Friction Characterization of a Cable-Driven Differential Actuation System for Lower-Limb Exoskeletons

Ground-truth human joint torque estimation relies on motion capture systems, which suffer from limited outdoor usability and significant deployment expenses. Furthermore, direct scaling of ground-truth joint torques to obtain motor torque commands is not necessarily the optimal strategy. To address the aforementioned limitations, inspired by the human motion generation process, this paper proposes a novel assistance torque estimation method based on the dynamic model. From an optimization perspective, the proposed method directly generates motor-assist torque and lowers the cost of data acquisition. Then, a data-driven assistance torque prediction network is trained to enable accurate real-time prediction under complex outdoor environments. Experimental results demonstrate that optimized (estimated) assistance torque exhibits better phase consistency with gait trajectories and better alignment with task characteristics. Relative to the Zero torque condition, the predicted torque can decrease metabolic rate by 11.8%-17.7%, heart rate by 8.9%-14.3%, and peak muscle activation levels by 28.2%-54.0%, respectively. This provides a new perspective for low-cost adaptive exoskeleton assistance.

Existing wearable exoskeleton architectures are typically constrained by a single mechanical output modality, providing either joint torque around an anatomical joint or linear traction along a limb-training-oriented direction, which limits adaptability to diverse training scenarios. This letter presents a cable-driven switchable actuator (CDSA) that can rapidly switch between torque and tension modes while centralizing all sensing and actuation components at the proximal drive unit. A Coupled Movable Pulley Mechanism (CMPM) provides tension amplification at the distal end-effector, while a bidirectional Cable-Driven Ratchet Mechanism (CDRM) enables mode switching and preload regulation. To eliminate the need for distal instrumentation, multi-source proximal sensors are integrated with a data-driven fusion model to estimate distal output forces. An adaptive dual-mode force control strategy based on iterative learning control (ILC) is further developed. Platform experiments demonstrate transmission efficiencies of $(92.4 \pm 2.0)\%$ and $(96.5 \pm 3.3)\%$ in the torque and tension modes, respectively, along with a tension amplification ratio of $2.77 \pm 0.10$ under tension mode. Tracking tests on simulated knee-joint gait trajectories and short-stroke tension profiles yield stable control, with RMSEs of $(4.52 \pm 0.51)\%$ and $(3.15 \pm 0.19)\%$ of the uncontrolled peak value, respectively. Finally, seated human-coupled experiments validate the system's controllable force generation in both joint-torque and linear-traction application modes.

Lower-limb powered exoskeletons have demonstrated substantial improvements in mobility and function, but most designs place actuation components lateral to the legs or remotely at the waist or back. These configurations often extend beyond the body's natural envelope, making devices intrusive in everyday use and potentially limiting societal adoption. We posit that rethinking actuation geometry could enable exoskeletons that conform more closely to the body. Here, we explored an actuation layout in which the actuator encircles the limb in a plane orthogonal to the limb axis, potentially reducing its spatial footprint around the body. We developed the Limb-Encircling Actuator (LEA) and characterized its electromechanical properties using a custom-built testbed. The LEA also features a novel radial bearing layout with potential as a lightweight or lower-cost alternative to traditional large-diameter bearings. The actuator achieved a continuous torque density of 7.5 Nm/kg with a mass of 894 g. Despite this high torque density and innovative layout, the system remained difficult to contain close to the body. These results highlight opportunities and challenges in limb-encircling actuation and provide insights into torque-dense exoskeleton designs that could integrate more readily into everyday apparel if challenges in actuator sizing and geometry are overcome.