Patent ID: 12240108

The drawing figures are not necessarily drawn to scale, but instead, are drawn to provide a better understanding of the components thereof, and are not intended to be limiting in scope, but to provide exemplary illustrations.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

A better understanding of different embodiments of the disclosure may be had from the following description read with the drawings in which like reference characters refer to like elements.

While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are shown in the drawings and are described below. It should be understood; however, there is no intention to limit the disclosure to the specific embodiments disclosed, but on the contrary, the aim is to cover all modifications, alternative constructions, combinations, and equivalents falling within the spirit and scope of the disclosure.

The references used are provided merely for convenience and hence do not define the sphere of protection or the embodiments.

The system described is a system, for example, an exoskeleton system, for assisting an operator in exerting efforts, of the type comprising:a garment that can be worn by the operator, which is to engage, when worn, the mutually mobile parts of a joint of the operator and which defines at least one axis of rotation to assume a position corresponding to the joint; the garment is optional; anda compensation device carried by the garment and designed to operate to compensate for the resistive moments that act on the joint during the effort exerted by the operator.

The system described has been devised, referring to applications for assisting the operator in efforts involving the shoulder joint. As seen in what follows, the same principles set forth may also be applied for systems for assisting the operator in efforts involving other joint groups or other joints, such as the hip joint or the knee joint.

The system described is characterized in that the compensation device comprises:a first rotatable member or gear and a second rotatable member or gear, which are connected and are brought into relative motion about the axis of rotation because of the movement of the joint of the operator's body, wherein the second rotatable member is rotatable about its axis; andan assembly or elastic mechanism equipped with one or more elastic elements, which is prearranged for acting on the second rotatable member to impart on the axis of rotation a moment opposite to the resistive moments;wherein the first and second rotatable members and the assembly are mutually prearranged in such a way that, in at least one pre-set position of the joint, the force exerted by the assembly on the second rotatable member is oriented in a direction incident regarding the axis of rotation of the second rotatable member.

In the pre-set position referred to above, the elastic mechanism can impart no moment of compensation on the axis of rotation of the system.

The aforesaid pre-set position hence corresponds to a neutral position of the system, in which the operator receives no impulse on the joint.

Preferably, in the application to the shoulder joint, the above-mentioned neutral position is made to correspond to the position of the arms extending along the torso. In the application to the hip joint, the neutral position is made, instead, to correspond to the upright position of the operator.

The present applicant has found that the possibility for the system to identify such a neutral position constitutes a fundamental characteristic for guaranteeing adequate comfort for the operator, above all for the person who, wearing the system, must perform a range of tasks not all linked, for example, to raising of the arms.

The system described herein is hence suited for constituting a system that can be worn by the operator for the entire work shift, with the convenience for the operator to put it on just once when getting dressed at the start of the shift without doffing the system to perform ancillary tasks unrelated to the functions of the system.

Once again in the perspective of improving comfort for the operator, in various preferred embodiments, the elastic mechanism of the system is provided with a system for adjustment of the tensioning or pre-tensioning of the elastic mechanism. This system enables the operator to choose a desired assistance, possibly, to even exclude the assistance altogether, for example, during a prolonged pause from the work shift. The system for adjustment of the tensioning of the elastic mechanism may further allow the system to be interchangeable between or worn by multiple operators, e.g., during successive shifts, and who by operators who may have different dimensions, abilities, or tasks to perform.

As seen in what follows, in various preferred embodiments, the system described has a system of axes of movement, which can assist and follow in a precise and fluid way practically all the movements of the joint and of the possible joint group or girdle to which the joint belongs.

This system of axes of movement has proven to render the system of assistance optimal from the ergonomic standpoint, and increase further the perception of comfort by the operator.

Embodiments of the system for assisting an operator in exerting efforts may comprise a garment arranged to be worn like an article of clothing and to support a mobile frame. The mobile frame may be arranged to define an assisted axis of motion of the system and to define one or more degrees of freedom allowing the system to approximate the operator's movements closely. The mobile frame may attach to the garment by and comprise linear guides arranged at the operator's back and proximate the operator's scapulae for close conformity with the operator's unique dimensions and strength and based on the operator's current task.

The linear guides may define axes of translation relative to the operator. They may support a compensation device comprising articulated elements that define an assisted axis of rotation of the system. The articulated elements may define first and second axes of rotation corresponding to abduction/adduction of the arm and rotation of the shoulder, respectively. The third axis of rotation defined by the articulated elements corresponds to the assisted axis of rotation of the system about which an assistive torque is provided to augment and assist efforts of the operator.

The articulated elements may comprise first and second gear or rotatable members that move about the assisted axis of rotation in response to movement of the operator's arm. The articulated elements may comprise an assembly comprising an elastic mechanism arranged to provide a moment about the second rotatable member and compensating resistive moments, e.g., gravitational forces, that act on the joint, e.g., a shoulder joint, during movements of the operator.

In embodiments, the elastic mechanism may be supported by brackets arranged in the articulated element, so as the operator's joint moves and generates rotation about the third axis of rotation, the first rotatable member is caused to rotate. The rotation of the first rotatable member causes rotation of the second rotatable member and adjusts the tension in the elastic mechanism. The increased or decreased tension in the elastic mechanism is then transferred or transmitted through the second rotatable member to the first rotatable member, influencing the operator's joint, e.g., to make raising the operator's arm from a neutral position easier. The tension may be transmitted from the second rotatable member to the first rotatable member according to a gear reduction ratio of the first and second rotatable members. The ratio is chosen, so the torque applied to the operator's joint has a profile similar to that caused by gravity; for example, the torque profile generated by the gear reduction ratio may have a maximum value at 90 degrees.

One bracket of the elastic mechanism may be mounted eccentrically on the second rotatable member, so the force applied by or transferred from the elastic mechanism to the operator depends on the angle of rotation of the second rotatable member. The components may be arranged in a predetermined fashion to generate the desired torque at desired arm positions; for example, an operator may be assisted in raising and keeping their arms above their head by the torque generated around the third axis of rotation by the elastic mechanism.

The degree of tension applied by the elastic mechanism may be manually adjusted or selected by way of a screw-operated or knob-type manual device, which may comprise discrete settings. The manual device may adjust a distance between the brackets, so tension in the elastic mechanism is adjusted independently of the rotation of the second rotatable member. An operator may select a desired tension.

Embodiments of the present disclosure advantageously provide an improved mechanism for selecting and adjusting tension in the elastic mechanism, as the degree of tension may vary dynamically during an operator's tasks and based on the dimensions and abilities of different operators.

As shown inFIG.1, an exoskeleton system410for assisting an operator in exerting efforts may comprise a garment412that can be worn by an operator and arranged to assume a position corresponding to a joint of the operator. The garment412may additionally or be arranged as one or more straps extending about the operator to secure the exoskeleton system410to the operator. The garment is optional and the exoskeleton system may provided without such garment.

The exoskeleton system410may further comprise a compensation device450carried by or supported on the garment412and arranged to compensate resistive moments acting on the joint during the operator's efforts, such as the effects of gravity pulling the operator's arms down. In embodiments, the compensation device450may comprise a separate or distinct unit arranged at each arm of the operator and generally at the operator's upper arm or shoulder. In other embodiments, the compensation device450may be arranged centrally at the operator's back or at yet other locations. The compensation device450may function to assist an operator in exerting efforts, such as but not limited to, raising the arms, lifting or manipulating an object, pressing against a surface, holding the arms in the desired position, or other efforts.

The exoskeleton system410may comprise a frame411arranged to support at least the compensation device450on the operator. The frame411may comprise linear guides414extending proximate a user's scapulae and generally opposite each other from a spinal support portion413. The spinal support portion413may attach to the garment412and/or by a lumbar support portion not shown. The frame411may be formed of a material having sufficient strength to support the compensation device450and to transfer forces as the operator engages in potentially physically demanding tasks. The frame411may additionally or be formed of a material with sufficient malleability to be adjusted or shaped to a particular operator's dimensions.

The compensation device450may attach to the frame411and the linear guides414in particular by sliding block assemblies416. The sliding block assemblies416may be arranged to selectively translate along the linear guides414to adjust to the operator's unique dimensions, such as shoulder width and user height, for optimal comfort and compliance. The sliding block assemblies416may be arranged to lock at desired locations and be released to translate to a new location. The sliding block assemblies416may attach to abduction/adduction assemblies418at each arm, the abduction/adduction assemblies418arranged to provide a first degree of freedom and allow the operator to abduct/adduct the arm naturally.

First and second elements420,422may connect the compensation device450to the abduction/adduction assemblies418. The first and second elements420,422may be hingedly joined at a joint arm424arranged to allow the operator to extend and flex the arm relative to the body in a second degree of freedom.

The compensation device450may attach to the operator's arm at a band426, allowing the motion of the arm to activate a rotatable member of the compensation device450, as described in greater detail herein. The depicted arrangement is not limiting, but alternative arrangements, movements, degrees of freedom, attachments, and components may be arranged to form a system according to the disclosure.

As seen in the embodiment ofFIGS.2-3, the compensation device450may comprise first and second rotatable members or gears462,464housed within a casing452. The second rotatable member464may engage and be rotatable relative to the first rotatable member462at an engagement portion454. The first rotatable member462may be arranged to be brought into relative motion about a first axis of rotation I3because of the movement of the joint of the operator.

The compensation device450may further comprise an elastic mechanism456having a first end connected to the second rotatable member464and arranged to impart at the first axis of rotation I3a moment opposite the resistive moments, e.g., gravity pulling the operator's arms downward. The elastic mechanism456may comprise at least one spring472,474,476tensioned between first and second bracket assemblies466,468. The first bracket assembly466may pivotally connect to the casing452of the compensation device450by a pivot pin478extending through the pivot point485. The pivot pin478allows the first bracket assembly466to rotate about a fourth axis of rotation I6. While the elastic mechanism is described as having one or more springs, the depicted embodiment is not limiting and may comprise any suitable component or combinations thereof.

The fourth axis of rotation I6may be offset and parallel to a second axis of rotation I4corresponding to the second rotatable member464. By being located separately from the second axis of rotation I4, the first bracket assembly466may be arranged in a predetermined location for adjusting tension in the elastic mechanism456according to particular movements of the joint of the operator and throughout a range of allowed motion in the joint.

The system410may advantageously ascertain the movements and/or position of the joint of the operator by way of an encoder470arranged in the compensation device450. The encoder470may comprise a sensor in communication with the first rotatable member462and may measure an angle of the joint of the operator. In an embodiment, the encoder470may be arranged coaxially with the first rotatable member462and reads or senses a rotation of an element, such as a magnet, attached to the first rotatable member462. The first rotatable member462may rotate according to the second rotatable member464by contacting and rotating relative to the first rotatable member462at an engagement portion454. The first and second rotatable members462,464may define a plurality of corresponding teeth477,479engaging one another.

The first rotatable member462may be formed as a shoulder gear or any suitable fixture. As the first rotatable member462rotates in response to movements of the operator's arm, the encoder470records and sends a signal comprising position information. The second rotatable member464is rotated. The casing452may define an arcuate groove483arranged to receive a guide pin481. The guide pin481may extend from the second rotatable member464and into the arcuate groove483to define a predetermined path or rotation of the second rotatable member464, which pivots about a pivot pin478relative to the casing452as the operator's arm moves. The arcuate groove483is arranged to define two end-strokes for the second gear and consequently for the range of motion of the assisted joint.

The exoskeleton system410may further comprise a regulation device458connected to a second end of the elastic mechanism456and arranged to adjust tension therein. The regulation device458may adjust a length L3, L4of the elastic mechanism456between its first and second ends, for example, in response to a detection of a position of the operator's joint or by the operator's specified preferences.

The regulation device458may comprise a motor480, such as a servomotor, arranged to linearly adjust a length of the elastic mechanism456by actuating a spindle axis or screw485that changes the length of a spring486. The spring486may be connected at a first end of the spring486by a mount484to the motor480and a linkage assembly460including a first bracket468A having a central portion490and a first portion488proximate a second end of the spring486. The spring486may terminate at an end portion489at or proximate the casing452, and more particularly at a spindle nut491fixed on the linkage assembly460. The first bracket468A may support an end of the elastic mechanism456and adjust tension as the position of the first bracket468A relative to the second rotatable member464is adjusted. While the motor480is depicted actuating a screw485in a rotating manner, the depicted embodiment is not limiting, and any suitable arrangement may be used.

The system410can operate without the spring above. The outcome of the spindle drive can be the linear motion of the linkage assembly460due to the thread of the spindle nut491inFIG.2. A goal of the spring486, in this embodiment, is to reduce the load acting on the spindle axis, allowing to use a smaller and lighter spindle drive. The load on the spindle axis is lowered employing the spring486compressed between the spindle nut491and the wall of the mount484to which the spindle is fixed484. Since the linkage assembly,460can glide on the casing452due to the rail495and slider494, almost the whole load of the springs would be transmitted to the spindle axis. The tension of the springs472,472,476, according to the level of assistance and the angle of the arm, can vary in a range of forces that would lead to a similar compression on the spindle screw. Through adding a proper spring486, the action on the screw is balanced between traction and compression, and its absolute value lowered.

For example, as the screw485is rotated by the motor480, it may function to move the linkage assembly460in a direction D2away from the second rotatable member464, and conversely in a direction D1toward the second rotatable member464as the operator's needs may require, and as discussed in greater detail herein. The motor480may be provided with a sensor, such as an encoder, which may be arranged to communicate a position of the screw485to a control unit430.

The linkage assembly460may include the first and central portions488,490of the first bracket468A. It may further comprise a pivot pin492arranged to extend through the first bracket468A to pivotally secure the elastic mechanism456to the first bracket468A about a third axis of rotation I5. The pivot pin492attaches a second bracket468B supporting first, second, and third springs472,474,476of the elastic mechanism456to the first bracket468A and allowing the first, second, and third springs472,474,476to be tensioned by the regulation device458while rotating according to the movement of the operator's arm.

The first bracket468A may facilitate movement of the elastic mechanism456by translating relative to the casing452along a rail495with a slider494attached to the first bracket468A as the motor480actuates the screw485to change a length of the spring486and thus the position of the linkage assembly460. The slider494may attach to the rail495by and at the second portion475of the first bracket468A. The system can work even without the spring. The outcome of the spindle drive is the linear motion of the linkage assembly460due to the thread in the spindle nut491. An objective of the spring, in this embodiment, as mentioned, is to reduce the load acting on the spindle axis, allowing to use a smaller and lighter spindle drive.

As seen in greater detail inFIG.3, the compensation device450may further comprise a rotational stop assembly461comprising both extension and flexion stops to define an allowed degree of motion of the compensation device450. The rotational stop assembly461may be arranged to engage a follower463attached to the second rotatable member464. The follower463may define first and second notches or detents467A,467B arranged to engage a stop surface471when the maximum flexion and extension angles, respectively, have been reached. The stop surface471may comprise an arm469pivotally connected to the casing452. The arm469may comprise a lever473arranged for pivoting the arm469for disengagement from the follower463. The rotational stop assembly461and the elastic mechanism456may be arranged such that the compensation device450is inactive at a predetermined neutral or pre-set position at which compensation or forces are not provided to the operator's joint.

The rotational stop assembly can be used for safety, by securing the compensation device when not worn, to avoid a sudden release of the elastic energy. The safety lock can be voluntarily engaged, acting on the lever473only when the maximum extension angle is reached.

The compensation device450may be connected to a joint arm422of the frame411at a rotational element465. The rotational element465may be arranged to permit rotation of the compensation device450relative to the joint arm422in a third degree of freedom for the operator.

The compensation device450further supports the band426for securing about the arm of the operator. The band426may be formed of any suitable material and may attach to the casing452in any suitable fashion. The casing452may further define a bar428along which the band426may be slidingly mounted. The bar428may be secured on the casing452by a guide429. The sliding arrangement of the band426on the casing452allows the system410to be adjustable to the unique dimensions, needs, and tasks of individual operators. It yet further allows for better kinematic compatibility between the device and the user's movements.

As seen inFIGS.5A-6B, the compensation device450offers improved assistance to an operator relative to existing exoskeleton devices in that the compensation device450provides for dynamic tensioning of the elastic mechanism456based on the position of the operator's joint as determined by the encoder470and operator feedback, thereby allowing the system410to meet the needs of different users having different dimensions and performing different tasks. In the state or condition ofFIG.5A, the elastic mechanism456has a first length L1creating a first tension which may be compressed to a second length L2and a second, reduced tension in the state ofFIG.5B. As seen, the elastic mechanism456may also vary in configuration based on a rotation of the second rotatable member464according to a position of the operator's joint.

Based upon data from the encoder470and/or operator feedback obtained through a control system430as described in greater detail herein, the motor480may adjust the tension in the elastic mechanism456by actuating the screw482to change a length of the spring485. In the example ofFIG.6A, the spring486may have a first length L5such that the second linkage assembly460has a position relative to the casing452defining a length L3of the springs472,474,476of the elastic mechanism456. Based on the encoder470data or operator feedback, the motor480may be activated to change the length of the spring486to a second, increased length L6. The increased length L6of the spring486causes the second linkage assembly460to translate relative to the casing452, so the springs472,474,476of the elastic mechanism456have an increased length L4, increasing a degree of tension in the elastic mechanism456and assistance to the operator.

The exoskeleton system410may further comprise a control system430attached at the spinal support portion413of the frame411. The control system430may be arranged to connect by cabling431,432to the compensation device450at each arm, and to provide electrical power to the compensation device450. The control system430may further adjust the tension in the elastic mechanism456in the compensation device450.

The control system430may receive operator feedback via a control panel496arranged on the casing452. The control panel496may be arranged as an interface between the operator and the system410. It may comprise buttons497allowing the operator to specify one or more settings or saved preferences, for example. The control panel496may also communicate notifications to the operator; for example, the buttons497may be arranged with LEDs that can blink in predetermined patterns to indicate conditions or other information to the operator.

The control panel496may connect to the control system430at the spinal support portion413. The control system430may comprise a battery434to actuate the motor480at least. The control system430may further comprise a router436, power management unit438, a digital zone comprising control logic440, motor drivers442, and an inertial measurement unit444. The depicted arrangement and combination of elements is not limiting but rather may comprise any suitable arrangement of any suitable elements.

The inertial measurement unit444may be arranged to determine the overall trunk angles of the operator and may provide fall prevention/protection or otherwise optimize the operation of the compensation device450. The control logic440may comprise an algorithm to specify a degree of actuation to the motor drivers442, which may provide a signal to actuate the motor480, so the tension in the elastic mechanism456is optimized for a particular operator at a particular moment. The power management unit438may serve to properly govern the distribution of power from the battery434to the motor480. By providing the control system430including the battery434at the spinal support portion413, the system410advantageously combines the benefits of passive exoskeleton devices which may provide easy-to-use and automatic assistance to a user with the benefits of active exoskeleton devices which may provide powered assistance and sensor control.

By providing a system for assisting efforts by an operator according to embodiments of the disclosure, the problem of the exoskeleton and other assist systems being poorly adapted to individual operators' unique dimensions, needs, and tasks is addressed, as the compensation device may be adapted to include a regulation device adjusting a degree of tension, and therefore assistance, provided to an operator based on both the operator's specified preferences and feedback and the position of the operator's joint. The system is thereby enabled to provide improved and more accurate assistance to the operator. The embodiments described further provide a system for assisting an operator in exerting efforts that provide improved ergonomics and ease of use, particularly through operating the compensation device to provide adjustable and discrete amounts of torque to aid an operator in performing certain effortful motions.

Without prejudice to the principle of the invention, the details of construction and the embodiments may vary, even significantly, regarding what has been illustrated purely by way of non-limiting example, without departing from the scope of the disclosure, as this is defined by the annexed claims.

While the disclosure discusses embodiments for the shoulder, embodiments of the disclosure may be used with other limbs, joints, and anatomical portions, including the torso, elbow, wrist/hand, hip, knee, and foot/ankle. Embodiments of the system may be used in other orthopedic, prosthetic, medical, and other devices, and are not limited to the embodiments shown.

Not necessarily all such objects or advantages may be achieved under an embodiment of the disclosure. Those skilled in the art will recognize that the disclosure may be embodied or carried out to achieve or optimize one advantage or group of advantages as taught without achieving other objects or advantages as taught or suggested.

The skilled artisan will recognize the interchangeability of various components from different embodiments described. Besides the variations described, other known equivalents for each feature can be mixed and matched by one of ordinary skill in this art to construct a hinge assembly under principles of the present disclosure. Therefore, the embodiments described may be adapted to systems for any suitable device, including orthopedic, prosthetic, medical, and other devices.

Although the system for assisting an operator in exerting efforts has been disclosed in certain preferred embodiments and examples, it, therefore, will be understood by those skilled in the art that the present disclosure extends beyond the disclosed embodiments to other alternative embodiments and/or uses of the system and obvious modifications and equivalents. It is intended that the scope of the present system disclosed should not be limited by the disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.