Search Results (19)

Bone stress injuries are prevalent among athletes and military recruits and can significantly compromise training schedules. The development of an ankle–foot orthosis to reduce tibial load and enable a faster return to activity will require new device testing methodologies capable of capturing the contribution of muscular force on tibial strain. Thus, an actuated robotic surrogate leg was developed to explore how tibial strain changes with different ankle–foot orthosis conditions. The purpose of this work was to assess the reliability, scalability, and behavior of the surrogate. A dual actuation system consisting of a Bowden cable and a vertical load applied to the femur via a material testing system, replicated the action-reaction of the Achilles-soleus complex. Maximum and minimum principal strain, maximum shear strain, and axial strain were measured by instrumented strain gauges at five locations on the tibia. Strains were highly repeatable across tests but did not consistently match in vivo data when scaled. However, the stiffness of the ankle–foot orthosis strut did not systematically affect tibial load, which is consistent with in vivo findings. Future work will involve improving the scalability of the results to match in vivo data and using the surrogate to inform exoskeletal designs for bone stress injuries. Full article

Bowden cable–fabric is a key force transfer device for flexible exoskeletons, and its precise control of force/displacement is a significant factor in the human–machine interaction of flexible exoskeletons. In this paper, a force/displacement control method based on friction compensation and impedance control was proposed based on a flexible Bowden cable–fabric force transfer testbed system. First, a set of in vitro experimental platforms simulating Bowden cable–fabric force transfer was built according to a typical flexible exoskeleton force transfer system, and following the walking gait of lower limbs, the expected force and knee joint motion were set. Secondly, the Bowden cable–fabric force transfer friction model was constructed as the basis of the system’s force transfer compensation. In addition, the stiffness model of Bowden cable–fabric and the lower leg movement model were established and combined with impedance control to realize the precise control of system displacement. Finally, the damping and stiffness parameters suitable for the system were obtained through the impedance control simulation. In terms of the experiment, an in vitro Bowden cable–fabric force transfer experimental platform was built, and the expected force with the input peak value of 40 N, 50 N, and 60 N was set. Through the friction and position compensation model of Bowden cable–fabric force transfer and impedance control, the relative root-mean-square errors of the output force and expected force were obtained as 2.53%, 2.16%, and 2.07%, respectively. Therefore, the effectiveness of the proposed method is verified, which provides a foundation for the engineering application of flexible exoskeletons. Full article

With a view to maintaining the competitiveness required by the market, the automotive industry strongly encourages its suppliers to develop new production methods and technologies capable of reducing the costs of produced products, ensuring the necessary quality, and increasing flexibility, with a view to responding more easily to the customization of the products that the market increasingly demands. The main goal of this work was to increase the flexibility and productivity of equipment capable of producing the first subset that constitutes the product commonly known as the Bowden cable. To this end, the design science research methodology was used, which was understood as the most effective in describing scientific work related to the improvement of existing systems. Bowden cables are cables that activate various devices in the car, such as opening doors, moving window glasses, and adjusting some car seats, among others. The work consisted of integrating several operations usually carried out for the manufacture of the referred subset, reducing logistics operations and manual work, increasing operator safety, and increasing the production rate and flexibility of the equipment, by reducing the setup time. For this purpose, new mechanical concepts were developed, and automation was applied, which resulted in a completely new concept, able to fulfill all the objectives initially set. It should be noted here that the new equipment allowed a production rate of 1140 p/h, when the initial objective was 1100 p/h; it requires an investment of only around EUR 55,000 (easy return on investment), occupies only 11.6 m², and has reinforced safety systems to avoid workers’ injuries, an aspect that is very important in this type of equipment, where operators deal with cutting systems and high temperatures. The dissemination of this concept could help other researchers to easily find solutions to certain problems that they face in the development of modern equipment. The main contributions of this paper are the novel concepts created to overcome some process difficulties, which can be used for a wide range of other processing situations with similar difficulties. The solutions proposed allow a decrease in the cycle time, present high flexibility, save workshop space, and are affordable in terms of global cost. Full article

A minimally-invasive manipulator characterized by hyper-redundant kinematics and embedded sensing modules is presented in this work. The bending angles (tilt and pan) of the robot tip are controlled through tendon-driven actuation; the transmission of the actuation forces to the tip is based on a Bowden-cable solution integrating some channels for optical fibers. The viability of the real-time measurement of the feedback control variables, through optoelectronic acquisition, is evaluated for automated bending of the flexible endoscope and trajectory tracking of the tip angles. Indeed, unlike conventional catheters and cannulae adopted in neurosurgery, the proposed robot can extend the actuation and control of snake-like kinematic chains with embedded sensing solutions, enabling real-time measurement, robust and accurate control of curvature, and tip bending of continuum robots for the manipulation of cannulae and microsurgical instruments in neurosurgical procedures. A prototype of the manipulator with a length of 43 mm and a diameter of 5.5 mm has been realized via 3D printing. Moreover, a multiple regression model has been estimated through a novel experimental setup to predict the tip angles from measured outputs of the optoelectronic modules. The sensing and control performance has also been evaluated during tasks involving tip rotations. Full article

Degenerative diseases and injuries that compromise hand movement reduce individual autonomy and tend to cause financial and psychological problems to their family nucleus. To mitigate these limitations, over the past decade, hand exoskeletons have been designed to rehabilitate or enhance impaired hand movements. Although promising, these devices still have limitations, such as weight and cost. Moreover, the movements performed are not kinematically compatible with the joints, thereby reducing the achievements of the rehabilitation process. This article presents the biomimetic design of a soft hand exoskeleton actuated using artificial tendons designed to achieve low weight, volume, and cost, and to improve kinematic compatibility with the joints, comfort, and the sensitivity of the hand by allowing direct contact between the hand palm and objects. We employed two twisted string actuators and Bowden cables to move the artificial tendons and perform the grasping and opening of the hand. With this configuration, the heavy part of the system was reallocated to a test bench, allowing for a lightweight set of just 232 g attached to the arm. The system was triggered by the myoelectric signals of the biceps captured from the user’s skin to encourage the active participation of the user in the process. The device was evaluated by five healthy subjects who were asked to simulate a paralyzed hand, and manipulate different types of objects and perform grip strength. The results showed that the system was able to identify the intention of movement of the user with an accuracy of 90%, and the orthosis was able to enhance the ability of handling objects with gripping force up to 1.86 kgf. Full article

Aiming at the nonlinear expansion/contraction drive problem between different cables in multi-joint cable drive mechanisms, a mechanical drive method based on a non-circular gear drive was proposed, which could replace the servo-sensing control system and minimize the system’s complexity and cost. A multi-joint single-degree-of-freedom (DOF) bending mechanism was constructed with several T-shaped components and cross-shaped components. The principle of the multi-joint mechanism driven by non-circular gears was clarified. The corresponding relationships between the joint bending angle, cables’ extension/retraction amount and non-circular gear transmission ratio were established. Using the Bowden cable driving, a multi-DOF bending mechanism decoupling scheme was proposed. Considering the adverse effect of non-circular gear hysteresis on the motion of multi-joint mechanisms, a non-circular gear backlash elimination method was proposed. The expression of the backlash of the non-circular gear with respect to the axial movement amount was deduced, which could enable the precise control of the backlash. A two-DOF multi-joint bionic mechanism driven by the non-circular gear was developed. The experimental results show that the mechanism can achieve coordinated bending motion by precisely controlling the line extension/contraction through non-circular gears. This multi-joint bionic mechanism driven by non-circular gears has the characteristics of reliable structure and simple control, and it is expected to be applied to bionic fish and bionic quadruped robots in the future. Full article

Flexibility and light weight have become the development trends in the field of exoskeleton research. With high movement flexibility, low movable inertia and excellent wearable comfort, such a type of system is gradually becoming an exclusive candidate for applications such as military defense, rehabilitation training and industrial production. In this paper, aiming at assisting the walking of human lower limbs, a soft exosuit is investigated and developed based on the considerations of fabric structure, sensing system, cable-driven module, and control strategy, etc. Evaluation experiments are also conducted to verify its effectiveness. A fabric optimization of the flexible suit is performed to realize the tight bond between human and machine. Through the configuration of sensor nodes, the motion intention perception system is constructed for the lower limb exosuit. A flexible actuation unit with a Bowden cable is designed to improve the efficiency of force transmission. In addition, a position control strategy based on division of the gait phase is applied to achieve active assistance during plantar flexion of the ankle joint. Finally, to verify the assistive effectiveness of the proposed lower extremity exosuit, experiments including a physiological metabolic test and a muscle activation test are conducted. The experiment results show that the exosuit proposed in this paper can effectively reduce the metabolic consumption and muscle output of the human body. The design and methodology proposed in this paper can be extended to similar application scenarios. Full article

The development of control technology on wind turbine application robots has played an integral role in facilitating the digitization of inspection and maintenance in the wind energy industry. This paper presents a wind-turbine-climbing robot that determines the service lifespan of the wind turbine components subject to its payload capacity. The model has four rubber wheels, as the driving mechanism for its locomotion is being supported by a Bowden cable as a winding mechanism for its adhesion. The design further incorporates an Arduino microcontroller, distance sensors, motors, and a step motor to form its electromechanical structure. The overall capability of the robot has been analyzed through its kinematics and dynamics. Practical indoor experiments using a wind turbine tower mockup have been conducted for the validation of the various speeds and payload capacity of the prototype. The results indicate the effectiveness of its driving and winding mechanism to climb at the various speeds and with or without a payload. The advantage of the operations of its mechanism conformed with the wind turbine application robots. Full article

Bowden-cable-actuated soft exoskeleton robots are known for their light weight and flexibility of power transmission during rehabilitation training or movement assistance for humans. However, friction-induced nonlinearity of the Bowden transmission cable and gearbox backlash pose great challenges forprecise tracking control of the exoskeleton robot. In this paper, we proposed the design of a learning-based repetitive controller which could compensate for the non-linearcable friction and gearbox backlash in an iterative manner. Unlike most of the previous control schemes, the presented controller does not require apriori knowledge or intensive modeling of the friction and backlash inside the exoskeleton transmission system. Instead, it uses the iterative learning control (ILC)to adaptively update the reference trajectory so that the output hysteresis caused by friction and backlashis minimized. In particular, a digital phase-lead compensator was designed and integrated with the ILC to address the issue of backlash delay and improve the stability and tracking performance. Experimental results showed an average of seven iterations for the convergence of learning and a 91.1% reduction in the RMS tracking error (~1.37 deg) compared with the conventional PD control. The proposed controller design offers promising options for the realization of lightweight, wearable exoskeletons with high tracking accuracies. Full article

Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line. Full article

The manufacture of automotive components requires innovative technologies and equipment. Due to the competitiveness in the sector, the implementation of automatic and robotic equipment has been vital in its development to produce the largest number of products in the shortest amount of time. Automation leads to a significant reduction in defects and enables mass production and standardization of the final product. This work was based on the need of an automotive components’ company to increase the rate of spiral cable cutting, used as protection for Bowden (control) cables. Currently, this component, used in automotive systems, is processed with simple cutting machines and cleaning machines. Based on the design science research (DSR) methodology, this work aims to develop a machine capable of performing the cutting and cleaning of two spiral cables simultaneously and automatically. The development of this machine was based on existing machines, and the biggest challenge was the implementation of a double-cutting system. The designed machine met the initial requirements, such as enabling the simultaneous cut of two spirals, being fully automatic, doubling the output over the current solution, and fully complying with the current legislation. Full article

Globally, the most popular upper-limb prostheses are powered by the human body. For body-powered (BP) upper-limb prostheses, control is provided by changing the tension of (Bowden) cables to open or close the terminal device. This technology has been around for centuries, and very few BP alternatives have been presented since. This paper introduces a new BP paradigm that can overcome certain limitations of the current cabled systems, such as a restricted operation space and user discomfort caused by the harness to which the cables are attached. A new breathing-powered system is introduced to give the user full control of the hand motion anywhere in space. Users can regulate their breathing, and this controllable airflow is then used to power a small Tesla turbine that can accurately control the prosthetic finger movements. The breathing-powered device provides a novel prosthetic option that can be used without limiting any of the user’s body movements. Here we prove that it is feasible to produce a functional breathing-powered prosthetic hand and show the models behind it along with a preliminary demonstration. This work creates a step-change in the potential BP options available to patients in the future. Full article

The automotive industry is one of the driving forces of the global industry; thus, it is a very competitive sector which creates a constant need for process improvement, regarding productivity, quality, and flexibility. Automation has proven to be a viable solution for these production problems, with the rising adoption of these automated system by companies that try to design and implement more flexible systems, while reducing costs and improving process quality. Furthermore, the use of automation reduces the manpower factor and its associated variability. In the present work, a new concept for a Bowden cable production process is presented by employing the design science research (DSR) methodology. The project starts with the analysis of the previous production concept, determining possible problems and improvements, as well as setting objectives/requirements for a possible new concept/equipment. This information was used to develop a new automated Bowden cable production equipment, implementing several changes to the old concept and filling a gap in the literature in this field. The developed system was implemented and tested. A considerable reduction in cycle time was registered by 25%, which resulted in an increase of 30% in process productivity. Full article

Over the past few decades, wearable exoskeletons of various forms have been developed to assist human activities or for rehabilitation of movement disorders. However, sustainable exoskeletons with efficient energy harvesting devices still have not been fully explored. In this paper, we propose the design of a lightweight wearable Bowden-cable-actuated soft exoskeleton robot with energy harvesting capability. Unlike previous wearable exoskeletons, the presented exoskeleton uses an electromagnetic generator to both harvest biomechanical energy and to output mechanical torque by controlling an operation mode relay switch based on a human’s gait. Moreover, the energy-harvesting module also acts as a knee impact absorber for the human, where the effective damping level can be modulated in a controlled manner. The harvested energy is regulated and stored in super capacitors for powering wireless sensory devices when needed. The experimental results show an average of a 7.91% reduction in thigh muscle activity, with a maximum of 3.2 W of electric power being generated during movement downstairs. The proposed design offers important prospects for the realization of lightweight wearable exoskeletons with improved efficiency and long-term sustainability. Full article

The advantages of exoskeletons based on the Bowden cable include being lightweight and flexible, thus being convenient in assisting humans. However, the performance of an exoskeleton is limited by the structure and human–exoskeleton interaction, which is analyzed from the established mathematical model of the human–exoskeleton system. In order to improve the auxiliary accuracy, corresponding control methods are proposed. The disturbance observer is designed to compensate for disturbances and parameter perturbations in the inner loop. The human–exoskeleton interaction feedforward model is integrated into the admittance control, which overcomes the limitation of the force loading caused by the friction of the Bowden cable and the change in stiffness of the human–exoskeleton interaction. Furthermore, an angle prediction method using the encoder as the signal source is designed to reduce the disturbance of the force loading caused by human motion. Finally, the effectiveness of the design method proposed in this paper is verified through experiments. Full article