Patent ID: 12220328

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In some embodiments, the system includes at least one robotic assembly/apparatus and at least one exoskeleton and/or system for control of the at least one robotic assembly. The robotic assembly may include, but is not limited to, a prosthetic and/or robotic arm and/or hand, which, in some embodiments, may be one of the various embodiments of prosthetic/robotic hands/arms described below. However in some embodiments, the system may include at least one robotic apparatus, which, in some embodiments, may be a prosthetic arm, but in other embodiments, may be any robotic apparatus including, but not limited to, a robotic hand, a robotic arm, a robotic leg, a robotic foot and/or a robotic being that may resemble a robotic human or a robotic mammal. In some embodiments, the robotic assembly/apparatus may be any assembly/apparatus with at least one robotic feature.

In some embodiments, the system includes at least two robotic arms, complete with hands. In some embodiments, the at least one robotic arm may be attached to a device which may be a mobile platform. However, in some embodiments, the device may not be attached to a mobile platform, but rather, may be attached to anything, including, but not limited to, a wall, floor or other non-movable structure. In some embodiments, the device may be attached to a structure which may be movable, however, may not be “mobile” in the sense that it may not include one or more wheels. In some embodiments, at least one, and in some embodiments, at least two, prosthetic arms may be attached to a structure, and in some exemplary embodiments, at least two prosthetic arms may be attached to a mobile platform.

In some embodiments, the robotic assembly may not require attachment to any structure but rather, may be a stand alone robotic object.

The system may include at least one exoskeleton apparatus. The exoskeleton apparatus may be adapted to be worn/configured to be worn by a being of any size. In some embodiments, the exoskeleton may be adjustable such that the exoskeleton may be configured to any user. A “user” may be defined as anything, whether human, other mammalian or robotic, that may wear the exoskeleton. In the exemplary embodiments, the exoskeleton is used to at least partially/partly control the at least one robotic assembly. In some embodiments, the exoskeleton may be used to fully control the at least one robotic assembly.

In some embodiments, the exoskeleton may be worn by a human and used to control two robotic arm/hand assemblies. In some embodiments, the exoskeleton may also include at least one component for control of a mobile platform to which the two robotic arm/hand assemblies are mounted by way of at least one compliant feature. In some embodiments, the exoskeleton may control the at least one robotic assembly from a remote location, including, but not limited to, using wireless communication.

In some embodiments, the robotic assembly may be controlled using a camera mapping/camera tracking device which may, using a camera, track the movements of a user, and map the movement of the user onto the robotic assembly. In some embodiments, the cameral mapping/camera tracking device may be one known in the art, for example, the Osprey Digital RealTime Sytem made by Motion Analysis Corporation, Santa Rosa, California, U.S.A, however, other system may also be used.

As discussed above, in the exemplary embodiment, the robotic assembly is a robotic arm/hand assembly which may be referred to herein, for purposes of description, as a prosthetic arm apparatus. In some embodiments, the prosthetic arm apparatus may be one described below. Referring toFIGS.1and2, a prosthetic arm apparatus10for attachment to a shoulder of a shoulder disarticulated amputee includes a plurality of segments, including a shoulder abductor12, a shoulder flexion assembly14, a humeral rotator16, an elbow flexion assembly18, a wrist rotator20, a wrist flexion assembly22, and a hand assembly24. The prosthetic arm apparatus10, in the exemplary embodiment, has the dimensions and weight of a female arm of a fiftieth percentile, so that many different users may comfortably use the prosthetic arm apparatus10. As should be understood by those skilled in the art, the prosthetic arm apparatus10may be constructed to larger or smaller dimensions if desired. The prosthetic arm apparatus10may be controlled by a control system (not shown), such as the various control systems described in U.S. patent application Ser. No. 12/027,116, filed Feb. 6, 2008, now U.S. Publication No. US-2008-0243265, published Oct. 2, 2008 and entitled METHOD AND APPARATUS FOR CONTROL OF A PROSTHETIC DEVICE; U.S. patent application Ser. No. 12/706,609, filed Feb. 16, 2010, now U.S. Publication No. US-2010-0274365, published Oct. 28, 2010 and entitled ARM PROSTHETIC DEVICE; U.S. patent application Ser. No. 12/706,471, filed Feb. 16, 2010, now U.S. Publication No. US 2010-0211185, published Aug. 19, 2010 and entitled SYSTEM, METHOD AND APPARATUS FOR ORIENTATION CONTROL each of which is hereby incorporated by reference in its entirety.

Referring toFIG.3, one embodiment of the shoulder abductor12is shown. The shoulder abductor12includes a harness mount26for connecting the prosthetic arm apparatus10, shown inFIG.1, to a support apparatus, as the various prosthetic supports described in U.S. patent application Ser. No. 12/026,971, filed Feb. 6, 2008, now U.S. Publication No. US-2009-0271000, published Oct. 29, 2009 and entitled DYNAMIC SUPPORT APPARATUS; U.S. patent application Ser. No. 12/706,340, filed Feb. 16, 2010, now U.S. Publication No. US-2010-0211189, published Aug. 19, 2010 and entitled DYNAMIC SUPPORT APPARATUS AND SYSTEM, each of which is hereby incorporated by reference in its entirety. The harness mount26has harness interface holes28that may be used to attach the abductor12to a prosthetic harness (not shown) or other system for supporting the prosthetic arm apparatus10. In the exemplary embodiment, the harness or prosthetic support apparatus may also be one disclosed in co-pending U.S. patent application Ser. No. 12/026,971, filed Feb. 6, 2008, now U.S. Publication No. US-2009-0271000, published Oct. 29, 2009 and entitled DYNAMIC SUPPORT APPARATUS, which is hereby incorporated by reference in its entirety.

Referring toFIG.4, the shoulder abductor12also has a shoulder flexion assembly mount30, shown according to one embodiment. The shoulder flexion assembly mount30interfaces with the shoulder flexion assembly14to mount the shoulder flexion assembly14onto the shoulder abductor12. In one embodiment, the flexion assembly mount30has interface holes32to facilitate connection of the shoulder flexion assembly14by attachment means such as bolts.

Referring toFIG.5, the shoulder abductor12further includes an abductor joint34, shown according to one embodiment. The abductor joint34is used to pivot the shoulder flexion assembly mount30away from the harness mount26and back toward the harness mount26.

Referring toFIGS.6and7, the shoulder abductor12includes an abductor motor36to control the pivotal movement of the abductor joint34, both the shoulder abductor12and abductor motor36shown according to one embodiment. In this embodiment, the abductor motor36is a brushed DC motor controlling the pivotal movement through an abductor belt38connected to a worm drive41driving a worm wheel39connected to an abductor harmonic drive gearing system40.

Referring toFIGS.8and9, the shoulder flexion assembly14, in one embodiment, has a main shoulder housing42, with an abductor interface44for connecting the shoulder flexion assembly14to the shoulder abductor12. The shoulder flexion assembly14also has a humeral interface46for connecting the humeral rotator16to the shoulder flexion assembly14.

Referring toFIGS.10and11, in one embodiment, shoulder flexion motor magnets52are disposed around a shaft58of a shoulder flexion motor rotor54. In this embodiment, a shoulder flexion motor armature55drives the shoulder flexion motor rotor54, which in turn drives a shoulder flexion motor pulley56around a motor shaft58. The shoulder flexion motor pulley56supports a shoulder flexion belt60, which is linked between the shoulder flexion motor pulley56and a shoulder flexion belt-driven pulley62. The shoulder flexion belt-driven pulley62drives a shoulder flexion harmonic drive gearing system wave generator64. A shoulder flexion harmonic drive gearing system flexspline66rotates against the shoulder flexion harmonic drive gearing system wave generator64and a shoulder flexion harmonic drive gearing system circular spline68, resulting in reduced speed for the joint movement. The shoulder flexion harmonic drive gearing system flexspline66is connected to the abductor interface44, and is thus able to rotate the shoulder flexion assembly14in reference to the abductor interface.

Referring toFIG.11, in one embodiment, a non-backdriving clutch70is disposed inside the main shoulder housing42. The non-backdriving clutch70allows the prosthetic arm10to hold position by locking when the prosthetic arm10is not moving.

Referring toFIG.12, in one embodiment, roller bearings72line the interface between an input cage74and an output hex76. When a force is applied to the shoulder abductor interface44, the output hex76locks against the bearing race78and the roller bearings72. This prevents the shoulder flexion assembly14from moving due to force applied to its output, shoulder abductor interface44. Upon the exertion of a necessary amount of input force through the clutch input cage74, the output hex76disengages and allows the shoulder flexion assembly14to move. The clutch input cage74and the output hex76are both constrained by a clutch race78. It should be understood by those skilled in the art, that other mechanisms could be used to prevent backdriving of the prosthetic arm10, such as a clutch that locks in one direction or a solenoid with brakes that engage when the solenoid is powered. Additionally, although described in connection with the shoulder flexion assembly14, it should be understood by those skilled in the art that the non-backdriving clutch70may be included in other prosthetic joints described herein.

Referring toFIG.13, in one embodiment, a compliance subassembly50includes a compliance reactor80positioned on top of the shoulder flexion harmonic drive gearing system circular spline68and held in place by the clamp82. The compliance reactor80measures the amount of displacement in the compliance subassembly50in relation to the position of a compliance sensor magnet84.

Referring toFIG.14, in one embodiment, the interior of compliance subassembly50includes series elastic elements86. The shoulder flexion harmonic drive gearing system circular spline68defines the interior of the compliance subassembly50and is formed to accommodate the placement of the series elastic elements86around an outer diameter87of the shoulder flexion harmonic drive gearing system circular spline68. The series elastic elements86are confined by the shoulder flexion harmonic drive gearing system circular spline68and the clamp82.

Referring toFIG.15, the placement of the compliance reactor80in relation to the series elastic elements86and reactor elements88is shown. In this embodiment, three reactor elements88are positioned around the compliance reactor80, equidistant to each other. One series elastic element86is placed on either side of each reactor element88. When the shoulder flexion assembly14is subjected to unexpected force, such as a sudden jolt or impact, the compliance reactor80and reactor elements88displace from their rest positions and compress against the series elastic elements86. In that way, the compliance subassembly50attenuates the shock being transferred to the rest of the shoulder flexion assembly14. The compliance reactor80may also measure the amount of displacement and compliance by measuring the movement of the compliance reactor80in relation to the stationary position of the compliance sensor magnet84.

Referring toFIG.16, one embodiment of the humeral rotator16is shown. The humeral rotator16includes an outer bearing carrier90attached to the first control housing92, shown inFIG.2. The first control housing92, shown inFIG.2, is used to connect the humeral rotator16to the shoulder flexion assembly14. The inner rotational elements of the humeral rotator are held in place by a clamp94, which is fastened to the outer bearing carrier90. A humeral mount96passes through the clamp94and includes an elbow interface98for attaching the elbow flexion assembly18to the humeral rotator16.

FIG.17shows a cross-sectional view of the humeral rotator16. A humeral motor armature100drives a humeral motor rotor102having humeral magnets104disposed on its surface. The lower portion of the motor rotor102engages a humeral harmonic drive gearing system wave generator106. A humeral harmonic drive gearing system flexspline108rotates with the humeral harmonic drive gearing system wave generator106against the humeral harmonic drive gearing system circular spline110, resulting in a speed of rotation reduction as the humeral harmonic drive gearing system flexspline108causes the humeral mount96to move. Bearings111and113support the humeral motor rotor102. Bearings112support the harmonic drive gearing system components106,108,110. A bearing support114caps the outer bearing carrier90between the outer bearing carrier90and the first control housing92.

Still referring toFIG.17, the one embodiment, a humeral potentiometer116of the humeral rotator16, measures the rotational displacement of a humeral potentiometer shaft118that rotates proportionately to the humeral mount96.

Referring toFIG.18, the elbow flexion assembly18includes an elbow joint120and a radial mount122. The elbow joint120includes a slot124into which the elbow interface98of the humeral rotator is inserted to facilitate connection of the elbow flexion assembly18to the humeral rotator16. The radial mount122provides a second electronics housing126, in which an ACM stack128is located. “ACM” as used herein refers to Arm Control Module. The radial mount122includes a wrist interface130, for attachment of the wrist rotator20.

Referring toFIG.19, the elbow joint120includes an elbow motor armature132that drives an elbow motor rotor134. Elbow magnets136are disposed at one end of the motor rotor134, and the opposing end of the motor rotor134has a sun gear138. As the motor armature132drives the sun gear138, the sun gear138in turn drives four planetary gears140positioned equidistant from each other around the sun gear138. The four planetary gears140in turn react against a ring gear142, giving the elbow flexion assembly18a first stage of speed reduction through an elbow harmonic drive gearing system wave generator148which also acts as the planet carrier. The elbow harmonic drive gearing system wave generator148powers the elbow harmonic drive gearing system flexspline146, which drives against the elbow harmonic drive gearing system circular spline144, giving the elbow flexion assembly18a second stage of reduction. The elbow harmonic drive gearing system flexspline146then drives the motion of the elbow flexion assembly18. Bearings150and crossed roller bearings152support the outer perimeter of the elbow flexion assembly18. Although described with both a planetary gear system and an elbow harmonic drive gearing system, the elbow flexion assembly18could be controlled solely by a harmonic drive gearing system by changing the gear reduction ratio.

In various embodiments, it may be desirable to avoid having to perform additional measurement by using the measurement in the compliance process. One example includes, in various embodiments, where the planetary gears may be used for compliance and measurement of load.

Referring toFIG.20, in the embodiment shown, the radial mount122is structurally fixed to the elbow joint120, such that when the elbow joint is actuated, the radial mount122moves.

Referring toFIG.21, an elbow compliance subassembly154is incorporated into the elbow flexion assembly18. A plurality of arms156extends from the center portion of the elbow compliance subassembly154. Each arm156has an elbow series elastic element158disposed on either side of the am156. Similar to the shoulder flexion assembly14, if the elbow flexion assembly18is subject to a torque, the elbow compliance subassembly154, with its series elastic elements158, is capable of absorbing the shock attenuating the torque magnitude through the rest of the elbow flexion assembly18.

Referring toFIG.22, the ACM stack128, includes circuit boards160connected to one another by structural standoffs162. The structural standoffs162are constructed of a conductive material, so that electrical power may be passed through the circuit boards160. The structural standoffs allow power to be supplied to each circuit board160without conventional power connections.

Referring toFIG.23, the wrist rotator20includes a wrist outer bearing carrier164, a wrist clamp166, a wrist potentiometer168, an elbow interface170, and a wrist flexion assembly interface172.

Referring toFIG.24, movement of the wrist rotator20is controlled by a harmonic drive gearing system similar to that described for the humeral rotator. A wrist rotator motor armature174drives a wrist rotator motor rotor176having wrist rotator magnets178disposed to its surface. The lower portion of the wrist rotator motor rotor176integrates a wrist rotator harmonic drive gearing system wave generator180. A wrist rotator harmonic drive gearing system flexspline182rotates with the wrist rotator harmonic drive gearing system wave generator180against a wrist rotator harmonic drive gearing system circular spline184, resulting in reduction in the speed of rotation as the wrist rotator harmonic drive gearing system flexspline182causes the wrist flexion assembly interface172to move with respect to the rest of the wrist rotator20. Bearings185support the wrist rotator motor rotor176. Bearings186support the harmonic drive gearing system components180,182, and184.

Still referring toFIG.24, the wrist potentiometer168of the wrist rotator20is disposed at one end of a wrist shaft188and measures the rotational displacement thereof. The wrist shaft188may be tubular, having an electronics channel190for passing electronic power and controls through the wrist rotator20.

Referring toFIG.25, the wrist flexion assembly22includes hand control module circuit boards192, an input support structure194, an output arm196, and a hand interface198. The input support structure194connects the wrist rotator20with the wrist flexion assembly22. The output arm196has positive and negative flexion, such that the output arm196is able to move in two opposite directions in reference to the support structure194. The hand interface198allows the hand assembly24to be connected to the wrist flexion assembly22. Referring toFIG.26, the wrist flexion assembly22, has wrist electrical connections200for supplying power to a wrist flexion motor202.

Referring toFIG.27, in the embodiment shown, the wrist flexion motor202drives a wrist flexion output gear204, which in turn drives a wrist flexion final stage-driven gear206. A wrist flexion pivot axle208of the output arm196is axially disposed inside an opening defined by the interior of the wrist flexion final stage-driven gear206. Wrist flexion series elastic elements210are disposed in the interior of the output arm196. Movement of the wrist flexion final stage-driven gear206facilitates the positive and negative motion of the output arm196. A non-backdriving clutch212is disposed at one end of the wrist flexion output gear204.

Referring toFIG.28, the output arm196has a wrist flexion drive arm214, which is driven by the wrist flexion final stage-driven gear206. The end of the wrist flexion drive arm214accommodates a wrist flexion compliance sensor magnet216. The wrist flexion series elastic elements210are disposed on either side of the wrist flexion drive arm214, and the wrist flexion series elastic elements210and the drive arm214are substantially enclosed within the output arm196. Similar to the elbow flexion assembly18and the shoulder flexion assembly14, if the wrist flexion assembly22is subjected to a force, the wrist flexion drive arm214compresses the wrist flexion series elastic elements210and attenuates the force or impact through the rest of the wrist flexion assembly22.

The following is a description of one embodiment of the hand assembly. Other embodiments of the hand assembly are described and shown elsewhere in this specification. Referring toFIGS.29and30the hand assembly24includes a hand support218for providing an interface for connecting the hand assembly24to the wrist flexion output arm196. The hand assembly24also includes a thumb structure220, an index finger structure222, and an MRP structure224replicating a middle finger226, a ring finger228, and a pinky finger230. In various embodiments, the thumb structure220may be driven by two thumb drives232that feed into a single differential, giving the thumb structure220two degrees of freedom of movement. The index finger structure222may be driven by a single index drive234and the MRP structure224may be driven by a single MRP drive236that feeds a double differential. The MRP approach allows for an indeterminate versus determinate linkage.

Referring toFIG.31, the index finger structure222(not shown) is driven by the index drive234through an index drive pulley238, an index tensioner240, an index tension belt242, and an index finger pulley244. The index drive pulley238is stage driven and transfers the torque to the index tension belt242, which in turn rotates the index finger pulley244, causing the index finger structure222to move. As the index tension belt242transfers the torque, one side of the index tension belt242tightens and the other side loosens, depending on which direction the index drive pulley238is rotated. The index tensioner240is located between the index drive pulley238and the index finger pulley244and the index tensioner240displaces in relation to the change in load to maintain the tension of the index tension belt242. The index tensioner240has one side grounded and the other side capable of displacement upon the application of a load. The index tensioner240may instead ground the moveable side of the index tensioner240with a spring.

Referring toFIG.38, in another embodiment, the index finger structure222is driven through an index sun shaft350, a set of index planets352, an index planet carrier354, an index ring gear356, and an index drive gear358. The index drive360drives the index ring gear356, turning the index planets352, the turning of which causes the index planet carrier354to rotate. The index drive gear358is driven by the external teeth of the index planet carrier354, causing the index structure222to move. Any torque transmitted by the index planet carrier354will react against the index sun shaft350causing it to rotationally displace the index spring362through the index spring mount364. This rotational displacement, sensed by an index potentiometer366can be used to infer the load on the index finger structure222. This rotational displacement may be used to store elastic energy and to provide the index finger structure222with a measure of compliance that may aid in gripping and with load absorption.

Referring toFIG.31, the thumb structure220is mounted on a thumb support246, which is driven by the two thumb differential drives232. The thumb structure220has flexural cuts248at its base allowing the compliant thumb structure220to move when a load is applied to it. This compliance in the thumb structure220may aid in gripping and with load absorption, which may prevent the hand assembly24from damaging objects (not shown) by closing around them too quickly and forcefully.

Referring toFIG.32, the hand assembly24includes an MRP drive pulley250driven by the MRP drive236(not shown). The MRP drive pulley250is connected through an MRP tension belt252to the MRP pulley254, enabling movement of the MRP structure224. The MRP drive pulley250is stage driven and transfers the load to the MRP tension belt252, which in turn rotates the linked MRP structure224via the MRP pulley254. As the MRP tension belt252transfers torque, one side of the MRP tension belt252tightens as the other side loosens. An MRP tensioner256located at one side of the MRP tension belt252displaces in relation to the change in load to maintain the tension of the MRP tension belt252. This also provides the MRP structure224with compliance to aid in gripping and with load absorption, which may prevent the hand assembly24from damaging object s(not shown) by closing around the objects (not shown) too quickly and forcefully.

Referring toFIG.38, in another embodiment, the MRP finger structures224are driven through an MRP sun shaft370, a set of MRP planets372, an MRP planet carrier374, an MRP ring gear376, and an MRP drive gear378. The MRP drive380drives the MRP ring gear376, turning the MRP planets372, the turning of which causes the MRP planet carrier374to rotate. The MRP drive gear378is driven by the external teeth of the MRP planet carrier374, causing the MRP structures224to move. Any torque transmitted by the MRP planet carrier374will react against the MRP sun shaft370causing it to rotationally displace the MRP spring382through the MRP spring mount384. This rotational displacement can be used to store elastic energy.

Referring toFIG.33the MRP differential drive236includes a main MRP drive gear258. The MRP drive gear258drives a first MRP input axle260. The first MRP input axle260drives a first differential idler gear259which optionally drives a middle spur gear262or a differential interface gear261. The middle spur gear262drives a middle pivot axle264. The middle finger226is mounted on the middle pivot axle264and is thus actuated by the MRP differential drive236. The differential interface gear261drives a second MRP input axle266. The second MRP input axle266drives a second differential idler gear263which optionally drives a ring spur gear268or a pinky spur gear272. The ring spur gear268drives a ring pivot axle270. The ring finger228is mounted on the ring pivot axle270and is thus actuated by the MRP differential drive236. The pinky spur gear272drives a pinky pivot axle274. The pinky finger230is mounted on the pinky pivot axle274and is thus actuated by the MRP drive236. While the MRP drive236drives the middle finger226, the ring finger228and the pinky finger230, the gear configuration of the first input axle260and the second input axle266allows independent movement for the under-actuated finger gear system of the MRP structures224.

Referring toFIG.41, in another embodiment of the hand, the MRP differential drive includes an MRP drive gear378which drives a double differential allowing the MRP fingers to conformably wrap around an object. The MRP drive gear378drives a first MRP input axle400. The first input axle400drives a first differential idler gear402which optionally drives a middle spur gear404or a differential interface gear406. The middle spur gear404drives a middle pivot axle264. The middle finger226is mounted on the middle pivot axle264and is thus actuated by the MRP drive236. The differential interface gear406drives a second MRP input axle408. The second MRP input axle408drives a second differential idler gear410which optionally drives a ring spur gear412or a pinky spur gear414. The ring spur gear412drives a ring pivot axle270. The ring finger228is mounted on the ring pivot axle270and is thus actuated by the MRP drive236. The pinky spur gear414drives a pinky pivot axle274. The pinky finger230is mounted on the pinky pivot axle274and is thus actuated by the MRP drive236. While the MRP drive236drives the middle finger226, the ring finger228and the pinky finger230, the gear configuration of the first input axle400and the second input axle408allows independent movement for the under-actuated finger gear system of the MRP structures224.

Referring toFIG.34the thumb differential drives232control the movement of the thumb structure220and are driven by thumb actuators276. The thumb actuators276have nonbackdriving thumb clutches278to prevent output loads from reaching and backdriving the thumb actuators. One thumb actuator276drives a first thumb output drive280and a first thumb output gear282. The first thumb output gear282in turn drives a first thumb transfer gear284, which drives a fixed differential shaft286. The fixed differential shaft286drives one thumb differential bevel gear287. The second thumb actuator276drives a second thumb output drive288and a second thumb output gear290. The second thumb output gear290drives a second thumb transfer gear292, which drives a thumb differential bevel gear294. The two thumb differential bevel gears287and294operate the thumb structure220in its two degrees of motion.

The thumb structure220, the index finger structure222, and MRP structure224in one embodiment are covered in silicone, which provides additional friction and aids in gripping objects. In some embodiments, the entire hand assembly24may also be covered in silicone to provide additional grip for holding objects. In other embodiments, the silicone material may be replaced by other compliant materials.

The hand assembly24is advantageous because the thumb structure220, index finger structure222and MRP structure224provide various degrees of freedom that allow the formation of various grasps or grips. Additionally, the different drives for each of the thumb structure220, index finger structure222and MRP structure224provide various beneficial characteristics to the hand assembly24. For instance, the thumb structure220moves relatively slow, but with greater force than the index finger structure222and MRP structure224. The index finger structure222moves quickly, but with less force and is non-backdrivable. This combination of thumb structure movement and index finger structure movement allow the quick formation of strong hand grips. Additionally, the combination allows for a smaller index finger actuator, which reduces size and weight of the hand assembly24. Additionally, the index finger structure222and MRP structure224move similar to human fingers, which makes them look more natural and makes them more intuitive for the user to control. The MRP structure224provides only bulk control for gripping objects, without providing for individual finger manipulation, since fine control is not necessary for the MRP structure224. Additionally, the MRP structure224advantageously moves each finger of the MRP structure224with a single actuator, eliminating excessive bulk in the hand assembly24. Like the index finger structure, the MRP structure224moves quickly with low force but is also non-backdrivable. Additionally, the fingers of the MRP structure224are highly flexible, allowing them to grip objects of varying size and shape. The MRP structure224functionality allows the user to grasp an object with the MRP structure224and thumb structure220, while allowing the user to move the index finger structure222separately, for example, to activate a button on the object.

The various parts of the prosthetic arm apparatus10are, in some embodiments, constructed from plastic or magnesium. However, where more strength is desired, the parts may be made of aluminum, titanium or steel. In other embodiments, the various parts of the prosthetic arm may be constructed of other metals or plastics, depending on the desired characteristics, including strength, weight, compliance or other similar performance characteristics of the various parts.

Referring toFIG.35, a tactile feedback sensor296may be positioned on the inner side of the thumb structure220. The tactile feedback sensor296may be a pressure sensor, force sensor, a displacement sensor, or other similar sensor capable of providing the user with feedback. Referring toFIG.36, the tactile feedback sensor296is operatively connected to a feedback actuator298. The tactile feedback sensor296may be connected to the feedback actuator298by either wires or wirelessly. In operation, as the user grips an object with the hand assembly24, feedback sensor296reads the displacement of or the force exerted on the thumb structure220. That reading is then sent to the feedback actuator298, which gives the user tactile feedback that indicates the strength of the grip. Feedback actuator298may be placed on the chest of the user, located on a prosthetic support apparatus299in an area of tactile communication with the user, or in any other location capable of receiving tactile feedback, such as on a user's residuum300. Referring toFIG.37, the feedback actuator298may be located on a foot controller302that is used to control hand assembly24.

Feedback actuator298may be a vibration motor, such as any vibration motor known in the art, placed against the skin of the user. As the user grips an object, feedback actuator298begins vibrating, notifying the user how strong the object is being gripped. As the force on or displacement of the tactile feedback sensor296changes, frequency and/or amplitude of vibration may also change, notifying the amputee of a changing grip. For example, if a vibrating actuator298is placed at the chest of the user as inFIG.36, the user will feel the vibration at his chest.

The feedback actuator298may also be placed wherever the controller for the hand assembly24is located. For example, if a foot controller302controls the hand assembly24, the feedback actuator298may be incorporated into the foot controller302. The user will then receive tactile feedback of the strength of the prosthetic grip at the same location where the controller is located.

The actuator298may also be a pressure actuator that applies pressure against the user's skin. For example, the actuator298may have a rod that increases pressure against the amputee's skin as the hand assembly24increases its grip on an object.

Although described with a single tactile feedback sensor296, additional tactile feedback sensors may be placed at other locations on the hand assembly24. For example, additional tactile feedback sensors296may be placed on the index finger structure222, the MRP structures224, on the palm of the hand assembly24, or on any combination of these positions or any other location. Each tactile feedback sensor296would then be operatively connected to an associated feedback actuator298. Multiple tactile feedback sensors296and actuators298would provide more sophisticated tactile feedback of the strength of the grip, improving the control of the hand assembly24.

In some embodiments, the tactile feedback sensor296may indicate a change in pressure or force, rather than an absolute pressure or force. For example, if the force detected by the tactile feedback sensor296is constant, the feedback actuator298does not actuate, but if that pressure or force increases or decreases, the actuator298would actuate to indicate the change in pressure or force. Additionally, although described in terms of grip strength, the tactile feedback sensors296and actuators298may provide a variety of other feedback in including temperature, an operational mode of the prosthetic arm10, surface finish of a object, slip of an object within the hand assembly24or the like.

In operation, the prosthetic arm apparatus is able to move substantially similar to a human arm. Referring toFIGS.29and30, starting with the hand assembly24, the thumb structure220, index finger structure222, and MRP structure224are each driven independent of the others, and therefore, each may be actuated without actuating the other two structures. Both of the thumb actuators276control motion of the thumb structure220in a direction toward or away from the center of the palm of the hand assembly24, as shown inFIG.34, through the miter gear294and in a direction toward or away from the side of the palm of the hand assembly24, as shown inFIG.34, through the lateral rotation shaft, depending upon the direction and speed of rotation of each thumb actuator276. Thus, the thumb actuators276, shown inFIG.34, provide the thumb structure220with two degrees of freedom in the thumb structure's movement. Coupling the two thumb actuators276through the differential described above to provide the two degrees of freedom to the thumb structure220is advantageous over providing a single degree of freedom with each actuator276because the torque of each actuator276through the differential is used for movement in both degrees of freedom, which effectively doubles the torque of the thumb in each direction as compared to single actuators. The index finger structure222, driven by a single index differential drive234, may be actuated with two degrees of freedom. Specifically, the index finger structure222may be actuated toward or away from the palm of the hand assembly24, wherein the movement path is similar to that of a human index finger while making or releasing a fist. The middle finger226, ring finger228, and pinky finger230of the MRP structure224are actuated by the MRP differential drive236. Additionally, the middle finger226, ring finger228, and pinky finger230are actuated toward or away from the palm of the hand assembly24, similar to the index finger structure222. However, the middle finger226, ring finger228, and pinky finger230are each geared separately, such that the rate of movement of each is different, simulating human finger movement and making the hand assembly24more similar to a human hand than conventional prior art prosthetic devices.

Referring toFIG.1, the hand assembly24is mounted on the wrist flexion assembly22via the hand interface198, as shown inFIG.25. Referring toFIG.25, as the output arm196of the wrist flexion assembly22is actuated, the hand assembly24is also caused to move. The output arm196of the wrist flexion assembly22may be actuated pivotally about wrist flexion pivot axle208, as shown inFIG.27, moving the hand interface198to the left or right, and thus pivoting the hand assembly24in relation to the input support structure192.

Referring back toFIG.1, the wrist flexion assembly22is attached to the wrist rotator20via wrist flexion assembly interface172, shown inFIG.23. Referring toFIGS.23and24, when actuated, the wrist flexion assembly interface172is rotated about wrist shaft188in relation to10the wrist outer bearing carrier164. Therefore, the wrist flexion assembly22, and attached hand assembly24are also caused to rotate in reference to the wrist outer bearing carrier164by actuation of the wrist rotator20. Therefore, the wrist rotator20allows the prosthetic arm apparatus10to move in rotation similar to a human wrist joint.

Referring back toFIG.1, the wrist rotator20is attached to the elbow flexion assembly18via the wrist interface130, shown inFIG.18. Referring toFIG.20, when the elbow flexion assembly18is actuated, the radial mount122is rotated about the axis of motor rotor134. The wrist rotator20, wrist flexion assembly22, and hand assembly24are thus also caused to rotate about the axis of motor rotor134because they are attached at the wrist interface to the radial mount122. Therefore, the elbow flexion joint18allows the prosthetic arm apparatus10to move similar to flexion extension of a human elbow joint.

Referring back toFIG.1, the elbow flexion assembly18is attached to the humeral rotator16via the humeral mount96, shown inFIG.27. Referring toFIG.16, actuation of the humeral rotator16causes the humeral mount96to rotate in relation to the outer bearing carrier90of the humeral rotator16. Since the elbow flexion assembly18, wrist rotator20, wrist flexion25assembly22, and hand assembly24are attached to the humeral mount96, they are also caused to rotate in relation to the outer bearing carrier90. This allows the prosthetic arm apparatus10to rotate to perform an arm wrestling motion.

Referring back toFIG.1, the humeral rotator16is attached to the shoulder flexion assembly14through the humeral interface46, shown inFIG.9. Referring toFIG.9, actuation of the shoulder flexion assembly14causes the main shoulder housing42to pivot about the center of the abductor interface44. Since the humeral rotator16, elbow flexion assembly18, wrist rotator20, wrist flexion assembly22, and hand assembly24are attached to the main housing42, they are also caused to rotate in relation to the abductor interface44. Therefore, the shoulder flexion assembly14allows the prosthetic arm apparatus10to move along the torso simulating running motion.

Referring toFIG.1, the shoulder flexion joint14is attached to the shoulder abductor12through the shoulder flexion assembly mount30, shown inFIG.5. Referring toFIG.5, the shoulder abductor12is attached to a harness that is worn by the user via harness mount26. When the shoulder abductor12is actuated in a positive direction, the shoulder flexion assembly mount30pivots away from the harness mount26, and the user. Similarly, by actuating the shoulder abductor in a negative direction, the shoulder flexion assembly mount30is pivoted toward the harness mount26and the user. Since the shoulder flexion assembly14, humeral rotator16, elbow flexion assembly18, wrist rotator20, wrist flexion assembly22, and hand assembly24are attached to shoulder abductor12at the flexion assembly mount30, they are also caused to pivot with the shoulder flexion assembly mount30.

One characteristic of the prosthetic arm apparatus described herein is that it provides the user with substantially the same movement capabilities and degrees of freedom of a human arm, including two degrees of freedom in shoulder functionality. Additionally, the modularity of each segment of the prosthetic arm apparatus10provides a significant advantage over conventional prosthetic devices. In particular, since each segment of the plurality of segments operates independently of each other segment of the plurality of segments, fewer segments may be used for less severe amputees. For example, a transhumeral amputee may have full shoulder functionality in the residuum, in which case the shoulder abductor12and shoulder flexion assembly14segments would be omitted from the prosthetic arm apparatus10. The resulting prosthetic arm apparatus10would include the humeral rotator16, the elbow flexion assembly18, the wrist rotator20, the wrist flexion assembly22, and the hand assembly24, wherein the humeral rotator16would be attached to the prosthetic harness. In some cases, the residuum of the transhumeral amputee may even have humeral rotation, in which case the prosthetic arm apparatus10may be further simplified to include only the elbow flexion assembly18, the wrist rotator20, the wrist flexion assembly22and the hand assembly24, with the elbow flexion assembly22being attached to the prosthetic support apparatus. Similarly, for a transradial amputee, the prosthetic arm apparatus10may include only the wrist rotator20, wrist flexion assembly22and the hand assembly24, with the wrist rotator20being attached to the prosthetic support apparatus. Additionally, in some embodiments, the prosthetic arm apparatus10may be further simplified to include only the wrist flexion assembly22and the hand assembly24when the transradial amputee has wrist rotation in their residuum. In these embodiments, the wrist flexion assembly22may be attached to the prosthetic support apparatus. Thus, the modularity of each segment of the prosthetic arm apparatus10advantageously allows for customization of different prosthetic arm configurations for various users based on the differing degrees of amputation of each user.

A further advantage of the present invention is the use of non-backdriving clutches to preclude movement of the segments due to forces exerted on the prosthetic arm apparatus10when not in motion. These non-backdriving clutches may be particularly beneficial when the segments of the prosthetic arm apparatus10have different strength capacities so that the clutches for specific segments of the prosthetic arm apparatus10may lock those segments while other stronger segments are actuated to lift heavy objects. For instance, the non-backdriving clutch in the shoulder flexion assembly14may be used to lock out shoulder movement while the elbow flexion assembly18is actuated to lift a heavy object. The non-backdriving clutches may also advantageously conserve power since the non-backdriving clutches prevent motion without using power. Thus, the power to specific segments of the prosthetic arm apparatus10may be shut off, on a segment-by-segment basis, when not in use, since the non-backdriving clutches in those segments are locking out motion. Additionally, the non-backdriving clutches may also save power by allowing power to the entire prosthetic arm apparatus10to turned off whenever the arm is not in motion while maintaining the prosthetic arm apparatus10in a locked position.

An additional characteristic of the apparatus is that the hand assembly includes independently moving fingers and is capable of completing fine tasks such as pinching, grasping non-uniform objects, and lifting small objects off flat surfaces. Also, the tactile feedback sensor provides the user with feedback, during use of the prosthetic arm apparatus, such as the force of a grip. The apparatus also includes a cosmesis covering on the finger structures, which will be discussed in greater detail below, providing, amongst other things, grip for grasping objects. The rigid fingernail304, which may be included on any of the finger structures, provides a backstop for the finger cover to enhance gripping capability. The rigid fingernail304also enhances gripping capability by anchoring the finger cover to the finger and allows the user to lift small objects from a surface with the prosthetic arm apparatus10.

Referring toFIG.42, wherein like numerals represent like elements, in some embodiments, the shoulder abductor12and the shoulder flexion assembly14shown inFIG.2, may be integrated as a single shoulder unit1416, providing both degrees of freedom provided by the shoulder abductor12and shoulder flexion assembly14ofFIG.2. The single shoulder unit1416includes a shoulder housing1418pivotally connected to the harness mount1026, which allows the shoulder unit1416to be connected to a prosthetic harness (not shown) as discussed above. In some embodiments, the shoulder housing1418has a smooth outer surface1419to shape the shoulder unit1416to be similar to a human arm. The shoulder housing1418is divided into a flexor portion1420and an abductor portion1422, which are movable relative to one another. The flexor portion1420of the shoulder housing1418includes the humeral interface1046for connecting the humeral rotator16, shown inFIGS.1and2, to the shoulder unit1416. The abductor portion1422of the shoulder housing1418is pivotally connected to the harness mount1026, which allows the shoulder unit1416to interface with a prosthetic harness (not shown) as discussed above.

Referring toFIGS.43and44, within the housing1418is a shoulder flexion drive1424for causing flexion motion of the flexor portion1420about a shoulder flexion axis1426and an abduction drive1428for causing abduction motion of the shoulder housing1418about an abduction axis1430. Additionally, the housing also defines an electronics compartment1432for housing control systems and circuits for the integrated shoulder unit1416.

The shoulder flexion drive1424, in one embodiment, includes a shoulder flexion motor1434having motor shaft1058for driving the shoulder flexion motor pulley1056. The shoulder flexion motor pulley1056drives the shoulder flexion belt1060, which, in turn, drives the shoulder flexion belt-driven pulley1062. The shoulder flexion belt-driven pulley1062drives the wave generator1064of a shoulder flexion harmonic drive gearing system1436, the output of which is fixedly interfaced with the abductor portion1422. Thus, as power is transmitted through the shoulder flexion drive1424from the shoulder flexion motor1434to the output of the harmonic drive gearing system1436, the flexor portion1420rotates relative to the abductor portion1422about the shoulder flexion axis1426. In some embodiments, the motor shaft1058and the wave generator1064are both hollow shafts to allow passage of an abductor motor shaft1438and an abductor screw shaft1440, respectively, as will be discussed in greater detail below.

In the exemplary embodiment, the abduction drive1428includes the abductor motor1036for driving the abductor motor shaft1438. The abductor motor shaft1438is configured to drive the abductor belt1038about its distal end. The abductor belt1038, in turn, drives the abductor screw shaft1440, which has an abductor nut1442threadedly coupled thereto. The abductor nut1442is connected to the harness mount1026through a linkage1444, which is, in some embodiments, a four bar linkage. As power is transmitted through the abductor drive1426from the abductor motor1036to the abductor screw shaft1440, the screw shaft1440rotates. The rotation of the screw shaft1440causes the abductor nut1442to displace axially along the screw shaft1440, which causes pivotal motion of the shoulder housing1418through the linkage1444about the abduction axis1430.

The relative movement between the flexor portion1420and the abductor portion1422provides the shoulder unit1416with a first degree of freedom similar to that of the shoulder flexion joint14ofFIG.2. The abductor portion1422of the shoulder housing1418is pivotally connected to the harness mount1026at the abductor joint1034, providing the shoulder unit with the second degree of freedom by allowing the shoulder housing1418to pivot relative to the harness mount1026in a similar manner to that discussed above in connection with the shoulder abductor12ofFIG.2. The integrated shoulder unit1416locates the shoulder flexion axis1426and the abduction axis1430relatively close to one another as compared to separate shoulder flexion and shoulder abduction assemblies, which provides for more intuitive motion that more closely simulates the movement of a human shoulder.

The shoulder flexion drive1424and the abduction drive1428discussed above include coaxial motors and coaxial shafts to minimize the size of the single shoulder unit1416and to reduce the weight thereof. Thus, these exemplary single shoulder unit1416is beneficial because its weight relative to the separate shoulder abductor12and shoulder flexion assembly14, shown inFIG.2. Additionally, the single shoulder unit1416provides more narrow housing1418, which allows a more natural anatomical position of the shoulder for a broader range of users and may reduce bumping with the user's residuum during use. embodiments have an additional benefit of decreasing the weigh of the prosthetic. Additionally, as seen inFIGS.43and44, both the abduction motor1036and the shoulder flexion motor1434may be located in the vicinity of the electronics compartment1432, so the electronics for both the shoulder flexion drive1424and the abduction drive1428may be located in the same place, which eliminates any need to route wiring through the shoulder unit1416. This is advantageous since running wires across joints is a failure mode in which the wires may crimp and break when moved. Thus, the shoulder unit1416eliminates this failure mode by eliminating wires running across the joints that could cause failure of the prosthetic arm1010.

Although the shoulder flexion drive1424and the abduction drive1428have been shown in an exemplary configuration, it should be understood by those skilled in the art that other drive configurations may also be used to drive the single shoulder unit1416about the shoulder flexion axis1426and the abduction axis1445. For instance, referring toFIG.45, the shoulder flexion motor2434and the abduction motor2036do not need to be coaxial and they may still each be located in the vicinity of the electronics compartment2432. Additionally, rather than driving the linkage1444, shown inFIG.43, the worm drive2041may instead threadably engage an abduction gear2446coupled to the harness mount2026, shown inFIG.43, to generate pivotal movement about the abduction axis2430.

Additionally, referring now toFIG.46, in various embodiments, the integrated shoulder unit3416may shift the abduction output to change the location of the harness mount3026to improve mounting location and/or to allow for ninety degrees (90°) of abduction about the abduction axis3430without bumping with the residuum (not shown). For example, the location of the abduction output may be changed by extending the abduction drive3428with one or more additional shafts, gears, and/or belts.

Referring toFIG.47, the flexion assembly mount4030may also be shifted away from the harness mount4026in the non-integrated shoulder abductor4012. Referring toFIG.48, the flexion assembly mount4030may also include an accommodating slot4031adapted to accommodate portions of the abductor joint4034, shown inFIG.47. Referring back toFIG.47, the shifted flexion assembly mount4030allows the user to orient the shoulder abductor4012on the prosthetic support apparatus (not shown) in different orientations while still allowing a range of motion of the shoulder abductor4012of at least approximately ninety degrees (90°). This may be particularly advantageous since the mounting orientation of the shoulder abductor4012may vary from user to user, which may limit the range of abduction motion with the non-shifted flexion assembly mount30, shown inFIG.6. Additionally, in some embodiments, the shifted flexion assembly mount4030may house a flex sensor plunger for detecting flexion motion of the shoulder flexion assembly4014.

Referring now toFIG.49, another embodiment of the wrist rotator1020is shown for providing improved electronic wiring capability to the prosthetic device. Although shown as the wrist rotator1020, it should be understood by those skilled in the art that a similar configuration may be used for other rotating joints, such as the humeral rotator16, shown inFIG.1. In this embodiment of the wrist rotator1020, the wrist rotator motor1448, including the wrist rotator motor armature1174and a driven portion1450of the wrist rotator motor rotor1176having wrist rotator magnets1178disposed thereon, and the wrist harmonic drive gearing system1452, including the wrist rotator harmonic drive gearing system wave generator1180, the wrist rotator harmonic drive gearing system flexspline1182and the wrist rotator harmonic drive gearing system circular spline1184, are separated into coaxial side-by-side units with the wrist rotator motor1448being proximate to the elbow interface1170and the harmonic drive gearing system1452being proximate to the wrist flexion assembly interface1172. By arranging the wrist rotator motor1448and the wrist harmonic drive gearing system1452in the side-by-side configuration, the electronics channel1190passing through the center of the wrist rotator rotor1176may be formed large enough to allow electronic wiring to be run internally through the center of the wrist rotator1020. Referring toFIGS.50and51, the wiring through the prosthetic arm10, shown inFIG.1, in some embodiments, may run through one or more extension springs1454, in particular around the flexion joints, such as the elbow flexion assembly18and the wrist flexion assembly22, shown inFIG.1, where internal wiring is difficult or impractical.

Routing the wiring through the center of the wrist rotator1020eliminates the need for external wiring, thereby minimizing any flexing movement experienced by the wiring, which can cause wire pinching, abrasions and failure. The internal wiring also eliminates the possibility that external wiring will become caught on something and break. Routing the wiring through the one or more extension springs1454where internal wiring is not practical, possible or desired allows for controlled loading of the external wiring and protects the wiring from pinching to reduce wire failure.

Referring toFIG.52, in another embodiment of the wrist flexion assembly1022, the output arm1196is able to move in flexion relative to the input support structure1194about a flexion axis1456and to move in ulnar-radial deviation relative to the input support structure1194about a deviation axis1458. Thus, when the hand assembly24, shown inFIG.1, is attached to the output arm1196of the wrist flexion assembly1022, the hand assembly24, shown inFIG.1, is able to move in both flexion and ulnar-radial deviation.

Referring toFIG.53, the wrist flexion assembly1022includes two wrist motors1202, for controlling the flexion and ulnar-radial deviation of the output arm1196, shown inFIG.52. Each wrist motor1202drives an input gear train1460, which, in turn, drives a wrist worm gear1462. Each worm gear1462drives an input gear1464of a wrist differential1466. The wrist differential1466includes a first bevel gears1468and a second bevel gear1470that are rotatable about the flexion axis1456. The first bevel gear1468and the second bevel gear1470may be driven by one of the input gears1464. The wrist differential1466also includes a differential body1472rotatably attached about the flexion axis1456between the first and second bevel gears1468and1470. An ulnar-radial axle1474extends from one side of the differential body1472along the ulnar-radial axis1458and a third bevel gear1476extends from the differential body1472on the opposite side thereof. The third bevel gear1476is rotatable about the ulnar-radial axis1458and meshes with and is driven by the first bevel gear1468and the second bevel gear1470.

In operation, the user is able to actuate wrist flexion, wrist ulnar-radial deviation and combinations thereof by actuating the motors1202in various ways. For example, referring toFIG.54, if the motors1202are driven at the same speed in opposite directions, i.e. one is driven clockwise and the other counterclockwise, the output arm1196, shown inFIG.52will move in flexion in one direction about the flexion axis1456. If the direction of each motor is reversed, i.e. from spinning clockwise to counterclockwise and vice versa, the output arm1196, shown inFIG.52, will flex in the opposite direction. Similarly, referring toFIG.55, if the motors1202are driven at the same speed in the same direction, i.e. both are driven clockwise, the output arm1196, shown inFIG.52, will move in ulnar-radial deviation in one direction about the deviation axis1458. If the direction of each motor is reversed, i.e. from spinning clockwise to counterclockwise, the output arm1196, shown inFIG.52, will move in ulnar-radial deviation in the opposite direction about the deviation axis1458. In addition to varying the direction of rotation of the motors1202, varying the speed of one motor1202relative to the other will result in a combination of flexion and ulnar-radial deviation. Accordingly, in this embodiment, wrist flexion and ulnar-radial deviation may both be controlled simply by varying the direction and speed of the motors1202.

Although the wrist flexion assembly1022is described as having a differential drive1466for imparting wrist flexion and wrist ulnar-radial deviation movement to the output arm1196, it should be understood by those skilled in the art that other drives may be used to achieve similar capabilities. For instance, referring toFIG.56, the wrist flexion assembly2022may include a separate wrist flexion gear train2478for imparting flexion motion to the output arm2196about the flexion axis2456and a separate ulnar-radial geartrain2480for imparting ulnar-radial deviation to the output arm2196about the deviation axis1458.

Referring toFIG.76, in another embodiment of the present invention, a wrist flexion assembly4022is provided for imparting a combination of both flexion about the flexion axis4456and ulnar-radial deviation about the deviation axis4458to the hand assembly4024in a single movement. The wrist flexion assembly4022includes the input support structure4194adapted to be connected to the wrist rotator20, shown inFIG.1, in the same manner as discussed above. The wrist support structure4194includes a hand interface4626proximate to the hand assembly4024for attaching the hand assembly4024to the wrist support structure4194. The wrist support structure4194houses a wrist motor202, shown inFIG.26, which drives the wrist pivot axle4208in rotary motion about the wrist flexion axis4456through an appropriate gear train (not shown). The wrist pivot axle includes flattened end portions4628at each end thereof, extending outwardly from the wrist support structure4194and into the hand interface4626. Each flattened end portion4628has two substantially parallel planar surface4630extending parallel to the wrist flexion axis4456. The hand interface4626includes a first cam bearing4632fixedly secured to the wrist support structure4194about the flattened end portion4628of the wrist pivot axle4208proximate to the thumb structure4220of the hand assembly4024. The hand interface also includes a second cam bearing4634fixedly secured to the wrist support structure4194about the flattened end portion4628of the wrist pivot axle4208proximate to the pinky finger4230of the hand assembly4024. Referring toFIG.77, the first cam bearing4632includes a first cam profile4636formed therein. Referring toFIG.78, the second cam bearing4634includes a second cam profile4638formed therein. Referring back toFIG.76, the hand interface4626also includes first and second slider blocks4640coupling the hand assembly4024to the wrist flexion assembly4022. The first and second slider blocks4640each have a proximate end4642at the hand interface4626and a distal end4644near the hand assembly4024. Each of the first and second slider blocks4640has a slot4646formed therein that slidably receives one of the flattened end portions4628of the wrist pivot axle4208. The first and second slider blocks4640include cam followers4648at their proximate ends4642that are received within the first cam profile4636of the first cam bearing4632and the second cam profile4638, shown inFIG.78, of the second cam bearing4634. The first and second slider blocks4640are pivotally coupled to the hand assembly4024at their distal ends4644about pivot axes4650.

In this embodiment, the hand assembly4024may be angled away from the flexion axis4456about a wrist rotation axis4652to reduce the motion that the first cam profile4636and the second cam profile4638need to produce to achieve the desired combined flexion and ulnar-radial deviation movement of the hand assembly4024. In some embodiments, the hand assembly4024is angled approximately thirty degrees clockwise (30° clockwise) assuming left hand user perspective from the flexion axis4456.

Referring toFIGS.79A-79C, in operation, the wrist motor202, shown inFIG.26, drives the wrist pivot axle4208in rotation movement about the flexion axis4456, which provides the hand assembly4024with flexion movement. Additionally, the sliding engagement between the flattened end portions4628of the wrist pivot axle4208and the first and second slider blocks4640causes the first and second slider blocks4640to pivot about the flexion axis4456as the wrist pivot axle4208rotates. As the first and second slider blocks4640pivot, the cam followers4648, shown inFIG.76, follow the first cam profile4636, shown inFIG.76, and the second cam profile4638, shown inFIG.76, which causes the first and second slider blocks4640to slide relative to the wrist pivot axle4208. This sliding motion of each of the first and second slider blocks4640causes the hand assembly4024to pivot about the pivot axes4650, shown inFIG.76, which results in the ulnar-radial deviation movement of the hand assembly4024. Thus, as the wrist motor drives the wrist pivot axle4208, the hand assembly4024moves from a first position4654, shown inFIG.79A, in which the hand is fully flexed and deviated in the ulnar direction, to a second position4656, shown inFIG.79B, which is a neutral position with respect to flexion movement but includes some degree of ulnar deviation. Then, the hand assembly4024continues to move until it reaches a third position4658, shown inFIG.79C, in which the hand assembly4024is fully extended about the flexion axis4456and is also fully deviated in the radial direction.

Referring toFIG.80, the first cam profile4636, shown inFIG.77, and the second cam profile4638, shown inFIG.78, provide for movement of the hand assembly4024, shown inFIG.76, along a constrained flexion-deviation movement path4660that includes components of both flexion motion and ulnar-radial deviation motion. The constrained flexion-deviation movement path4660is advantageous because the user only needs to think about controlling a single degree of freedom, unlike the embodiments discussed above that provide independent wrist flexion movement and ulnar-deviation movement. Additionally, the constrained flexion-deviation movement path4660is beneficial because it provides for full flexion movement and also provides for nearly full ulnar deviation without requiring full wrist flexion. Thus, functionality is particularly beneficial when users use the prosthetic arm apparatus10, shown inFIG.1, to pick up an object (not shown) from overhead. The constrained flexion-deviation movement path4660also advantageously allows for some degree of flexion movement without significant ulnar deviation, which allows the user to move an object, such as a spoon, in flexion motion without spilling its contents. This range of flexion movement with minimal ulnar deviation provided by the constrained flexion-deviation movement path4660may also be beneficial to compensate for offset in situations where the prosthetic arm apparatus10, shown inFIG.1, is mounted at an offset, for example, to avoid the user's residuum. Additionally, since the hand assembly4024, shown inFIG.76, is angled in the neutral second position4656, shown inFIG.79B, pinching of the thumb structure4220, shown inFIG.76, and index finger structure4222, shown inFIG.76, are more in line with the wrist rotation axis4652, which makes various tasks easier for the user, such as turning a door knob, turning a key or the like. Thus, the constrained flexion-deviation movement path4660provided by the wrist flexion assembly4022, shown inFIG.76, provides a variety of advantages over conventional prosthetic devices.

Although described in terms of constrained flexion-deviation movement path4660, it should be understood by those skilled in the art that the first cam profile4636, shown inFIG.77, and the second cam profile, shown inFIG.78, may be formed in various configurations to achieve a variety of different constrained movement paths. Additionally, although the constrained flexion-deviation movement path4660has been described in connection with the wrist flexion assembly4022, the constrained flexion-deviation movement path4660may also be commanded using the flexion assembly1022, shown inFIG.52, by programming the prosthetic controller to actuate the motors1202, shown inFIG.53, to move the prosthetic hand assembly24along the same constrained flexion-deviation path4660.

Referring toFIG.57, in various embodiments, the non-backdriving clutch1070may replace spacers of the input cage1074with springs1482between the rollers1072. The springs1482push the rollers1072apart and into contact with both the race1078and the output polygon1484, which may be an output hex1076. Thus, when a backdriving torque (not shown) is applied to the output hex1076to friction lock the rollers1072between the output hex1076and the bearing race1078, the rollers1072are already contacting both the race1078and the output hex1076, thereby eliminating backlash, i.e. a slight rotation of the output polygon1076, when the backdriving torque (not shown) is applied. Thus, the non-backdrivable clutch1070imparts a frictional lock, which additional backdriving torque (not shown) through the output hex1076will not overcome. Additionally, as discussed above in connection withFIG.12, in various embodiments, the non-backdriving clutch1070may unlock itself through the application of an input load through the input cage1074. Variations of this embodiment may include, but are not limited to, additional or fewer springs1482, additional or fewer rollers1072or a differently shaped race1078. For example, in various embodiments, the relative position of the output hex1076and the race1078may be shifted, i.e., rather than the hollow, circular race1078with the output polygon1484inside, in various embodiments, the clutch may include an outer hollow output polygon surrounding a circular race. Additionally, although shown as a coil spring, it should be understood by those skilled in the art that the springs1482may be formed in various configurations and/or from a variety of metal or elastomeric materials to provide the force for separating the rollers1072.

Referring toFIG.58, an embodiment for output load sensing through a drive1486having a worm gear1488, such as the shoulder abduction drive1428ofFIG.46, is shown. Including one or more worm gears1488in the drive1486is beneficial because the worm gear1488may itself prevent backdriving. The worm gear1488may be arranged on a splined shaft1490between a first spring1492and a second spring1494. The splined shaft includes a plurality of splines1496arranged axially around the surface of the splined shaft1490and a shaft input1498portion, which may be rotated directly by a motor (not shown) or through a gear train or the like. The worm gear1494is tubular and has an interior surface1500designed to slidably interface with the splines1496of the splined shaft1490such that the worm gear1488may slide axially along the surface of the splined shaft1490. The worm gear1488meshes with an output gear1502such that when the splined shaft1490is caused to rotate through its shaft input portion1498, the splined shaft1490rotatably drives the worm gear #1488through the splines1496which, in turn, drives the output gear1502. When a load (not shown) is applied to the drive through the output gear1502, for example, if the user is lifting an object, the load will generate a torque T at the output gear1502. Although the torque T will not cause the worm gear1488to rotate, the torque T may cause the worm gear1488to displace axially along the splined shaft1490compressing one of the first spring1492or the second spring1494, depending upon the direction of displacement. Thus, by designing the drive system1486with the first spring1492and the second spring1494of known spring constants, the compliance, i.e. the displacement of the worm gear1488, may be measured to estimate the output load (not shown). This drive system1486for output load sensing is particularly beneficial since the compliance is still present or active while the worm gear1488is not being rotated, but is instead acting as a non-backdriving element.

The prevention of backdriving with the various systems discussed above is beneficial because it allows the user to maintain a position of the prosthetic arm10, shown inFIG.1, while under a load (not shown). However, referring toFIGS.59and60, in some embodiments, it may be desirable to provide the various arm segments with break-away mechanisms2504that will separate the drive output from the drive input to prevent damage to the drive system if the load becomes too large. The break-away mechanism2504may include an input shaft2506, an output shaft2508and two break-away spacers2510that are held in contact with the input shaft2506and output shaft2508by a compression member2512. The input shaft2506and the output shaft2508each include a shaft body2514and a torque transmission tab2516extending axially outward from the shaft body2514between the break-away spacers2510. The compression element member2512surrounds the break-away spacers2510and sandwiches the torque transmission tabs2516therebetween. The compression member2512may be, for example, a snap ring, a round metal ring, an o-ring, multiple o-rings, a coil spring, or the like. The compression member2512applies a preset compressive force to the breakaway spacers2510.

In operation, the input shaft2506of the break-away mechanism2504is rotated by a motor (not shown) or the like to generate a desired movement of the prosthetic arm10, shown inFIG.1. Thus, the torque transmission tab2516of the input shaft2506rotates and transmits the rotation through the break-away spacers2510to the torque transmission tab2516of the output shaft2508as long as the torque required to cause rotation of the torque transmission tab2516of the output shaft2508is not large enough to overcome the preset compressive force provided by the compression member2510. If the torque is large enough to overcome the preset compressive force, the torque transmission tab2515will push the break-away spacers2510apart and the torque transmission tab2516will rotate between the break-away spacers2510without transmitting torque therethrough. Thus, the break-away mechanism2504may prevent torque above a preset level from being transmitted through the drive system, where it can damage the drive system components. Accordingly, the break-away mechanism2504may limit the amount of torque applied to sensitive parts of the various drive systems of the prosthetic arm10, shown inFIG.1, and may, therefore, impart a longer lifespan on the prosthetic arm.

Referring toFIG.61A, another embodiment of a breakaway mechanism3504includes an input ring3518and an output ring3520connected by a detent ring3522. The breakaway mechanism3504may be connected between two prosthetic arm segments, for example, the input ring3518may be connected to the shoulder unit1416, shown inFIG.42, and the output ring3520may be connected to the humeral rotator16, shown inFIG.1. In some embodiments, the input ring3518, output ring3520and the detent ring3522each includes an alignment marker3524on its outer surface3526to indicate proper positioning of the breakaway mechanism3504.

Referring toFIG.61B, the output ring3520includes a central hub3528having an outer surface3529with a plurality of spring fingers3530radiating therefrom. Each spring finger3530has a first detent3532and a second detent3534along its length and a pin3536at its distal end3538. The input ring3518includes a plurality of detents3540around the circumference of its inner surface3542, within which the pins3536of the spring fingers3530may engage, as will be discussed in greater detail below. The detent ring3522includes a plurality of detent pins3544located partway between the inner surface3542of the input ring3518and the outer surface3529of the output ring3520. The detent pins3544engage the first detents3532of the spring fingers3530during normal operation of the breakaway mechanism3504, i.e. when torque is being transmitted through the breakaway mechanism3504.

However, referring toFIG.62A, if an overtorque situation occurs, the pins3536at the distal ends3538of the spring fingers3530will pop out of the ring detents3540so that the torque will not be transmitted back to the input ring3504. Additionally, referring toFIG.62B, the overtorque situation will also cause the alignment markers3524to move out of alignment. The user may then realign the alignment markers3524to transmit torque through the breakaway mechanism3504.

Referring toFIG.63A, the user may also intentionally disengage the torque transmission by moving the alignment marker3524on the detent ring3522up to engage the breakaway mechanism3504in freeswing. As seen inFIG.63B, this configuration entirely disengages the spring fingers3530from the input ring3518, thereby allowing the output ring3520to rotate freely without driving the upstream components through the input ring3518. Thus, this embodiment of the breakaway mechanism3504is advantageous because it also allows for the user to engage freeswing of the prosthetic arm10, shown inFIG.1.

These break-away mechanisms discussed above are beneficial because they prevent damage to the prosthetic arm apparatus10due to high loading situations. Additionally, the break-away mechanisms are advantageous in that once the break-away mechanisms break under high loading, they may be reset by the user without the need to see a prosthetic technician.

As discussed above, various embodiments of the prosthetic arm10, shown inFIG.1, include feedback mechanisms, such as potentiometers for position sensing. Referring now toFIG.64, in some embodiments, the prosthetic arm10, shown inFIG.1, may include other feedback mechanisms, for example, a magnetic position sensor1546. In these embodiments, at least one magnetic strip1548may be attached about the circumference of an inner surface1550of a rotatable drive component1552. The magnetic strip1548includes a plurality of magnets1554of known length L1arranged in series, each having a north pole N and a south pole S. Thus, the magnetic strip1548generates a magnetic field having a repeating pattern of alternating north poles N and south poles S. The magnetic position sensor1546is arranged to detect this magnetic field generated by the magnetic strip1548. In operation, the rotatable drive component1552rotates, which causes the magnetic strip1548to rotate, thereby moving the portion of the magnetic strip1548being detected by the magnetic position sensor1546. The magnetic position sensor1546detects this change in the magnetic field as the magnetic strip1548rotates from each north pole N to each south pole S and vice versa. Since the length L1of each magnet1554is known, the detected changes in the magnetic field between each north pole N and/or each south pole S may be converted into the distance of rotational movement of the rotatable drive component1552. Thus, the change in position of the rotatable drive component1552may be detected. The magnetic position sensor1546is also advantageous because it does not contact the rotating drive component1552and, therefore, will not experience contact wear due to the rotation of the rotatable drive component1552.

Referring toFIG.65, in some embodiments, two magnetic position sensors1546may be used to detect the magnetic fields generated by the first magnetic strip1548and a second magnetic strip1556arranged next to each other around the circumference of the inner surface1550of a rotatable drive component1552. A length L2of each magnet1558of the second magnetic strip1556is, in some embodiments, different than the length L1of the magnets of the first magnetic strip1548. This difference in length allows for the magnetic position sensors1546to sense unique combinations of magnetic field values from the first magnetic strip1548and the second magnetic strip1556over the circumference of the inner surface1550. Each unique magnetic field value may correspond to a position of the drive component1552and, therefore, absolute position of the drive component1552may be detected by the two magnetic position sensors1546.

In practice, the hand assembly24, shown inFIG.1, and particularly, the fingers of the hand assembly24, i.e. the thumb structure220, index finger structure222, middle finger226, ring finger228and pinky finger230, all shown inFIG.3, come into contact with objects frequently and, therefore, may be susceptible to wear and damage. Thus, referring toFIG.66, it may be desirable for the prosthetic hand assembly1024to include removable fingers1560. In this embodiment of the prosthetic hand assembly1024, the removable fingers1560may be removed to allow for easier replacement of damaged fingers1560and also, to allow for easily customizable or tailored finger lengths for different user.

Each removable finger1560is driven in substantially the same manner as the fingers of the previously discussed embodiments. However, the removable fingers1560pivot about a common finger shaft1562, rather than the individual pivot axles discussed in connection withFIG.33. In some embodiments, end caps1564cover each end of the common finger shaft1562to prevent dirt or other contaminants from getting into the gear trains of the hand assembly1024and also to ensure that the common finger shaft1562does not become axially displaced unintentionally. In operation, either end cap1564may be removed from the hand assembly1024and the common finger shaft1562may be extracted to free the removable fingers1560. Each finger1560may then be removed and replaced individually, as required.

As discussed above, the fingers1560of the hand assembly1024come into contact with objects frequently and are, therefore, susceptible to wear. Thus, referring toFIG.67, some embodiments of the present invention may include a cosmesis1566for covering the hand assembly1024to reduce wear of the hand assembly1024and the fingers1560, in particular. The cosmesis1566may be formed from silicone or a similar material, such as a urethane, to improve the grip capabilities of the hand assembly1024to assist with the various grasping and pinch functions of the hand, thereby, providing additional functionality.

In use, the cosmesis1566may wear more quickly around the fingers1560and the thumb structure1220. Therefore, in some embodiments the cosmesis1566may separate into two or more sections to allow high wear areas to be replaced more frequently than low wear areas. For instance, referring toFIG.68A, in some embodiments, the cosmesis2566includes a separate palm section2568covering the hand support2218, finger sections2570covering each finger2560and a thumb section2572covering the thumb structure2220. Thus, the finger sections2570and thumb section2572may each be replaced separately from the palm section2568. Although shown as having separate finger sections2570and thumb section2572, in various embodiments, the cosmesis2566may also include only two sections, for example, the finger sections2570and the thumb section2572may be combined into one section and the hand support2218may be covered by the separate palm section2568.

Referring toFIG.68B, in some embodiments of the present invention, the fingers3560may be provided with geometric features3574, such as slots, in their outer surfaces3576that may accept corresponding geometric interlocks3578provided on the inner surface3580of the cosmesis3566. This interlocking geometry may resist shear loads on the cosmesis3566, thereby preventing the cosmesis3566from slipping off of the fingers3560. Additionally, with respect to the hand cosmesis, fine pinch and other functions may require a structural backing at the tips of the fingers3560and thumb structure3220. Therefore, in some embodiments, the geometric features3574of the fingers3560and thumb structure3220may each include a fingernail apparatus579, shown inFIG.40. The fingernail apparatus579, shown inFIG.40, interacts with the finger and thumb structure cosmesis3566to anchor the cosmesis3566of the fingers3560and thumb structure3220, thereby mitigating and/or preventing the cosmesis3566from rolling over on the tips of the fingers3560and thumb structure3220.

Referring toFIG.69, the palm section1568of the cosmesis1566may also be formed to resist slippage due to shear loads. For instance, a palm side1582of the cosmesis1566may be formed with a tacky inner surface1584. In some embodiments, the material of the cosmesis1566itself will provide the tacky inner surface1584, for example, silicon or a urethane material may be naturally tacky. In other embodiments, a tacky surface coating may be applied to the cosmesis to form the tacky inner surface1584. Thus, as objects being held are pressed against the palm side1582of the cosmesis1566, the tacky inner surface1584is pressed against the hand support1218, shown inFIG.29, thereby resisting slippage. In some embodiments, in this embodiment, a back side1586of the cosmesis1566is formed with a slippery inner surface1588to facilitate installation and removal of the cosmesis1566. For example, the slippery inner surface1588may be formed by applying a surface modifying coating to the cosmesis, or applying a surface texture to the cosmesis1566. For example, to install the cosmesis1566onto the hand support1218, shown inFIG.29, the cosmesis1566may be pulled down and away from the palm so that the slippery inner surface1588of the back side1586slides along the hand support1218, while the tacky inner surface1584of the palm side1582is pulled away from the hand support1218. Thus, the cosmesis1566may be easily slid onto the hand support1218. To remove the cosmesis1566, the palm side1582may again be pulled away from the hand support1218while the cosmesis1566is pulled toward the fingers1560, thereby allowing the cosmesis1566to slide easily off the hand support1218.

Additionally, in some embodiments, the fingers1560may include one or more additional functions. For example, referring toFIG.70, one or more fingers1560may include a thermal sensor1590disposed thereon to determine the temperature of an object (not shown) brought into contact with the finger1560. The signal from the sensor1590may be transmitted to a controller (not shown) for the prosthetic arm1010and displayed to the user as will be discussed in greater detail below. In some embodiments, temperature detection may be provided by forming the cosmesis1560, or a portion thereof, from a temperature sensitive polymer, such as a polymer with a thermochromic color changing additive therein or thermochromic liquid crystal that allows a variety of colors to be shown as temperature changes, which will change color depending upon the temperature of the cosmesis1566. For example, the cosmesis1566may change from one color to another if a present temperature is exceeded. This temperature sensing functionality may be used to determine the temperature of an object (not shown) in the hand1024and to warn the user of a high temperature or low temperature condition to mitigate the threat of bums or other harm.

Referring toFIG.71, another embodiment of the thumb structure2222is shown for providing thumb compliance detection. The thumb structure includes a thumb base2592and a thumb tip2594, which are each substantially rigid and are joined together by an elastomeric spring2596. In some embodiments, the interface between the thumb tip2594and the elastomeric spring2596includes one or more alignment features2598to ensure proper alignment of the thumb tip2594with the elastomeric spring2596. Similarly, the interface between the thumb base2592and the elastomeric spring2596also includes one or more alignment features2598to ensure proper alignment of the thumb base2592and the elastomeric spring2596.

Referring toFIG.72, within the thumb structure2222, the thumb base2592includes a pivotal interface tube2600extending upward into a central bore2602of the elastomeric spring2596. A pivot shaft2604, having a magnet2606disposed at its lower end2608, is arranged with the pivotal interface tube2600and extends upwardly therefrom into a central bore2610in the thumb tip2594of substantially the same diameter as the pivot shaft2604. Below the pivot shaft2604within the thumb base2592is arranged a Hall effect sensor2612on a sensor bracket2614. The sensor bracket2614includes a wire channel2616to facilitate wiring the Hall effect sensor2612to the prosthetic control circuits (not shown). Referring toFIG.73, in operation, when a load L is applied to the thumb tip2594the elastomeric spring2596compresses on the side of the thumb structure2222opposite the applied load L, allowing the thumb tip2594to tilt. The tilt of the thumb tip2594causes a corresponding tilt of the pivot shaft2604within the pivotal interface tube2600, thereby displacing the magnet2606disposed on the lower end2608of the pivot shaft2604. The Hall effect sensor2612detects this displacement of the magnet2606, which can be correlated to the applied load L on the thumb tip2594. By detecting the various loads on the thumb structure2222, the user may ensure that objects are not gripped so hard that they could break and that the thumb is not subjected to loads that could cause failure of the thumb structure2222.

Referring toFIG.74, in some embodiments, the humeral rotator1016may include a yolk1618, rather than the cantilever mounting interface shown inFIG.16, for interfacing with the elbow flexion assembly1018. The yolk1618, interfaces with a first side1620and a second side1622of the elbow flexion assembly1018to provide increased strength to the interface when compared to the cantilever mounting interface shown inFIG.16, which only interfaces with one side of the elbow flexion assembly1018.

Referring toFIG.75A, in some embodiments of the present invention, the prosthetic arm3010may be provided with a status indicator3620. In some embodiments the status indicator3620may include, but is not limited to, one or more LEDs3622arranged on the hand assembly3024. However, in other embodiments, the one or more LEDs3622may be located in various locations. The one or more LEDs3622may be configured to communicate a variety of information to the user, including, but not limited to, one or more of the following, battery power level, an operational mode of the prosthetic device, faults, alarms, alerts, messages, and/or the like. Additionally, although shown as one or more LEDs3622the status indicator3620may, in other embodiments, include a digital display and/or user interface, which may be arranged on the prosthetic device3010, built into the prosthetic device3010and/or may be a separate display unit (for example, as shown inFIG.75Bas3630), and in some embodiments, may be a unit worn similarly to a wrist watch or bracelet as shown inFIG.75Bas3630. However, in other embodiments, the unit3630may be a portable unit that may be worn or carried near the user, for example, but not limited to, clipped on clothing, belt and/or attached to the user, and/or carried in a pocket either in the user's clothing and/or in a separate bag and/or pack. In some embodiments, the unit3630may be a PDA (personal data assistant), smart phone or other electronic device configured to communicate with the prosthetic device3010by way of a wireless communications protocol, including, but not limited to, RF and Bluetooth®.

Thus, in some embodiments, it may be desirable to include both a separate display unit and one or more LEDs3622, where, for example, but not limited to, the one or more LEDs3622may be used to display one or more critical piece of information to the user, while the separate display unit,3630may provide a greater variety of information in more detail.

Still referring toFIG.75, in some embodiments of the present invention, the prosthetic arm3010may be provided with an emergency switch3624which may turn off power to the system and thus engage the various brakes and/or clutches in the prosthetic arm3010. In some embodiments, the emergency switch3624is a chin switch that the user may activate with their chin.

The prosthetic arm apparatus of the present invention has a variety of benefits over conventional prosthetic devices, such as the modularity of each segment of the prosthetic arm apparatus as discussed above, which allows the formation of customized prosthetic devices for different users. In particular, each segment of the prosthetic arm apparatus10contains all of the actuators for that segment so that it may be removed as a separate unit. For instance, the hand assembly includes all of the finger actuators therein, allowing it to be connected and/or removed as a separate unit. Additionally, various degrees of freedom of the hand assembly are particularly beneficial because they allow the formation of various grasps or grips.

Exoskeleton System and Apparatus for Robotic Device

Referring now toFIGS.81and82, an exemplary embodiment of the exoskeleton system may include an exoskeleton apparatus8100, at least one robotic device8102,8104, which, in the embodiment shown, may be robotic arms8102,8104. In some embodiments, the system may include a structure8106for attaching the one or more robotic devices8102,8104. In the exemplary embodiment shown, the structure8106may be a mobile platform/mobile structure8106which may include one or more wheels8108. In some embodiments, the mobile platform/mobile structure may include the a device, apparatus and/or control scheme as described in U.S. Pat. No. 5,971,091 issued Oct. 26, 1999 and entitled TRANSPORTATION VEHICLES AND METHODS; U.S. Pat. No. 6,223,104, issued Apr. 24, 2001 and entitled “FAULT-TOLERANT ARCHITECTURE FOR PERSONAL VEHICLE”, both of which are hereby incorporated herein by reference in their entireties. Although an exemplary embodiment is referred to herein, this is merely for illustrative purposes only. Additional embodiments are contemplated and discussed and the devices, system and apparatus are not limited to the embodiments shown as the exemplary embodiments.

In the exemplary embodiments, the robotic arms8102,8104are attached to the mobile platform8106by attachment via a compliant member8110. In some embodiments, the compliant member8110may be made from a compliant materials, e.g., polyurethane, which may be desirable for polyurethane includes compliance in all directions, i.e., “3D compliance”, as well, polyurethane has damping properties which may be desirable in some applications. However, in other embodiments, the compliant member8110may be another member, for example, but not limited to, one or more of the following: a metal spring or other compliant material, means, assembly and/or device. Referring toFIG.83, one embodiment of the attachment is shown. In this embodiment, the robotic assembly8302attaches to the complaint member8300and the compliant member8300attaches to the platform8304. A bolt8308may be used as an attachment point for the robotic assembly8302, the compliant member8300and the platform8304. A nut8306may be used, in some embodiments, to stabilize/maintain the bolt8308.

Referring toFIG.81, in some embodiments, including the embodiment shown inFIG.81, the exoskeleton may be worn by a human8112by way of an attachment system which may include a series of straps8114,8116,8118. In some embodiments, the straps8114,8116,8118may be adjustable (as shown inFIG.81), however, in other embodiments, one or more straps8114,8116,8118may not be adjustable. In some embodiments, the attachment system may be customized to the user and thus, adjustability may not be necessary. However, in some embodiments of the customizable embodiments, one or more straps may be adjustable. With respect to adjustable straps8114,8116,8118, these may be adjusted along the hips of the user using a hip strap8114, the torso of the user using shoulder straps8118and chest strap8114and the distance between the back of the user and the top of the exoskeleton may be adjusted using the upper torso straps8118. In some embodiments, the attachment system may be similar to one found on an ergonomic backpack for example, in the exemplary embodiment, the backpack strap system from Trekker3950backpack made by KELTY®, Boulder Co., USA, may be used as the attachment system. In some embodiments, the exoskeleton8100is removable. In various embodiments, the exoskeleton attachment system may include fewer straps than shown and described herein with respect to the exemplary embodiments and/or in some embodiments, the exoskeleton may include additional straps than shown and described herein with respect to the exemplary embodiments. For example, in some embodiments, the exoskeleton may include a lower body component and thus, may include different and/or additional straps adapted to removably or nonremovably attach to the user's lower body. For example, to attach to their hip, upper leg, knee, lower leg, ankle and/or foot. In some embodiments, the exoskeleton may be a lower body exoskeleton and may not include an upper body portion.

Referring now toFIGS.84A-84D, isometric, front, back and side views of one exemplary embodiment of the exoskeleton are shown. In addition to the straps discussed above, the exoskeleton, in some embodiments, may include an exoskeleton frame which may include a lower portion8400and an upper portion8402. In some embodiments, the upper portion8402may be telescopingly connecting to the lower portion8400such that the frame is adjustable. As shown in84C, in some embodiments, the adjustability may be in the form of a ball detent mechanism8404and may include one or more adjustable sizes. As shown in one embodiment, the adjustability may include seven sizes. As discussed above, in some embodiments, the frame may be a backpack frame, for example, a Trekker3950backpack made by KELTY®, Boulder Co., USA. In various embodiments, the adjustability mechanism may vary and, in some embodiments, the frame may not include adjustability and may be customzably sized and/or may be made based on the size of the intended user. In some embodiments, the frame may be made to average sizes of intended users.

In some embodiments, the frame may be made from aluminum. However, in some embodiments, the frame may be made from one or more plastic materials, stainless steel, magnesium or any other material that may be used to make a frame such as one of the embodiments discussed herein.

Still referring toFIGS.84A-84D, in some embodiments, the hip strap8114may be adjustable with respect to the distance from the top of the frame to the hip strap8114as well as adjustable with respect to the circumference of the strap. In some embodiments, the adjustability feature with respect to height may be a ball detent mechanism8406.

In some embodiments, the exoskeleton may include a support structure8408which may also serve as a handle for carrying the exoskeleton and/or for user mounting the exoskeleton either alone or with assistance.

Described herein are various sensors and feedback mechanisms which may be used to both control at least one robotic assembly and also, in some embodiments, to provide feedback regarding the at least one robotic assembly to the user. In some embodiments, where at least one sensor is used, the at least one sensor and, in embodiments including at least one feedback mechanism, the at least one feedback mechanism, may communicate via electronic wiring, i.e., they may be hardwired. However, in other embodiments, at least one of the at least one sensor and/or the at least one feedback mechanism may be wirelessly connected, i.e., via at least one form of wireless communication.

With respect to the exemplary embodiment shown in the various figures, the system includes a hard wired embodiment. In the exoskeleton, the wires are contained within a wiring housing8410,8412to organize the wires. This embodiment may be desirable to prevent accidental/unintentional catching of the wires on an object and or to protect the wires from breakage and tangling. In some embodiments, as shown in the various figures, there may be one or more wiring housing8410,8412, and, in some embodiments, there may be more than two wiring housings. In some embodiments, the wiring housing8410,8412may be made from any material desired, however, in the exemplary embodiments, is made from a flexible plastic. However, in other embodiments, may be made from other materials, including, but not limited to, rigid or flexible materials.

The wiring housing8410,8412is connected to the exoskeleton through a wire connection8414,8416. In some embodiments, there may be one wire connection, however, in other embodiments; there may be more than one wire connection, as shown in the exemplary embodiment. The wire connection8414,8416, is, in some embodiments, a housing for the wires that run through the wiring housing8410,8412, to connect to a point on the exoskeleton. The wire connection8414,8416may be made from any material desired, but in some embodiments, may be made from a metal, e.g., aluminum or stainless steel, or a plastic.

Referring also toFIGS.85A-85Bwhere isometric views of a shoulder, arm and hand portion of one embodiment of the exoskeleton are shown. In these views, the shoulder, arm and hand portion has been broken away from the exoskeleton apparatus shown in previous figures. Together with the previous figures, exemplary embodiments of the arm and hand portions are described below.

Various embodiments of the exoskeleton rely on mapping movement by the user to movement by the at least one robotic assembly. Thus, it is critical that the movement of the user be sensed appropriately to map the movement to the at least one robotic assembly. For purposes of the description of the exemplary embodiments, the description will refer to the at least one robotic assembly as “robotic assemblies”. However, it should be understood that in various embodiments, one robotic assembly may be used.

In some embodiments, gross movements by the user may be translated by the shoulder. Thus, the rotation points of the shoulder of the user are critical to map correctly in these embodiments. To do so, it may be necessary to determine the center point of the shoulder thus determining the center point of rotation of the shoulder. However, finding the center of rotation of a shoulder of a user may be difficult. Also, users may have different centers of rotation of the shoulder. Thus, adjustability of the exoskeleton is critical to mapping the center of rotation of the shoulders correctly to thus translate to true mapping of the gross movements of the user to the robotic assemblies.

Still also referring toFIGS.85A-85B, in the exemplary embodiment, the exoskeleton shoulder and arm portions are essentially located on two planes. In the exemplary embodiment, through various adjustability features, the lengths of the exoskeleton from the spine area of the user to the shoulder as well as the length of the exoskeleton from the shoulder to the elbow, the elbow to the wrist, are adjustable.

In the exemplary embodiment, the exoskeleton shoulder portion includes at least two sensors8510,8512, which, in some embodiments, are potentiometers. The type of potentiometer may be any potentiometer, including but not limited to, a linear potentiometer. In various embodiments, at least one potentiometer is used to measure/sense shoulder abduction and at least one potentiometer is used to measure/sense shoulder flexion. In some embodiments, the system may use two different potentiometers to measure the shoulder abduction and shoulder flexion, and in some embodiments, the system may use the same potentiometers to measure both motions. In the exemplary embodiment, each joint of the user's arm/shoulder includes at least one potentiometer to measure the amount of rotation. The signal data from the potentiometers is used by the control system (described below) to map movement to the robotic assemblies.

In the various embodiments, to fit the exoskeleton to a user, one goal is to adjust and/or design the exoskeleton for a particular user such that the center axis of rotation of each shoulder potentiometer meets in the center of the ball joint of the user's shoulder.

In various embodiments, to assist in adjusting the exoskeleton such that the center axis of the potentiometers meets in the center of the shoulder ball joint of the user, ball joints8514,8516are included in the exoskeleton. It should be understood that in the exemplary embodiments of the exoskeleton, there are two ball joints for each arm (shoulder, hand), thus, in the exemplary embodiments, there are four ball joints on the exoskeleton. However, in various embodiments, there may be more than four or less than four ball joints. Also, in various embodiments, components accomplishing the same functionality as described with respect to the ball joints may be used.

In the exemplary embodiment, the ball joint used is a RAM® mount such as one made by National Products Incorporated, Seattle, Wash., USA. Using these ball joints8514,8516, the exoskeleton may be adjusted such that the length and orientation/angle of the back portion8502and the side portion8504of the exoskeleton may be adjusted. Thus, the exoskeleton may be adjusted to fit a user such that the axis of rotation of the potentiometers8510,8512meet in the center of the user's shoulder ball joint.

With respect to the ball joint located on the back of the frame8514, in some embodiments, including the exemplary embodiment, a compliance section8518may be included to allow for sternoclavicular motion by the user. Thus, with the compliance section8518, the user may move their arms forward and having compliance in the joint. The compliance section8518, in the exemplary embodiment, may be a torsion spring which springs back the user stops movement in the forward direction. This allows articulation and the torsion spring8518automatically pulls the exoskeleton back. The torsion spring8518, in some embodiments, may be set such that the user may overcome the spring when forward movement is desired and the spring pulls the exoskeleton back in a light fashion such that the user may not notice. In the exemplary embodiment, the spring constant of the torsion spring8518may be 0.014 inch pounds per degree. Also, in the exemplary embodiment, the torsion spring8518may produce a torque of 5.15 inch pounds at 360 degrees of rotation with a preload of approximately 2.5 inch pounds. Additionally, in some embodiments, the torsion spring8518may be preloaded with a hard stop. The hard stop may be adjustable to the user such that the torsion spring8518is limited in how far it may pull the exoskeleton back. In some embodiments, this adjustment may be made at the time of initially using the exoskeleton. In some embodiments, this may be accomplished where the user rolls their shoulder back and the hard stop is adjusted to that position. In some embodiments, the adjustment may be made using a knob, however, in other embodiments; the adjustment may be made using anything that may adjust the hard stop. In the exemplary embodiments, the hard stop may be desirable to maintain the flexion joint in the correct place where the shoulder ball joint may be accurately tracked.

Still referring toFIGS.85A-85B, in the exemplary embodiment, the exoskeleton includes at least one tactor motor to provide feedback regarding the robotic assemblies to the user. In some embodiments, the at least one tactor may be connected to the exoskeleton by a strap which may be strapped to the user using a tactor strap8518such that the tactor motor8520may be in close proximity to the user such that the user may feel signals from the tactor motor8520. In the exemplary embodiment, the tactor strap8518may be an adjustable strap which may, in some embodiment, attach to itself by way of a hook and loop fastening system. However, in other embodiments, a buckle system, clip system or any other attachment or fastening mechanisms may be used. In some embodiments, the strap may not be adjustable, however, in the exemplary embodiment, the strap is adjustable.

In the exemplary embodiment, the at least one tactor motor8520may be a vibration motor or other motor that may provide a signal to the user. In the exemplary embodiments, at least one or the at least one tactor motor8520provides feedback to the user related to the torque of the shoulder and elbow joint of the robotic assembly. In the exemplary embodiment, the user may wear two tactor motors8520, one on each arm, each providing feedback from one robotic assembly.

Thus, the at least one tactor motor8520receives input from at least one joint on the at least one robotic assembly. For example, in the exemplary embodiments, the at least one tactor motor8520receives input from the compliance measurements on the robotic arm. In some embodiments, however, the at least one tactor motor8520may receive input from one or more compliance sensors which may be in the compliant member8110. In some embodiments, four or more compliance sensors may be on the compliant member8110and thus provide directional feedback, via at least one tactor motor8520, regarding the direction of force being imparted on to the robotic arms/assembly. In various embodiments of this embodiment, the user may wear four tactor motors to receive input in four directions. Thus, in some embodiments, where the user may not be able to see the robotic assembly, this may be desirable to determine the direction where there may be an object or wall and thus, navigate away from a problematic area.

In some embodiments, the feedback is proportional to the average of the two, and in other embodiments, may be the sum of the two, etc. However, in the various embodiments, the feedback relates to gross overall arm motion and whether or not the robot assembly may have hit anything or is jammed up against a structure/wall or other. Thus, in some embodiments, this feedback may indicate to the user if one or more of the robotic assemblies are jammed, stuck, etc. The tactor motor8520may also provide feedback related to how hard the robotic assembly is pushing on something which may be useful in controlling the robotic assemblies and completing one or more tasks. In some embodiments where a vibration motor is used, the intensity of the vibration may be proportional to the torque. In some embodiments, however, an auditory feedback may be used, which may include, but is not limited to, feedback where a single tone is given, the higher the tone, for example, the higher the torque. In other embodiments, one or more lights, for example, one or more LEDs, may be used, and this may include variations including, but not limited to, one or more of the following: using blinking/on/off patterns and/or color to indicate feedback to the user.

Still referring toFIGS.85A-85B, the exoskeleton between the shoulder and the elbow and between the elbow and the wrist may, in some embodiments, be adjustable. In the exemplary embodiment, a telescoping feature may be used for adjustment of the upper arm8504and lower arm portions8522,8524. In some embodiments, a mechanism similar to a camera tripod adjustability feature may be used. In some embodiments, the tripod-like mechanism may be desirable for its ability to lock in place easily and include a strong locking mechanism as well as its ability to open and close easily. However, in various other embodiments, any mechanism allowing for adjustability may be used. By using the various adjustability features, the location of the wrist joint and elbow joint of the exoskeleton may be adjusted to be proximate to the location of these joints on the user. Similarly as with the shoulder joint, the accuracy of the control of the robotic assemblies using the exoskeleton will depend partly on the exoskeleton's ability to map the movement of the user's joints, which may be improved with the one or more sensors being located proximate to the user's joints. The movement of the user may be mapped using at least one sensor for each user joint. In addition to the ones discussed above with respect to the shoulder joints, in the exemplary embodiments, the exoskeleton includes at least one potentiometer8526on the elbow joint and at least one potentiometer8528on the wrist joint which may sense wrist rotation and may be referred to as the wrist rotation sensor8528. It should be understood that although in some embodiments, potentiometers are used, in other embodiments, various other sensors may be used to track the movement of the joints. These sensors may include, but are not limited to, IMUs (inertial measurement units), which, in some embodiments, may be one of the IMUs described in International Publication No. WO 2010/120403 A2 to Van der Merwe et al. on Oct. 21, 2010 and entitled “System, Method and Apparatus for Control of a Prosthetic Device”. However, in other embodiments, the sensor may be any sensor, including but not limited to, bend sensors.

The elbow joint and wrist joints are formed from a series of rings. These are referred to as the humeral and wrist rotators. In the exemplary embodiments, the humeral and wrist rotators rotate with the user's humeral and wrist rotation.

Additionally, in some embodiments, where there may be limitations of movement inherent in the one or more robotic assemblies being controlled using the exoskeleton, those limitations may be built into and/or reflected in the movement of the exoskeleton. In this way, the user may be limited in motion in the exoskeleton, however, this may lead to more accurate control of the one or more robotic assemblies as the user will not expect or intend for the robotic assembly to move in a way that the user can not move while using the exoskeleton. Thus, in some embodiments, there may be one or more stops built into the joints at particular/predetermined locations which prevent the user from commanding the robotic assembly to move in a way it is not able to move. In some embodiments, the stops may also prevent the exoskeleton from being tangled.

In the exemplary embodiment, the humeral and wrist rotators may be similar. In the exemplary embodiments, the rotators include large thin ring bearings, which, in some embodiments, may be KAYDON bearings, or another similar bearing. These large thin ring bearings allow a cantilever mode to account for moment loads. Also, the rotators include a ring spur gear that go to a pinion gear attached to the sensor/potentiometer. However, as discussed above, in other embodiments, the sensor may a sensor other than a potentiometer and in some embodiments; the joint may include more than one potentiometer.

In some embodiments, such as the ones shown in the exemplary embodiment, the stops may be a plate with protrusions that protrudes from the plate that act as stops so that the user may not command the robotic assembly to go past where the robotic assembly can move. In some embodiments, the stops may be adjustable such that the exoskeleton may be used with different robotic assemblies. However, in some embodiments, the stops are nonadjustable and are designed to be used with specific robotic assemblies.

In some embodiments, as in the exemplary embodiment, the exoskeleton may include a feature such the area between the humeral and wrist rotators may rotate. This may be desirable for when a user extends their arm in the exoskeleton, their arm rotates. Thus, the exoskeleton, in some embodiments, also rotates to a second position to map the user's arm. However, in some embodiments, when the exoskeleton rotates, there is a return mechanism8530to rotate the area between the humeral and wrist rotator back to its original/starting/first position. In some embodiments, the return mechanism8530includes a pulley and a bungee wrapped about the pulley inside a housing. The bungee may be anchored to the humeral joint. Thus, in these embodiments, when the user rotates the humeral and wrist joint, this loads the bungee and the pulley/bungee system pull the joints back from the second position such that the joints rotate to the starting/original/first position.

In the exemplary embodiment, the wrist rotator is constructed in a similar fashion as the humeral rotator. However, in the exemplary embodiments, the wrist rotator has a smaller diameter and does not include a return mechanism. However, in various embodiments, the diameter of the wrist rotator may be the same as the humeral rotator. Also, in some embodiments, a return mechanism may be included on the wrist rotator.

Referring now toFIGS.86A-86B, as well asFIGS.86C-86G, the exoskeleton, in some embodiments, may include a hand portion8600which includes the wrist rotation portion including the wrist rotation sensor8528. In the exemplary embodiments, the hand portion8600may include a glove plate8602. In the exemplary embodiments, the user may place their hands in a glove8604. The glove8604, in the exemplary embodiment, includes a thumb splint8606, an index finger sensor8608and a middle finger sensor8610. In some embodiments, and as shown inFIGS.86A-86B, the index finger sensor8608and a middle finger sensor8610may be included on the same body8612. In some embodiments, any glove may be used and attached to the glove plate8602. In the exemplary embodiment, the glove plate8602may include various holes for attachment of the glove8604(the hole features may also be seen inFIGS.86C-86G). The various holes allow for attachment of various sized gloves to accommodate different sized users. However, in some embodiments, the glove plate8602may not include adjustability features.

In some embodiments, the sensors8612and thumb splint8606are connected to the exoskeleton and may fit into pockets8614,8616,8618on the glove8604. In the exemplary embodiments, the thumb splint8606includes at least two sensors8620,8622, which, in some embodiments, may be potentiometers. In the exemplary embodiments, the sensors8616,8618are flexible bend sensors such that the sensors detect when the user bends their index or middle fingers. The bend sensors8616,8618send signals, through an electrical connection, to a control system (described below). In various embodiments, the bend sensor may detect bend using resistance change data. Thus, in some embodiments, the further the user bends their finger, the more the resistance changes, thus indicating movement. In various other embodiments, additional sensors may be included on the middle, ring and pinky fingers. However, in the exemplary embodiment, these sensors may not be necessary as the control system works to control a robotic hand/arm and that robotic hand arm includes a hand in which the middle, ring and pinky move together. However, in other embodiments, where various robotic assemblies may be controlled using the exoskeleton, different sensors may be used and selected based on the robotic assembly functionality and the control system thereof.

As discussed above, the exemplary embodiment includes a thumb splint8606. In the exemplary embodiments, the thumb splint8606limits the movement of the user's thumb. It may be desirable, as discussed with respect to the stops discussed in the joint rotators above, to limit movement of the user where the robotic assembly the exoskeleton controls includes limited movements. Thus, in the exemplary embodiment, the exoskeleton controls two robotic arms/hands/shoulders (collectively referred to as a “robotic arm”). In some embodiments of the robotic arm, the robotic thumb includes specifically programmed movements. Thus, the exoskeleton includes a thumb splint8606to limit the user's thumb movements to those that are included in the robotic thumb's programmed movements. Although herein are some examples of limited movements in the exoskeleton to mimic the limited movement of the robotic assembly, these are not an exhaustive list. In various embodiments of the exoskeleton, mechanical features may be added to the exoskeleton to limit the movements of the user to match and/or mimic the allowed/possible movements of the robotic assembly. However, in some embodiments, as discussed in more detail below, the robotic assembly may include additional capabilities that the user may not accomplish. Thus, in some embodiments, although stops may be used to limit the movement of the user, the control system may allow for additional and expanded/continued movement of the robotic assembly.

With respect to the robotic arm controlled by the exoskeleton in the exemplary embodiment, the thumb includes two degrees of freedom, yaw and pitch. Thus, the exoskeleton includes two potentiometers8620,8622, one to sense yaw, one to sense pitch, which sense the movement of the thumb splint8606and provide signals to the control system map the movement of the robotic arm's thumb. In other embodiments, additional sensors or different sensors may be used. In some embodiments, a single sensor may be used.

In some embodiments, the exoskeleton hand or the glove may include a tactor motor8624. In some embodiments, the tactor motor on the glove or the exoskeleton hand is located such that the user may see, feel or hear the tactor. In some embodiments, the tactor motor is a vibratory motor. However, in some embodiments, the tactor may be an auditory tactor. In other embodiments, the tactor is a visual tactor and may include one or more lights, e.g., LEDs, which may indicate/signal to the user via blinking, on/off, and/or colors, to indicate various feedback to the user. In the exemplary embodiment, the tactor motor is a vibratory motor and provides feedback to the user with respect to the thumb grip strength of the robotic arm. Although in the exemplary embodiment, the thumb tactor is located on the glove or hand portion of the exoskeleton, in some embodiments, the tactor may be located elsewhere on the exoskeleton. In some embodiments, the tactor may be located on a strap and/or on a separate device containing one or more feedback indicators to the user. For example, in some embodiments, the tactor may be an indicator as described in WO 2010/120403 A2.

In some embodiments, the exoskeleton may include an inertial measurement device and/or potentiometer and/or sensor to indicate the movement of the users's torso and/or feet and/or head, etc. These one or more sensors may be used to control the platform/mobile platform/robotic assembly in one or more ways. For example, where the user's torso movement may be sensed, torso forward movement by the user may send a signal to the control system that the mobile platform should move forward. One or more sensors worn on the user's feet, which may include, but is not limited to, those described in WO 2010/120403 A2, may send control signals to the robotic assembly and/or the mobile platform.

Control System

WO 2010/120403 A2 includes description of various control systems and methods for a robotic arm or another robotic assembly. At least part of the description may be applicable to the exoskeleton control system. Referring toFIG.87, in the exemplary embodiment, and used for illustration purposes, the system8700includes an exoskeleton8100which controls at least one robotic arm8102,8104. The system8700may be powered by a power source located in a housing8702. However, in other embodiments, the exoskeleton8100may be powered by one power source and the mobile platform by another power source (not shown). This embodiment may be used where the mobile platform8106and the exoskeleton8100are remote one from another. Thus, in various embodiments, the user8704may be located in a location remote from the robotic assemblies8102,8104. However, in some embodiments, the user8704and the robotic assemblies8102,8104may be located in the same area.

As discussed above, the various joints of the exoskeleton include sensors such that the movement of the user may be captured by the sensors. The sensors, in the exemplary embodiment, send signals to a control system. In various other embodiments, a camera may be used to capture the movement of the user and send the signals to the control system. In some embodiments if these embodiments of the system, the user may use a hand portion, which, in some embodiments, may include one or more of the various sensors described herein, such that the camera may determine the gross movements of the user and the hand portion may send signals regarding the movement of the hand and/or fine movements. However, for description purposes, the exoskeleton embodiment is described below, although it should be understood that the system may include one or more devices, apparatus and/or systems to capture the user movements (both gross and fine) and send signals to the control system indicating the movements such that the control system may map the movement to the one or more robotic assemblies. Thus, in the various embodiments, the control system maps the movement of the exoskeleton to the movement of the robotic assemblies. For purposes of illustration, the exemplary embodiment will be used to describe the controls.

In the exemplary embodiment, the control system is a many to one or many to few mapping system. The movement of the user is captured by the one or more sensors of the exoskeleton. The movement data is sent to the control system which maps the movement and sends commands for movement to the at least one robotic assembly. Various embodiments may include preprogrammed gestures and/or preprogrammed signals that may be made by the user and automatically translated to a particular movement and/or movements of the robotic assembly. In this way, the user may easily, efficiently and with little to no training, control the at least one robotic assembly.

Further, as the exoskeleton allows the user to move in a natural way, and translate these natural movements to movements by the at least one robotic assembly, control of the at least one robotic assembly is easy and efficient and, as well, does not require extensive training. With respect to the exemplary embodiment, where the exoskeleton controls two robotic arms, the robotic arms move in a natural/human manner. Thus, where the user moves in a natural/human manner, and this movement is translated to robotic arms which move in natural/human manner, the system allows for easy and efficient use of the robotic arms and easy and efficient control, but the user, of the robotic arms, to perform natural/human-like tasks.

In the exemplary embodiment, the control system is calibrated to a user. This calibration, once completed, in some embodiments, may be “saved” or “stored” and recalled by the control system such that multiple users may use a single exoskeleton at different times. To do so, they may calibrate at each use, or, in some embodiments, may upload/load a previously configured calibration at time of use.

In various embodiments, calibration may be performed either manually or automatically. For example, in some embodiments, there may be a software system which takes the user through the calibration process by prompting the user, wearing the exoskeleton, to position their arms/torso in specific orientations, one after the next. The system thus may record the at least one sensor position/signal at a particular position of the arm. Thus, completing a series of calibration steps, the control system may then map movement of the exoskeleton/user to movement by the robotic arm/at least one robotic assembly.

With respect to the exemplary embodiment, where two robotic arms may be controlled by the exoskeleton, calibration may be particularly important with respect to positions where the hands/arms of the robotic arms are touching/meet/make contact in free space. Thus, it is critical to map the joints of the exoskeleton at these points to ensure that the robotic arms will touch when commanded by the user. Thus, in the exemplary embodiment, it may be critical that the robotic arms are capable of interacting with items of interest.

In the exemplary embodiment, after calibration, when the user moves while in the exoskeleton, the robotic arms will move in the same manner, i.e., will map to the user/exoskeleton.

Thus, in the exemplary embodiment, the exoskeleton collects data/signals from sensors on two arms of the user. The controls then maps these positions, thus, the controls map the joint positions of each of the two arms of the user directly to the arm positions of each of the respective robotic arms8102,8104. Thus, the movement of the right arm8704of the user is mapped to move/control the right robotic arm8102and so on and so forth with respect to the left arm of the user8706and the left robotic arm8104.

With respect to the hands of the user and the robotic arms8102,8104, as discussed herein and in WO 2010/120403 A2, the robotic arms include hands which include a plurality of grips. Although as discussed in WO 2010/120403 A2, mode switching may be used to control the hands, in the embodiment described herein with respect to the exoskeleton system, mode switching may not be used. Thus, when the user, wearing the exoskeleton, moves their hands, this movement may be mapped to the robotic arms.

However, in some embodiments, for ease or use and also, to ensure the user's intended grip is mapped to the robotic arms, gestures may be preprogrammed to the system as part of a calibration movement. Thus, where, for example, the user is intending to command a pinch grip, but in their hand movement, fails to correctly place their index finger with respect to their thumb, the robotic arms, without a gesture program, may mimic exactly the movement of the user. Thus, in this case, the robotic arm(s) would move in a user unintended, although commanded, manner. However, in some embodiments where gesture programming is used, while the user may not have completed the pinch grip movement correctly, the system may interpret the movement as a gesture, and signal to the robotic arm(s) to move to pinch grip. Although “pinch grip” is discussed, this is merely an illustrative example, all of the various grips and intermediate grips may be commanded by the user via a gesture that is preprogrammed into the control system.

Additionally, with respect to some embodiments of the hand mapping, where the human hand/fingers may be able to move in various ways, in some embodiments, the robotic arm/hand may not be able to move in all of the same ways. Thus, in some embodiments, the control system may be preprogrammed to interpret the movements by the human hand to specific movements by the robotic arm/hand, i.e., those movements that the robotic arm/hand are capable of performing. Thus, in some embodiments, the hand mapping may be a many to one or many to few mapping.

For example, in some embodiments, with respect the hand mapping, and specifically with respect to the index finger, although a user may close their index finger in a number of different ways, the control system may map the user closing their index finger (whichever way the user closes it) to a single way of closing the robotic hand/arm index finger. Thus, in some embodiments, the mapping may be a many to one mapping. Similarly, with respect to the middle, ring and pinky finger, as discussed above, the middle finger includes a sensor and, in some embodiments, the ring and pinky do not. Thus, when the user closes their middle finger, in some embodiments, this may translate to a specific closing of the ring and pinky fingers as well.

Another example is the thumb movements. In some embodiments, although the human thumb may close in a number of different ways, the control system may map these ways to a preprogrammed 2 degrees of freedom.

In some embodiments of the control system, the system is position based rather than orientation based. Thus, the position of the hand, for example, rather than the orientation of the hand, commands the robotic arm/hand. This may be desirable for wherever, with respect to orientation, the user's hand is; the user may command movement by the hand without respect to the orientation of the user's hand, rather, only with respect to the position of the user's hand. However, in other embodiments, the system may be orientation and position based.

In various embodiments, the control system need not include endpoint control, as discussed in WO 2010/120403 A2. Thus, the user may be mechanically constrained by the exoskeleton and their body to limit the movements commanded to the robotic arms. However, in some embodiments, endpoint control, similar to the embodiments described in WO 2010/120403 A2, may be used in the control system for the exoskeleton system.

In some embodiments, a method for freezing the robotic arm and/or hand in a particular position may be desired. For example, circumstances where an object may be grasped by one robotic hand while being worked upon by the second robotic hand, it may be desirable that the first robotic arm/hand remain in the same position. In some embodiments, in addition, a user may wish to maintain the robotic arm/hand in a frozen position for an extended amount of time and “rest” or “free” their arm simultaneously. Therefore, and referring now toFIG.93, in some embodiments, a method for freezing a robotic arm/hand in a position in shown. The user first moves the first robotic arm/hand to the desired position9300. The user commands the control system to freeze that particular robotic arm9302, which, in some embodiments, may be commanded using voice commands, IMU commands and/or other inputs to the control system. The user then may move their arm/hand without the control system mapping the user movement to the frozen robotic arm/hand9304. When mapping becomes desired9306, for example, once the second robotic arm has finished working on an object controlled by the first robotic arm, the user moves their arm/hand to the frozen position9308and commands the mapping resume9310. Thus, in some embodiments, the mapping will resume seamlessly from the frozen position.

In some embodiments, the robotic arm, in some embodiments, and/or other robotic assemblies in various embodiments, may have capabilities beyond that of the user. For example, the robotic arm may be capable of a longer “wing span” and may be capable of 360 degree rotation. However, the user, for which the control system maps their movement onto the robotic arm, for example, may be unable to command the robotic arm to its full expansion and capability. Thus, in some embodiments, a method for extended control may be used. In this method, various locations/points in the user movement path may be preprogrammed to trigger a mapping ratio of movement between the user and the movement to the robotic assembly. For example, at a preprogrammed location, the ratio may switch from “one-to-one” to “one-to-two”, and further, at a second location, the ratio may switch from “one-to-two” to “one-to-three”, etc. In this way, by increasing the mapping ratio, the user may command the robotic assembly to move in such a way as they can not. During user calibration, which is discussed in more detail above, the potential paths of the user may be preprogrammed into the systems and the trigger or switch locations as well as the mapping ratio associated with the “path” between two locations will be preprogrammed.

As discussed herein, in various embodiments, the robotic hand assembly may include preprogrammed grip trajectories. These embodiments may increase the accuracy of the remotely controlled robotic hand for without a preprogrammed trajectory, and where visibility of the fingers of the hand may be obscured on a video feed, the desired grip may be difficult to achieve. Thus, with preprogrammed trajectories, the user may instruct (for example, using an IMU) the robotic hand to move to a particular trajectory and therefore, the trajectory will be achieved regardless of the quality of visualization at the time.

In some embodiments, although each arm of the exoskeleton may weight about 3 pounds, it may be desirable for an assistance mechanism to alleviate the weight of the arms for the user may become tired over time. Thus, in some embodiments, the exoskeleton system may include supporting apparatus/mechanism/means, which, in some embodiments, may be wires that attach to both the arm and a ceiling or other structure, to aid in supporting the arms. In various embodiments, the supporting mechanism may allow for freedom of movement by the user, and, in some embodiments, the supporting mechanism may maintain the arms of the exoskeleton in a fixed position. In some embodiments, the exoskeleton may include motors and drives inside the joints of the exoskeleton to provide for less weight experienced by the user.

In various embodiments of the system, the user may wear one or more IMU or other type of sensor, to send additional control signals to the system. These additional control signals may be used to control one or more mobile platforms8106, one or more sensors, including, but not limited to, one or more cameras. Referring toFIG.87, in some embodiments, the exoskeleton8100and the mobile platform8106and robotic arms8102,8104are hard wired, however, as discussed above, in various embodiments, they may communicate by way of wireless communications. These wireless communications may be any wireless communications. In some embodiments, the one of more IMU may be used to control the hand grips, as is described in WO 2010/120403 A2.

In some embodiments where the user controls the mobile platform using one or more IMUs, the user may wear, for example, one IMU on their foot to control the forward, backward, right and left movement of the mobile platform. However, in some embodiments, the user may wear an IMU on both their right foot and left foot. In these embodiments, one of the IMUs (either right or left) may be used to control the forward, backward, right and left movement of the mobile platform. The other IMU may be used to select grips on the hand.

Although in some embodiments, the power supply8702may be provided in a housing and hard wired to one or more components of the system, in other embodiments, one or more power supplies may be worn by the user and/or integrated with the exoskeleton and/or integrated in the robotic arms8102,8104and/or integrated in the mobile platform8106.

Referring now toFIG.88, in some embodiments, the user8704may be located remotely from the mobile platform8106and thus, remotely from the robotic arms and/or one or more robotic assemblies8102,8104(hereinafter “robotic arms”). In these embodiments, the exoskeleton8100commands the mobile platform8106and/or robotic arms8102,8104by way of wireless communications8802,8808. Additionally, in some embodiments, the system may include one or more sensors, which, may include, but are not limited to, one or more cameras8804,8806, Ultraviolet (“UV”) sensors, thermal sensors and/or Infrared (“IR”) sensors. In various embodiments, additional sensors of any kind may be used and in some embodiments, may be selected based on factors, including, but not limited to, the task in which the robotic assemblies are being used to accomplish. The one or more sensors may be desirable to assist the user8704in decision making regarding the task being performed.

The cameras8804,8806(which may be any type of camera including, but not limited to, night vision cameras and underwater cameras) may be located anywhere desired, including but not limited to, distributed about the mobile platform8106such that they may collect images of the surroundings of the mobile platform8106. In some embodiments, there may be a plurality of cameras such that a 360 degree view may be communicated to the user8704. Referring toFIGS.88-90, in some embodiments, a camera8804may be used which may be capable of pivoting and collecting images where the user8704desires. In some embodiments, the camera8804may be controlled by an IMU or other sensor worn by the user and/or part of the exoskeleton. In some embodiments, the IMU may be one described in WO 2010/120403 A2. In some embodiments, the camera8804may be controlled by way of IMU sensors which may be worn on the user's feet. In some embodiments, as shown inFIG.90, the camera8804may be mounted anywhere on the mobile platform8106.

In some embodiments, the one or more cameras8804,8806may transmit images to the user8704. The user8704may, in some embodiments, view the images using LED glasses8810and/or at least one monitor/viewing apparatus9000. In some embodiments, multiple monitors/viewing apparatus9000are used. Although inFIG.90, the various system components are shown wired together, it should be understood that in the various embodiments, one or more components may wirelessly communicate with one or more components.

In some embodiments, the mobile platform8106may include one or more IMUs and transmit yaw, pitch and roll data to the user by way of one or more tactors. In some embodiments, the user8704may stand on a platform which may mimic movement of the mobile platform8106thus provided feedback to the user8704regarding terrain, etc. This may be desirable to communicate perspective to the user8704for the user8704to determine control strategy.

In some embodiments, as discussed above, the user8704may wear one or more sensors to control the mobile platform8106. These sensors may include, but are not limited to, one or more of the following: accelerometers, joysticks, IMUs. Thus, in these embodiments, the user8704may control the mobile platform8106using body English to move the platform.

In practice, the system may be used in any environment and the system may be distributed in any way, i.e., the user may be in any location and the mobile platform/robotic assembly may be in any location. Thus, the system may be used to accomplish any type of task including but not limited to, tasks related to the mining industry. For example, in some embodiments, the user may control two robotic arms to move about a mine, place explosives in the wall of the mine and attach detonation devices. In some embodiments, this task may be accomplished by a user in a remote location, far from any danger or harm related to the mine and/or the explosives. Using one or more sensors, which, in some embodiments, may be one or more cameras, are used such that the user may follow the progress of the robotic arms and the explosives. Also, in some embodiments, because the robotic arm moves naturally, the user may perform the task using “dummy” explosives and walls, while the mobile platform and robotic arms mimic the user and complete the actual task at hand. Many other uses are contemplated for the system described herein, including, but not limited to, Explosive Ordinance Disposal (sometimes commonly referred to as “EOD”).

Referring now toFIG.91, in some embodiments, a base station9100may be used for wireless communication between the user/exoskeleton and the robotic assembly9112. When navigating, communication with the robotic assembly9112may become interrupted due to the environment, for example, due to reflection on hard surfaces. Thus, in some embodiments, small, low power radio communication modules9102,9104that act as relays may be used. Thus, as the robotic assembly9112moves about the area9110, it will maintain communication with the base station9100and, in some embodiments, measure the signal strength of the communications. In some embodiments, when the signal strength reduces to, or below, a minimum threshold strength (which, threshold may be predetermined based on the signal strength needed to continue communication between the base station9100and robotic assembly9112, the robot may place a small, low power base relay radio9102,9104onto the area9110. As shown inFIG.91, for illustration purposes, the robotic assembly9112, including a mobile platform9106and a robotic arm9108, determined that the radio strength is at or below the predetermined minimum threshold strength, a placed a first low power base relay radio9102, then a second low power base relay radio9104onto the area9110. In some embodiments, the low power base relay radios9102,9104may be approximately 1 inch in diameter.FIG.91and the description thereto is an example of one embodiment. In various embodiments, multiple low power base relay radios may be used.

Referring now toFIG.92A-92C, in some embodiments, where a mobile platform is used, maneuvering in small, confined areas with or without uneven topography including, but not limited to, inclines, declines, deep trenches and steep vertical faces, may be improved using a system including a mobile platform configuration that may be stacked (seeFIG.92A) to allow subsequent mobile platforms9200to use the stack of mobile platforms9202,9204,9206as a ladder or step configuration. In some embodiments, the mobile platforms9202,9204,9206in the stacked configuration may either move a robotic assembly attached thereto prior to stacking, or, in some embodiments, the mobile platforms9202,9204,9206may be used to assist the mobile platform9200that includes the robotic arm9208. In some embodiments, the robotic arm9208on the mobile platform9200may be extended so as to position the center of gravity onto the front wheel of the mobile platform9200.

Referring now toFIG.92B, in some embodiments, the stacked mobile platforms may be replaced by moveable stacking blocks9212,9214,9216. In some embodiments, and as shown inFIG.92B, the robotic arm9208, including a hand assembly9210, may use a hand grip for climbing assist for example, for heavier payloads. In some embodiments, the stacking blocks9212,9214,9216may include hand holds for the hand assembly9210to grip for assistance.

Referring now toFIG.92C, in some embodiments, for example, to overcome obstacles of some sizes, a second robotic arm9218on a second mobile platform9224may lift a first mobile platform9222by holding onto the first robotic arm9220on the first mobile platform9222. When the first mobile platform9222is resting on a surface, the first robotic arm9220of the first mobile platform9222may then lift the second mobile platform9224by pulling up on the second robotic arm9218.

In the exemplary embodiment where two robotic arms such as those described here are used, any task that requires a tool and/or machinery and/or device that is used by humans may be used by the robotic arms. In some embodiments, the hand of the robotic arm may be removable by the other robotic arm, and replaced with an end effecter.

Although the invention has been described in the context of a prosthetic arm, an apparatus according to the elements of this invention could be used in other robotic tools, such as those used in manufacturing and/or teleoperations, where an operator is not connected directly to the controlled device. For example the prosthetic arm apparatus may be used for teleoperation in hazardous environments and/or hazardous activities, for the detonation of explosive devices or the like. In these environments, the prosthetic arm apparatus may provide a more intuitive interface for the user since the user will already be familiar with the natural movements of the arm, which may make control translation of the prosthetic arm apparatus easier.

While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention.