural supports. The combination of lightweight materials with reinforcement structures provides sufficient structural strength to handle hip movement torques while keeping overall weight minimal. The materials are selected to optimize the strength-to-weight ratio for each specific component.
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 exoskeleton provides sufficient torque for hip movement support, is comfortable to wear, and reduces the weight and cost barriers, making it suitable for long-term assistance and rehabilitation.
Implementation Method 1
A Bowden cable and pulley system for actuation
Data Source
AI summary
A wearable exoskeleton comprising: a base; an articulable mechanical member configured to be secured to a portion of the human anatomy having a joint; a pulley motor secured to the base; a Bowden cable secured to the pulley motor and the articulable mechanical member; wherein the mechanical member is configured to articulate in response to the pulley motor imparting force to the Bowden cable.