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2017 International Conference on Rehabilitation Robotics (ICORR)

QEII Centre, London, UK, July 17-20, 2017.

Design and Experimental Evaluation of a Lightweight, High-Torque


and Compliant Actuator for an Active Ankle Foot Orthosis*
Marta Moltedo1 , Tomislav Baček, Kevin Langlois, Karen Junius, Bram Vanderborght and Dirk Lefeber

Abstract— The human ankle joint plays a crucial role during


walking. At the push-off phase the ankle plantarflexors generate
the highest torque among the lower limb joints during this
activity. The potential of the ankle plantarflexors is affected
by numerous pathologies and injuries, which cause a decrease
in the ability of the subject to achieve a natural gait pattern.
Active orthoses have shown to have potential in assisting these
subjects. The design of such robots is very challenging due to
the contrasting design requirements of wearability (light weight
and compact) and high torques capacity. This paper presents
the development of a high-torque ankle actuator to assist the
ankle joint in both dorsiflexion and plantarflexion. The com-
pliant actuator is a spindle-driven MACCEPA (Mechanically
Adjustable Compliance and Controllable Equilibrium Position
Actuator). The design of the actuator was made to keep its
weight as low as possible, while being able to provide high
torques. As a result of this novel design, the actuator weighs
1.18kg. Some static characterization tests were perfomed on the
actuator and their results are shown in the paper.
Fig. 1. The lightweight and high-torque ankle actuator presented in this
work. The actuator is a MACCEPA [6], thus it is compliant. This actuator
I. INTRODUCTION is an improved version of the actuator presented in [7]. The actuator weighs
1.18kg (including sensors and excluding electronics and batteries) and it was
Walking is a fundamental activity in the daily life of designed to provide a minimum peak torque of 50Nm while following the
human beings and it is one of the key factors determining angle-torque characteristic of a biological ankle during walking at 2km/h.
the quality of life. During walking the largest contributions This low speed was considered to be feasible for impaired subjects.
to the total positive power of lower limbs are provided by the
hip and the ankle joints [1], however the ankle plantarflexors
alone are the major contributors in the last stage of the stance people. Human muscles are weakened as an effect of aging,
phase, the so-called push-off phase [2]. In this phase, the and this effect is larger in ankle plantarflexors compared with
muscles acting at the ankle joint are crucial for the generation other muscle groups in the lower limbs [5].
of forward velocity, the support of the body and the initiation The use of an AFO (ankle foot orthosis) and the attendance
of the swing of the leg [2], [3]. to sessions of manual rehabilitation performed by therapists,
Several disorders or injuries, such as stroke, multiple are the conventional approaches to restore the motion capa-
sclerosis, cerebral palsy, traumas, muscular dystrophies and bility of impaired subjects. Conventional AFOs are helpful
spinal cord injuries, can reduce the human ankle joint in stabilizing the ankle of the user during stance and in
abilities, altering the walking pattern of the affected patient guaranteeing foot clearance during swing. However they do
and impacting the quality of his/her life. Stroke patients not assure a natural gait pattern since they don’t prevent
often manifest a disrupted walking pattern, represented by foot slap in the initial part of the stance phase and they
slower walking speeds, reduced joint ROM (range of motion) cannot provide adequate ankle plantarflexion moment in the
and longer stance phase compared to healthy subjects [4]. last stage of the stance phase [8], [9]. The limitations of
Furthermore, due to the reduced strength of their ankle conventional AFOs can be overcome by an AAFO (active
muscles, these patients suffer from lack of propulsion, foot ankle foot orthosis). Several research groups have developed
drop and toe drag. Slower walking speeds and smaller ankle AAFOs to assist the ankle joint of impaired subjects. An
ROM are also characteristics of the gait pattern of elderly overview of these works and their results can be found
in [10].
*The presented work was developed within the projects BioMot (Eu- An AAFO is a suitable rehabilitation and assistive device
ropean Commission’s 7th Framework Program, Grant Agreement number if it fulfills some requirements. The first requirement is
IFP7-ICT-2013-10-611695) and MIRAD (Flemish agency for Innovation by
Science and Technology, IWT-SBO 120057) and it is supported by FWO the safety of the user. Another important characteristic is
project (no.G026214N). the wearability of the device, i.e. it has to be lightweight,
1 All the authors are with the Department of Mechanical Engineer-
compact and portable. Furthermore, the ankle actuator of the
ing, Robotics & Multibody Mechanics Research Group, Vrije Uni-
versiteit Brussel, 1050 Brussel, Belgium and with Flanders Make. AAFO has to be able to provide the necessary amount of
http://mech.vub.ac.be, marta.moltedo@vub.be torque to effectively assist the user in daily life activities.

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The AAFOs developed by researches are mainly divided shows the results of some characterization tests performed
into two categories: the first one has pneumatic artificial on the actuator. A conclusion about this work is given in
muscles (PAM) as actuation principle [11]–[15] and the Section IV.
second one is actuated by means of series elastic actuators
(SEAs) [8], [9], [16]–[18]. In general, to keep low the weight II. ANKLE ACTUATOR DESIGN
of the AAFO, researchers chose tethered, thus not portable, A. Design Criteria
solutions. However it has to be noticed that the weight of
these devices doesn’t take into account the off-board compo- The biological angle-torque characteristic at the ankle joint
nents (air sources, motors and controllers). For example the of a healthy subject during walking at 4.7km/h is given
PAM-actuated AAFO presented in [11] weighs only 0.95kg in Fig. 2. During this task, the ankle torque reaches a
and provides 110Nm and 53Nm, as peak dorsiflexion and value of 1.6Nm/kg [24] at the moment of push-off, which
plantarflexion torques, respectively. Another PAM-actuated corresponds to 128Nm if a subject of 80kg is considered.
AAFO [12] weighs 1.6kg and provides peak torques of This torque is the highest among the torques delivered by
70Nm and 38Nm in plantarflexion and dorsiflexion, respec- the three joints of the lower limbs during walking. A subject
tively. Its improved version [13], made to be easier to wear with a reduced capability at the ankle joint is not able to
and control by the user, weighs 1.7kg but reaches lower provide the amount of torque required for daily life activities.
peak torques. A tethered lightweight (0.875kg) and high- The amplitude and the timing of assistance needed by an
torque (150Nm peak plantarflexion torque) SEA-actuated impaired subject depend on the level of weakness and on the
AAFO is presented in [16]. The portability of an AAFO performed activity, as shown in [25]. According to this study,
can be achieved at the cost of higher weight and size. For during walking overground, subjects with 50%, 70% and
example, a portable PAM-actuated AAFO [14] weighs 3.1kg 90% of muscle weakness need at the ankle joint an assistive
and provides a peak torque of only 9Nm. A portable SEA- peak torque equal to 0.2Nm/kg, 0.7Nm/kg and 1.2Nm/kg
actuated AAFO [8], [9] can provide a peak plantarflexion respectively. Considering a subject of 80kg, the required
torque of 97Nm, but it weighs 2.8kg and it is bulky. assistive torques for these three levels of muscle weaknesses
As it can be observed from these works, designing an correspond to 16Nm, 56Nm and 96Nm.
AAFO with a high-torque actuator, but at the same time Considering these data and the experience gained from
portable and lightweight is very challenging. The weight of the design of the previous version of the actuator, it was
the AAFO is very critical, since the metabolic cost of loaded decided to design the actuator in order to be able to provide
walking raises with an increased weight of the load, but also a minimum peak torque of 50Nm while following the angle-
with a load placed at a more distal location [19]. torque characteristic of a biological ankle during walking.
The ankle actuator presented in this paper is a novel, high- This desired torque is twice the torque provided by the
torque, lightweight, compact and compliant ankle actuator previous version of the actuator. The natural speed of walking
based on the MACCEPA [6]. The MACCEPA has already overground of healthy subjects is equal to 4.7km/h, however
been used to actuate the joints of an assistive modular sit-
to-stand exoskeleton [20], [21]. However, the actuator used ANKLE ANGLE-TORQUE CHARACTERISTIC
0.2
in this exoskeleton can deliver a peak torque of 15Nm, it FF
weighs 1.4kg and it is 0.350m long (spanning both sides of 0
TO IC
the joints) and 0.112m wide. To achieve a more compact -0.2
design and a better inertia distribution of the actuator, the
spindle-driven version of the MACCEPA was developed [22]. -0.4
Normalized torque [Nm/kg]

A further reduction of the dimensions of the spindle-driven -0.6


MACCEPA was achieved in the ankle actuator described
-0.8
in [7], by housing the MACCEPA spring into the lever
arm. This lightweight (1.1kg) and compact (0.290m long, -1

spanning the joint, and 0.08m wide) actuator can provide a


-1.2
peak torque of 25Nm.
The actuator presented in this paper is an improved version -1.4
MD
of the last mentioned actuator. The main goal of its design
-1.6
was to increase the torque capability of the actuator, while
limiting as much as possible the increase of weight. If -1.8
-20 -15 -10 -5 0 5 10
complemented by appropriate control strategies [23], this Ankle angle [deg]
compliant actuator has the potential to be an energy efficient Ankle angle [deg] for the ankle joint in healthy
Fig. 2. Biological angle-torque characteristic
and safe solution for the actuation of an AAFO, due to subjects walking at 4.7km/h [24]. Plantarflexion is negative (both in torques
the capability of the compliant element to store and release and angles) and dorsiflexion is positive. IC is the moment of the initial
contact of the foot with the ground, in which the stance phase starts; FF is
energy and decouple the inertia of the motor from the load. the moment in which the foot is flat on the ground; MD is the moment of
The paper is organised as follows: Section II presents the maximum dorsiflexion; TO is the moment in which the toe is lifted from
mechanical design of the presented actuator, Section III the ground and the swing phase starts.

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for the design of the actuator a walking velocity of 2km/h Starting from this configuration, to change the equilibrium
was considered. This speed was estimated to be feasible for position of the MACCEPA, the spindle-drive modifies the
impaired subjects. position of the nut along the ballscrew. The ballscrew nut
is connected to the motor side of the lever arm, thus the
B. Conceptual design
change in its position along the ballscrew makes the lever
The MACCEPA [6] is a torque-controlled, variable stiff- arm rotate about the joint axis resulting in an increase of
ness actuator that works as a torsion spring and allows the angle α and a compression of the MACCEPA spring.
controlling independently its equilibrium position and joint The force generated by the spring compression produces a
stiffness. Fig. 3 shows the schematic drawing of the spindle- torque which re-alignes the output link to the spring side
driven MACCEPA designed for the presented ankle actuator. of the lever arm in the new equilibrium position. As in [7],
In this actuator the lever arm is composed of two segments, the MACCEPA spring is housed inside the spring side of
the spring side of the lever arm, which houses the MACCEPA the lever arm to keep the actuator design compact. The
spring, and the motor side of the lever arm, which is conventional design of the MACCEPA includes two motors,
connected to the ballscrew through the ballscrew nut. The the first one to control its equilibrium position and the second
two lever arm segments are rigidly connected and span the one to control its stiffness. To keep the weight and the size
joint axis. The MACCEPA parameters are shown in Fig. 3 of this actuator as low as possible, it was decided to exclude
and defined as follows: the second motor. However, the stiffness of the actuator, i.e.
• D: the length of the spring side of the lever arm; the pre-compression of the spring, can be changed manually
• L: the distance from the joint axis of the attachment by means of a pre-compression mechanism as explained later
point of the compression mechanism of the MACCEPA in the paper.
spring; The parameters of the MACCEPA define its angle-torque
• α: the torque-angle, i.e. the angle between the spring characteristics. To determine the parameters D, L, K and
side of the lever arm and the output link; P of the presented actuator, a constrained minimization
• ϕ: the equilibrium position angle, i.e. the angle between process was performed. The goal of this process was the
the spring side of the lever arm and the centerline of minimization of the energy requirement of the MACCEPA
motor link; while mimicking a desired angle-torque characteristic. This
• K and P: the spring constant and pre-compression. characteristic was defined by scaling the biological ankle
angle-torque characteristic of a healthy subject during walk-
ing (Fig. 2) in order to have a peak torque of 50Nm. The
resulting values for the MACCEPA parameters were: D =
0.069m, L = 0.095m, K = 70000N/m, P ' 0m.
All the other geometrical parameters (shown in Fig. 3)
were determined in order to keep limited the dimensions
of the actuator and the ballscrew maximal axial force and
linear velocity. The resulting values for these parameters
were DM = 0.045m, LM1 = 0.092m, LM2 = 0.021m, β
= 216◦ . Applying these values in the simulated model of
the actuator and considering a ballscrew of 0.002m pitch
and gearhead reduction 3.7:1, the necessary parameters for
the spindle-drive were calculated for the actuator to be able
to follow the desired ankle angle-torque characteristic at
2km/h as explained earlier. According to this simulation,
the maximum required linear velocity for the nut of the
Fig. 3. Schematic drawing of the presented spindle-driven MACCEPA for
ballscrew is 0.045m/s, which corresponds to a maximum
the ankle joint of an AAFO. The MACCEPA parameters are: D and L, the motor rotational velocity of 5050rpm. Considering a motor-
length of the spring side of the lever arm and distance from the joint axis ballscrew combination with efficiency of 67%, the peak
of the attachment point of the compression mechanism of the MACCEPA
spring, respectively; K and P, the MACCEPA spring constant and pre-
and RMS values of the motor torque were computed to be
compression, respectively; α, the torque-angle exerted by the MACCEPA; respectively 0.143Nm and 0.061Nm.
ϕ, the equilibrium position angle of the MACCEPA.

C. Realization
The ballscrew and the motor are hinged to the motor
link of the actuator, such that they can rotate with respect Fig. 4 shows the realization of the ankle actuator. The
to this link. They control the equilibrium position of the motor link corresponds to the side of the actuator attached
spindle-driven MACCEPA, which is the position in which the to the shank of the user, while the output link is connected
MACCEPA exerts no torque. This position corresponds to the to the foot of the user. This choice is made to have the
configuration in which the angle α is equal to zero, thus the heavier side of the actuator above the ankle joint, since, as
spring side of the lever arm and the output link are aligned. said before, more distal weights are energetically expensive.

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ACTUATOR ALPHA ANGLE-TORQUE CHARACTERISTICS
100
90 P = 0%
80 P = 10%
70 P = 20%
60 P = 30%
50 P = 40%
40 P = 50%
30 P = 60%
20 P = 70%

Torque [Nm]
P = 80%
10
P = 90%
0
P = 100%
-10
-20
-30
-40
-50
-60
Fig. 4. Realization of the ankle actuator. With respect to the conventional -70
design of the MACCEPA [6], in this actuator only the equilibrium position -80
can be controlled by a motor. Nevertheless the stiffness of the actuator can -90
be changed offline manually by means of a pre-compression mechanism -100
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
(composed of a Dyneema R rope and a worm-gear mechanism) and a Alpha angles [deg]
carriage system which compresses the spring.
Fig. 5. Simulated alpha angle-torque characteristics of the presented
actuator for different levels of pre-compression P of the spring (from 0%
to 100%, with steps of 10%). For lower levels of pre-compression, the
MACCEPA torque has a more non-linear behavior. For higher levels of pre-
The compliant element of the actuator was selected based compression the behavior of the MACCEPA becomes more linear. The level
on the values obtained for the K and D parameters in of pre-compression is expressed as the percentage of the working length of
the minimization process. The length of the spring side of the compressed spring.
the lever arm (D) is determinant in the selection of the
spring, since the spring has to be housed in it. The chosen
spring is a SODEMANN ISO die compression spring, with of the spring. Obviously, the opposite effect is obtained
constant equal to 68700N/m, a resting length of 0.051m and when the mechanism is rotated in the opposite direction.
maximal travel of work of 0.019m. Regarding the level of This mechanism is non-backdrivable, thus it ensures that the
pre-compression to be used in the actuator, it can be seen spring stays pre-compressed at the desired level all the time.
from Fig. 5 that the torque behavior of the actuator is a The selection of the spindle-drive was based on the results
non-linear function of the torque-angle α. However, this regarding the necessary motor velocity and torque obtained
relationship becomes more and more linear with an increased from the simulation. A Maxon EC-i 40 70W brushless motor
value of the pre-compression of the spring. Furthermore, (nominal voltage 36V, nominal continuous torque 0.137Nm,
a different setting of the spring pre-compression leads to stall torque 3.190Nm and nominal speed 6440 rpm) and a
a different behavior of the MACCEPA, from more stiff Maxon Spindle Drive GP32S Ballscrew10x2 (max feed
(with higher levels of pre-compression) to more compliant velocity 0.072m/s and 3.7:1 gear reduction) were selected.
(with lower levels of pre-compression). The optimal stiffness By choosing the length of the spindle equal to 0.08m, the
among different users may be different depending on several total range of motion of the actuator is of 53◦ , which results
factors. in 32◦ in plantarflexion and 21◦ in dorsiflexion, when the
The pre-compression of the MACCEPA spring is varied actuator is correctly placed on the leg of the user. These
by a manual pre-compression mechanism (Fig. 4), which is values are suitable for walking (Fig. 2).
composed of a Dyneema R rope and a worm-gear mechanism. To directly measure the torque-angle of the actuator, an
This mechanism drives a carriage system which compresses absolute magnetic encoder (AS5048A, SPI type, 6pins, 5V,
the spring. The carriage system is composed of two plates 14-bit) is implemented. An incremental optical encoder (US
(top plate and bottom plate in Fig. 4) positioned at the two Digital HUBDISK-2-2000-625-IE, module EM1-2-2000-I,
extremities of the spring. The top plate is fixed at the end DI/O type, 5 pins, 5V) is placed on the actuator in order
of the spring side of the lever arm, while the bottom plate to measure the angle between the output and the motor links
is made in a T-shape and it is positioned such that the long of the actuator, which corresponds to the biological ankle
part is inside the spring. The Dyneema R rope passes inside a angle.
hole in the bottom plate and the two extremities of the rope As said before, the main goal of the design of the actuator
are guided through the spring to be fixed to an axis (called was to improve a previous version of the same actuator in
Dyneema-axis) which is connected to the pre-compression order to provide high torques, while maintaining the increase
mechanism and placed on the output link at distance L of weight as low as possible. This goal put some challenges
from the joint axis (Fig. 3). When the pre-compression on the design of the actuator, since providing higher torques
mechanism turns in one direction, it makes the Dyneema- means also that the actuator components need to be more
axis rotating and wrapping the Dyneema R rope around it. In robust to sustain higher stresses caused by the aforemen-
this way the Dyneema R rope pulls the bottom plate closer tioned torques. To achieve this result, the design process was
to the top plate, resulting in an increased pre-compression guided by the analysis of the force distribution in the actuator

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structure. The effects of the stresses and deformations and Fig. 7 shows the results of the second characterization test
the force distribution in all the components of the actuator performed on the ankle actuator. In this test, the actuator
were verified by means of a Finite Element Method (FEM) was controlled to follow a predefined sinusoidal torque
analysis in Autodesk Inventor R . The aim of this analysis trajectory of 0.5Hz frequency. The amplitude of the reference
was to remove material as much as possible to reduce the sinusoidal signal was increased during the experiment from
weight of the actuator, but retaining the material needed for 0Nm to 90Nm with 7 Nm offset to account for higher
its structural integrity. Therefore, this analysis was performed plantarflexion torque (relative to dorsiflexion) expected for
in the configuration in which the spindle-drive exerts the the ankle actuator. The test was performed for six different
maximum expected force (according to the simulation). In pre-compression settings of the MACCEPA spring (20%,
the design process a safety factor was included to ensure the
requirement of providing a peak torque of minimum 50Nm.
WINTER TORQUE (40% spring pre-compression)
Thanks to this approach, the weight of the ankle actuator 50
is 1.18kg (including sensors and excluding electronics and 45
reference
batteries) and it is 0.305m long and 0.082m wide. measured
40
III. CHARACTERIZATION TESTS 35
The performance of the presented actuator has been 30

torque [Nm]
evaluated with several static characterization tests. During
25
these tests, both links of the actuator were rigidly fixed
to the experimental setup, the motor link (Fig. 4) directly 20

connected to the experimental setup and the output link 15


(Fig. 4) connected to the setup via a torque sensor. The
10
torque sensor was fixed to the test setup, thus the rotation
5
of the output link during the characterization tests was not
possible. The connections between the actuator and the test 0
setup were made to simulate the attachment to the user’s 0 2.5 5 7.5 10 12.5 15 17.5 20 22
time [s]
legs, i.e. the actuator was attached to the setup at the points
in which the connections to an AFO are foreseen. However, Fig. 6. Reference (in blue) and measured (in red) torque obtained during
a static characterization test of the ankle actuator. Positive torques are
the connections to the test setup were made to be very stiff plantarflexion torques. MACCEPA spring pre-compression was set to 40%.
and thus they don’t completely represent the attachment to The desired torque is the biological ankle torque trajectory [24] scaled
an AFO. During the tests, the lever arm was controlled by to have 50Nm as peak torque. Gait cycle time was set to be 2s. The
actuator followed very closely the reference torque. The discrepancies at
means of a PID controller. The input to the controller was the lower torques are a consequence of the gains of the PID controller.
torque error, i.e. the difference between the desired torque
trajectory and the actual torque, which was measured by the TORQUE (50% spring pre-compression)
torque sensor. The PID controller had as output the motor 100
90
velocity signal. Two of the tests performed on the actuator are 80 reference
presented in this section. The first test was performed to show 70 measured
60
the ability of the actuator in providing the biological torque 50
characteristic of the ankle joint during walking, scaled to 40
30
torque [Nm]

have a peak torque up to 50Nm, which is the peak torque for 20


which the actuator was designed. The second test was made 10
0
to show that the actuator is able to provide high torques. -10
Fig. 6 shows the response of the ankle actuator to the -20
-30
torque reference trajectory representing the biological ankle -40
torque of healthy subjects during overground walking [24]. -50
-60
The gait cycle was set to be 2 seconds, since, as said before, -70
the actuator was designed to assist patients walking at a speed -80
-90
equal to 2km/h, which is lower than the natural walking 0 20 40 60 80 100 120
time [s]
speed (4.7km/h). The reference signal (in blue) was scaled
setting the desired peak torque equal to an increasing value Fig. 7. Desired (in blue) and measured (in red) torque obtained during
from 5Nm to 50Nm (with steps of 5Nm). Only the results a static characterization test of the ankle actuator. Positive torques are
plantarflexion torques. MACCEPA spring pre-compression was set to 50%.
for the torque reference scaled to 50Nm are shown in Fig. 6. The desired torque is a sinusoidal trajectory of 0.5Hz, with offset 7Nm, to
During this test the MACCEPA spring pre-compression was account for higher plantarflexion torque (relative to dorsiflexion) expected
set to be 40%. The figure shows that the actuator successfully for the ankle actuator. The amplitude of the reference signal was manually
increased during the test, until reaching 97Nm in plantarflexion and 83Nm
followed the reference trajectory with the exception of small in dorsiflexion. These peak torques were reached with the actuator rigidly
errors at the lowest amplitude, due to the chosen gains of attached to the test setup via stiff connections. This condition doesn’t
the PID controller. completely represent the attachment to an AAFO.

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30%, 35%, 40%, 45% and 50%), but only the results for [7] M. Moltedo, T. Bacek, K. Junius, B. Vanderborght, and D. Lefeber,
the highest pre-compression setting are shown in Fig. 7. The “Mechanical Design of a Lightweight Compliant and Adaptable Active
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reference. This test showed that the actuator can provide pp. 1224–1229, 2016.
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attached with stiff connections to a rigid test bench. This Engineering, (Singapore), pp. 418–423, 2006.
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IV. CONCLUSIONS to restore normal gait function in patients with spinal cord injury: A
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