Powered prostheses conventionally rely on impedance controllers that require extensive manual tuning and explicit mode classification. In this work, we present real-time deployment of an end-to-end prosthesis controller that estimates continuous actuator signals from onboard sensors, eliminating the need for intent classifiers and subject-specific tuning. Temporal Convolutional Networks were trained on a multi-terrain dataset from 18 individuals with transfemoral amputation and deployed in real time across five locomotion modes. Four participants (three able-bodied, one with transfemoral amputation) ambulated across level ground, ramp ascent and descent, and stair ascent and descent. During level walking, the deployed controller reproduced the training-data scaling of peak ankle torque with walking speed (deployed 0.85 Nm/kg per m/s, p = 0.001; training 0.96 Nm/kg per m/s, 95% CI [0.42, 1.50], p = 0.002), after excluding one outlier traced to atypical prosthesis loading. During ramp ascent, the controller scaled knee pre-flexion with grade (deployed 2.92 deg/deg, p = 0.027; training 3.30 deg/deg, 95% CI [1.83, 4.77], p < 0.001). During ramp descent, the controller increased resistive knee torque relative to level walking (deployed +0.16 Nm/kg, p < 0.001; training +0.16 Nm/kg, p = 0.008). Seamless stair transitions were generated for both intact- and prosthetic-side-leading sequences in ascent and descent, despite the training data containing only one limb-leading sequence. These results provide initial evidence towards end-to-end control that can provide unified, mode-adaptive prosthetic assistance without subject-specific tuning.
Personalization of impedance controllers for powered prosthetic legs is critical to accommodating individual gait biomechanics but remains challenging. Existing methods rely on time-intensive human-in-the-loop exploration and/or constrain optimization to low-dimensional, single-joint parameter subspaces. Sim-to-real transfer has enabled high-dimensional locomotion control for legged robots, but in assistive device control the human partner remains un-modelable. We present a replay-constrained simulation framework: a MuJoCo-based simulator reproduces prosthetic knee-ankle dynamics while replaying recorded hip kinematics and feedback-based ground reaction forces from individual walking data, bypassing the need to model complex human neuromuscular control mechanisms. We demonstrate the framework with a deep reinforcement learning policy that personalizes phase-dependent stiffness, damping, and equilibrium angle at both joints simultaneously, maximizing a biomimicry-based reward computed solely from onboard prosthesis measurements. Experiments with three participants with transfemoral amputation during level-ground walking at 0.8~m/s demonstrate strong simulation-to-hardware predictive validity (Pearson r=0.96--0.997). The best-performing policy on hardware was consistently predicted within the top five simulation policies for all participants. The learned controllers improved overall biomimicry rewards by 42--59% relative to the unpersonalized baseline. The framework supports scalable high-dimensional personalization of powered prosthetic legs and is amenable to extension to higher-dimensional controller parameterizations such as neural-network controllers.
Lower limb exoskeletons show promise to assist human movement, but their utility is limited by controllers designed for discrete, predefined actions in controlled environments, restricting their real-world applicability. We present an uncertainty-aware control framework that enables ankle exoskeletons to operate safely across diverse scenarios by automatically disengaging when encountering unfamiliar movements. Our approach uses an uncertainty estimator to classify movements as similar (in-distribution) or different (out-of-distribution) relative to actions in the training set. We evaluated three architectures (model ensembles, autoencoders, and generative adversarial networks) on an offline dataset and tested the strongest performing architecture (ensemble of gait phase estimators) online. The online test demonstrated the ability of our uncertainty estimator to turn assistance on and off as the user transitioned between in-distribution and out-of-distribution tasks (F1: 89.2). This new framework provides a path for exoskeletons to safely and autonomously support human movement in unstructured, everyday environments.
Fatima Mumtaza Tourk, Bishoy Galoaa, Sanat Shajan +3
Fully-powered knee prostheses, unlike traditional passive knees, can perform controlled positive work, reducing the need for compensatory behaviors by users during energy-intensive activities. While quasi-direct drive (QDD) actuators provide superior torque control, backdrivability, and acoustic noise properties compared to traditional highly-geared actuators, prior QDD prototypes have been too heavy and bulky for commercial translation. In this work, we present the design and validation of a new lightweight (2.6 kg) and low-profile (24.5 cm tip-to-tip build height) QDD knee prosthesis. By optimizing an 18 to 1 two-stage transmission alongside thermal and structural finite-element analyses, we significantly reduce device mass while enabling a peak torque of 145 Nm. Through benchtop tests, we validate the device's high output torque, low backdrive torque (1 Nm), and its precision position and torque control capabilities. We also demonstrate biomimetic kinematics and peak knee extension torques (within one standard deviation of able-bodied references) during both level-ground walking and sit-stand transitions performed by three participants with transfemoral amputation and varying K-levels. By meeting or improving upon the mass, build height, peak torque, and acoustic noise of a leading commercial powered knee, this work establishes the clinical viability of emerging QDD prostheses that promise improved dynamic performance for their users.