Three-DoF Ankle Exoskeleton With Symmetric Frame And Torque Sensing

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Solution Overview

Problem

Existing ankle exoskeletons primarily focus on a single axis of rotation, neglecting the comprehensive range of ankle movements, compromising kinematic compatibility and weight, and lack precise angle and torque measurement, mechanical adjustability, and adaptability across diverse user anatomies.

Innovation Solution

An individually customizable ankle exoskeleton design with at least three degrees of freedom (DoF) featuring a symmetric parallel frame structure, adjustable components, and integrated sensors for precise torque and angle measurement, allowing use on either leg and minimizing weight through evenly distributed actuation forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If ankle exoskeletons incorporate sufficient movable joints to harmonize with user's kinematic structure for all three DoF, then kinematic compatibility and range of motion are improved, but device complexity, weight, and bulkiness increase

Engineering Contradiction:
Improvekinematic compatibilityVSAvoiddevice complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The exoskeleton is divided into modular components: a shoe interface assembly, an ankle assembly with separate DoF mechanisms, and a calf interface assembly. Each module can be independently designed, adjusted, and optimized, reducing overall system complexity while maintaining full DoF capability

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The device incorporates dynamic adjustment mechanisms including adjustable cushioning elements, movable ankle joints, and adaptable strap systems that can be configured in real-time to match user anatomy and movement patterns, enhancing kinematic compatibility without permanent complexity

Inventive Principle:
Principle #15Dynamics

2Adaptability or versatility

If ankle exoskeletons incorporate sufficient movable joints to harmonize with user's kinematic structure for all three DoF, then kinematic compatibility and range of motion are improved, but weight increases

Engineering Contradiction:
Improverange of motionVSAvoiddevice weight
Core Design Contradiction:
Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The device utilizes flexible cushioning elements, elastic straps, and thin-walled structural components that provide necessary compliance and motion range without adding significant weight. The flexible interfaces allow full DoF movement while keeping the overall mass low

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

By segmenting the exoskeleton into lightweight modular components connected by flexible interfaces, the design achieves full range of motion through distributed flexibility rather than heavy centralized mechanisms

Inventive Principle:
Principle #1Segmentation

3Adaptability or versatility

If conventional devices use actuators positioned anterior on the shin pulling on struts, then limited inversion/eversion and internal/external rotation are permitted, but accurate measurement capabilities for all three ankle rotations and joint torque are lost

Engineering Contradiction:
Improverange of motionVSAvoidmeasurement precision
Core Design Contradiction:
Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent replaces conventional mechanical actuation with a measurement-focused approach using strain gauge sensors embedded in the structural members. This substitution enables precise measurement of forces and moments while maintaining passive mechanical motion capabilities through the bearing arrangements

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Strain gauge sensors provide real-time feedback on joint torques and forces acting on the ankle, enabling accurate measurement of all three rotational degrees of freedom. This feedback mechanism allows the device to adapt to user needs while maintaining measurement precision

Inventive Principle:
Principle #23Feedback

4Adaptability or versatility

If ankle exoskeletons are designed with symmetric parallel frame structure and adjustable components, then adaptability across diverse user anatomies and mechanical adjustability are improved, but device complexity increases

Engineering Contradiction:
ImproveadaptabilityVSAvoiddevice complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The symmetric parallel frame structure serves multiple functions: it provides structural support, enables bidirectional wear (left or right leg), accommodates diverse anatomies through adjustment mechanisms, and maintains measurement capability. This multi-functionality reduces the need for separate components for each function

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

While the overall frame is symmetric, the design incorporates asymmetric adjustment capabilities and interchangeable components that allow adaptation to asymmetric user anatomies. The symmetric structure itself reduces complexity by allowing the same design to be used on both legs

Inventive Principle:
Principle #4Asymmetry

Data Source

PatentEP4644051A1Ankle exoskeleton
Publication Date: 2025.11.05 KARLSRUHER INST FUR TECH
  • EP4644051A1 patent drawingFigure 1
  • EP4644051A1 patent drawingFigure 2
  • EP4644051A1 patent drawingFigure 3

AI summary

Exoskeleton, comprising: a assembly having a fixture (1) fixing a foot thereto, having two points arranged on each side of the fixture, and a frame (2) positioning the points relative to each other, that is connected to the fixture, and having an area; an arrangement (3) is inserted at each of the points; two struts, each of which is mounted with one of the ends of the arrangements over two axes and each of which has another arrangement at the other end and another area at the respective strut; another frame positioning the other arrangements relative to one another and is mounted relative to the struts; another assembly with another fixture fixing a lower leg, wherein the other frame is fixed between the other arrangements with the other frame; wherein both other areas are each connected to the area via a tension element; and an actuator adjusting the tension elements.