Imagine the possibility of a cure for one of the most prevalent problems associated with aging. Numerous individuals experience difficulty getting out of bed, sitting, or performing normal tasks due to weak knees. This issue also affects manual laborers who may be compelled to change careers or retire as a result of the strenuous repetitive nature of their work. The purpose of this Barrett Honors Thesis/Project is to build, testing, and conduct studies to create a portable, lightweight, low-profile passive leg exoskeleton that supports the legs and knees to assist in standing up from a kneeling position or lowering oneself to a sitting position.

In nature, some animals have an exoskeleton that provides protection, strength, and stability to the organism, but in engineering, an exoskeleton refers to a device that augments or aids human ability. However, the method of controlling these devices has been a challenge historically. Depending on the objective, control systems for exoskeletons have ranged from devices as simple spring-loaded systems to using sensors such as electromyography (EMG). Despite EMGs being very common, force sensing resistors (FSRs) can be used instead. There are multiple types of exoskeletons that target different areas of the human body, and the targeted area depends on the need of the device. Usually, the devices are developed for either medical or military usage; for this project, the focus is on medical development of an automated elbow joint to assist in rehabilitation. This thesis is a continuation of my ASU Barrett honors thesis, Upper-Extremity Exoskeleton. While working on my honors thesis, I helped develop a design for an upper extremity exoskeleton based on the Wilmer orthosis design for Mayo Clinic. Building upon the design of an orthosis, for the master’s thesis, I developed an FSR control system that is designed using a Wheatstone bridge circuit that can provide a clean reliable signal as compared to the current EMG setup.

With the extensive technological progress made in the areas of drives, sensors and processing, exoskeletons and other wearable devices have become more feasible. However, the stringent requirements in regards to size and weight continue to exert a strong influence on the system-wide design of these devices and present many obstacles to a successful solution. On the other hand, while the area of controls has seen a significant amount of progress, there also remains a large potential for improvements. This dissertation approaches the design and control of wearable devices from a systems perspective and provides a framework to successfully overcome the often-encountered obstacles with optimal solutions. The electronics, drive and control system design for the HeSA hip exoskeleton project and APEx hip exoskeleton project are presented as examples of how this framework is used to design wearable devices. In the area of control algorithms, a real-time implementation of the Fast Fourier Transform (FFT) is presented as an alternative approach to extracting amplitude and frequency information of a time varying signal. In comparison to the peak search method (PSM), the FFT allows extracting basic gait signal information at a faster rate because time windows can be chosen to be less than the fundamental gait frequency. The FFT is implemented on a 16-bit processor and the results show the real-time detection of amplitude and frequency coefficients at an update rate of 50Hz. Finally, a novel neural networks based approach to detecting human gait activities is presented. Existing neural networks often require vast amounts of data along with significant computer resources. Using Neural Ordinary Differential Equations (Neural ODEs) it is possible to distinguish between seven different daily activities using a significantly smaller data set, lower system resources and a time window of only 0.1 seconds.

As the world moves towards faster production times, quicker shipping, and overall, more demanding schedules, the humans caught in the loop are subject to physical duress causing them to physically break down and have muscular skeletal injuries. Surprisingly, with more automation in logistics houses, the remaining workers must be quicker and do more, again resulting in muscular-skeletal injuries. To help alleviate this strain, a class of robotics and wearables has arisen wherein the human is assisted by a worn mechanical device. These devices, traditionally called exoskeletons, fall into two general categories: passive and active. Passive exoskeletons employ no electronics to activate their assistance and instead typically rely on the spring-like qualities of many materials. These are generally lighter weight than their active counterparts, but also lack the assistive power and can even interfere in other routine operations. Active exoskeletons, on the other hand, aim to avoid as much interference as possible by using electronics and power to assist the wearer. Properly executed, this can deliver power at the most opportune time and disengage from interference when not needed. However, if the tuning is mismatched from the human, it can unintentionally increase loads and possibly lead to other future injuries or harm. This dissertation investigates exoskeleton technology from two vantage points: the designer and the consumer. In the first, the creation of the Aerial Porter Exoskeleton (APEx) for the US Air Force (USAF). Testing of this first of its kind exoskeleton revealed a peak metabolic savings of 8.13% as it delivers 30 N-m of torque about each hip. It was tested extensively in live field conditions over 8 weeks to great success. The second section is an exploration of different commercially available exoskeletons and the development of a common set of standards/testing protocols is described. The results show a starting point for a set of standards to be used in a rapidly growing sector.