Magnetic Coupling for Exoskeleton Actuator Assembly
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Solution Overview
Problem
Conventional legged mobility devices, such as exoskeletons, are cumbersome and heavy, making them difficult to don and doff, especially for users with significant mobility impairments, and they often require assistance due to their rigid and interconnected design, which hinders independent use.
Innovation Solution
A modular exoskeleton design with an enhanced magnetic coupling system that allows for easy, one-handed assembly of actuator components, utilizing recessed pockets with neodymium disc magnets and mechanically keyed surfaces to ensure proper alignment and torque transfer, reducing the need for external assistance during donning and doffing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rigid and interconnected exoskeleton design is used, then structural stability and torque transfer are improved, but device complexity and difficulty of donning/doffing increase
Solution Approach 1:
The exoskeleton is divided into modular components (thigh module, shank module, foot module) that can be independently assembled and disassembled. Each module contains specific functional elements (actuators, joints, structural components) that can be coupled together through standardized interfaces, reducing overall assembly complexity while maintaining structural integrity.
Solution Approach 2:
Magnetic coupling elements serve as intermediaries between mechanical components. Magnets embedded in coupling interfaces provide both alignment guidance and holding force, enabling tool-free assembly while ensuring proper torque transfer paths. This intermediary magnetic field simplifies the coupling process without compromising mechanical strength.
2Ease of operation
If modular design with magnetic coupling is used, then ease of operation for donning/doffing is improved, but torque transfer capability may be compromised
Solution Approach 1:
Traditional mechanical fastening systems (screws, clips, latches) are replaced with magnetic coupling interfaces. The magnetic field provides sufficient holding force for torque transfer while allowing easy attachment and detachment. The magnetic coupling strength is engineered to exceed the torque requirements of the exoskeleton joints, ensuring adequate force transmission without complex mechanical fasteners.
3Strength
If heavy materials are used for structural components, then strength and torque capacity are improved, but weight of the device increases
Solution Approach 1:
The exoskeleton employs composite material construction, combining lightweight materials (such as aluminum alloys, carbon fiber reinforced polymers) with strategic placement of magnetic coupling elements. This composite approach maintains structural strength and torque capacity while significantly reducing overall weight compared to traditional heavy-duty metal construction throughout.
4Weight of moving object
If compact design is used, then portability and ease of manipulation are improved, but space for actuators and power supply is reduced
Solution Approach 1:
Actuators and power supply components are nested within the modular segments of the exoskeleton. The thigh module contains hip actuators, the shank module contains knee actuators, and power supply units are integrated into available spaces within modules. This nested arrangement maximizes space utilization, keeping the device compact while accommodating all necessary actuation and power components.
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 magnetic coupling system facilitates easier and independent assembly and disassembly of exoskeleton components, enhancing user mobility and reducing the need for caregivers, while maintaining adequate torque and driving forces for operation, thus improving user freedom and device portability.
Implementation Method 1
The actuator assembly and the driven component are magnetically coupled together by a magnetic coupling system
Data Source
AI summary
A joint actuator assembly includes a motor, a rotating driving member driven by the motor for driving a driven component, and a transmission assembly located between the motor and the rotating driving member that provides speed reduction from the motor to the rotating driving member. The rotating driving member comprises a magnetic coupling including a plurality of magnetic elements that are configured to magnetically couple with an opposing magnetic coupling of the driven component. The actuator and driven component may be combined into a mobility device including a magnetic coupling system having a first magnetic coupling on the actuator that magnetically couples to a second magnetic coupling on the driven component. The magnetic coupling system includes plurality of magnetic elements located as part of one or both of the first and second magnetic couplings. The first and second couplings have opposing mating surfaces that join together in a coupled position.