Study of design issues in a prototype lower-limb prosthesis - proof-of-concept in a 3D printed model

Dissertação de Mestrado Integrado em Engenharia Biomédica Ramo de Biomateriais, Reabilitação e BiomecânicaThe amputation of one or both lower limbs, which can be brought on by trauma, diabetes, or other vascular diseases, is an increasingly common occurrence, especially due to the increase in the number of cases of diabetes in the developed world. In Portugal alone 1300 amputations each year are attributed to diabetes. These amputations severely impact the mobility, self-esteem, and quality of life of the patients, a situation that can be alleviated via the installation of a lower limb prosthesis. Sadly, these prostheses are not yet capable of completely emulating a sound limb in an affordable fashion. In this dissertation, state-of-the-art research was carried out regarding the mechanics of human gait, both healthy and prosthetic. An investigation regarding the state-of-the-art research was also carried out regarding lower-limb prostheses, their evolution, mechanics, and prospects, as well as additive manufacturing techniques, and how they can be crucial to the development of affordable prostheses. Special attention was provided to the study of the leading edge of prostheses research, namely active prostheses, capable of generating and introducing energy into the human gait, rather than simply acting as passive devices. This dissertation follows up on previous work carried out in the BioWalk Project of Universidade do Minho’s BiRDLab: “Prosthetic Devices and Rehabilitation Solutions for the Lower Limbs Amputees”. This work consisted of the development of an active lower-limb prosthesis prototype, with the goal of providing an affordable, but functional, prosthesis for future testing with patients. However, the resulting prototype was laden with issues, such as excessive weight and an underpowered motor. As such, this work set out to identify these issues, design, implement and test modifications to the prosthesis to produce a satisfying prototype. Given the limited resources and facilities available, it was decided to work on a smaller model prosthesis installed in a bipedal robot, the DARwIn-OP, using it as proof-of-concept for modifications to be implemented in the BiRDLab prosthesis. Modifications were successfully implemented, chiefly among them a planetary gear-based reductor and a novel attachment mechanism built using additive manufacturing techniques. It is possible to conclude that there is a great potential in the implementation of additive manufacturing techniques in the development of affordable prosthesis.A amputação de um ou ambos os membros inferiores, que pode ser causada por trauma, diabetes, ou outras doenças vasculares, é um evento cada vez mais frequente, especialmente devido ao aumento do número de casos de diabetes no mundo desenvolvido. Em Portugal, 1300 amputações são atribuídas aos diabetes todos os anos. Estas amputações influenciam negativamente a mobilidade, autoestima e qualidade de vida dos pacientes, mas estes efeitos podem ser minimizados através da instalação de uma prótese de membro inferior. Infelizmente, estas próteses ainda não são capazes de emular completamente um membro saudável de forma económica. Nesta dissertação, um estado da arte do caminhar humano foi realizado, tendo em atenção o funcionamento deste, quer em sujeitos saudáveis ou amputados. Um estado da arte também foi realizado relativamente às próteses de membros inferiores, a sua evolução, funcionamento, e perspetivas futuras, e também relativamente a técnicas de fabrico aditivas e a forma como estas podem ser aplicadas em próteses acessíveis. Tomou-se atenção especial ao estudo das próteses ativas, capazes de gerar e introduzir energia no caminhar, ao invés das próteses passivas tradicionais. Esta dissertação baseia-se em trabalho prévio ao abrigo do projeto BioWalk do laboratório BiRDLab da Universidade do Minho: “Dispositivos prostéticos e soluções de reabilitação para amputados dos membros inferiores”. Este trabalho consistiu no desenvolvimento de um protótipo de prótese de membro inferior ativa, com o objetivo de criar uma prótese de baixo custo para testes em pacientes. No entanto, o protótipo produzido possuí vários problemas, tais como peso excessivo e um motor subdimensionado. Assim sendo, este trabalho propôs-se a identificar estes problemas e a desenhar, implementar, e testar modificações. Tendo em conta os limitados recursos disponíveis, decidiu-se trabalhar numa prótese modelo mais pequena, instalada num robô bipedal, o DARwIN-OP, e a usá-la para testar modificações a implementar na prótese do BiRDLab. As modificações foram implementadas com sucesso, especialmente um redutor de engrenagens planetárias e um novo método de conectar a prótese, usando técnicas de fabrico aditivas

Development of a knee prosthesis powered by electro-hydrostatic actuation

L'abstract è presente nell'allegato / the abstract is in the attachmen

Development of a Passive and Slope Adaptable Prosthetic Foot

Historically, users of prosthetic ankles have relied on actively operated systems to provide effective slope adaptability. However, there are many drawbacks to these systems. This research builds upon work previously completed by Hansen et al. as it develops a passive, hydraulically operated prosthetic ankle with the capability of adapting to varying terrain in every step. Using gait cycle data and an analysis of ground reaction forces, the team determined that weight activation was the most effective way to activate the hydraulic circuit. Evaluations of the system pressure and energy showed that although the spring damper system results in a loss of 9J of energy to the user, the footplate stores 34J more than a standard prosthesis. Therefore, the hydraulic prosthetic provides a 54% increase in stored energy when compared to a standard prosthesis. The hydraulic circuit manifold prototype was manufactured and tested. Through proof of concept testing, the prototype proved to be slope adaptable by successfully achieving a plantarflexion angle of 16 degrees greater than a standard prosthetic foot currently available on the market.Massachusetts Institute of Technology. Tata Center for Technology and Desig

Conceptual Design of a Fully Passive Transfemoral Prosthesis to Facilitate Energy-Efficient Gait

In this study, we present the working principle and conceptual design towards the realization of a fully-passive transfemoral prosthesis that mimics the energetics of the natural human gait. The fundamental property of the conceptual design consists of realizing an energetic coupling between the knee and ankle joints of the mechanism. Simulation results show that the power flow of the working principle is comparable to that in human gait and a considerable amount of energy is delivered to the ankle joint for the push-off generation. An initial prototype in half scale is realized to validate the working principle. The construction of the prototype is explained together with the test setup that has been built for the evaluation. Finally, experimental results of the prosthesis prototype during walking on a treadmill show the validity of the working principle

Emulation of Ankle Function for Different Gaits through Active Foot Prosthesis: Actuation Concepts, Control and Experiments

A main effort has been devoted in this thesis to consider the effects of the actuator components (i.e. springs, dampers and motors) and their configuration (i.e. the way they are assembled) in power and energy requirement of powered foot prostheses. It has been investigated which actuation mechanism would have the least requirements to perform a certain human gait (e.g. walking, running, ascending or descending the stairs). This thesis shows that the components of the robotic foot and their configurations are important design factors. This information is fundamental for building mechanical prototypes of active foot prostheses. In addition, the human body is equipped with muscle assemblies to actuate a joint. In robotics this phenomenon is called over-actuation. In this thesis, it was investigated if and how this fact could be used to reduce power-energy requirements in active foot prosthesis. Furthermore, the control structures of the active foot prostheses are investigated and discussed and the results of the first laboratory experiments with the Powered Ankle Knee Ortho-prosthesis (the PAKO platform) are explained. In continuation to this topic, some master controller schemes were introduced for gait identification. A video of experiments with PAKO platform can be seen here: https://www.youtube.com/watch?v=i7N3L6RsNN

Design of a Passive Ankle Prosthesis with Energy Return That Increases with Increasing Walking Velocity

Patients who undergo a transtibial (below the knee) amputation are often met with a difficult decision: selection of a prosthesis. Limitations of currently available prostheses motivate work on a new solution, the EaSY Walk, a passive device that mimics two key aspects of the natural ankle: non-linear rotational stiffness through implementation of a stiffening flexure mechanism and rotational work output that varies as a function of walking velocity to propel the user forward. To achieve the latter, a strategy to convert the maximum available translational energy acquired from deflection along the leg into rotational energy about the ankle joint through coupling of these two degrees of freedom is used. This strategy utilizes maxima/minima of known ankle profiles to control timing of critical device functions as well as the quantity of energy input from leg deflection. In doing so, both consistent operation of the device and maximal energy output at a given walking velocity are theoretically obtained. Optimizing for both aforementioned ankle criteria, 25.1% of the work of the average natural ankle was achieved for 15 mm of leg deflection, less deflection than is exhibited by many shock absorbing pylon prostheses. After fabricating and testing the optimized design using a repeatable robot trajectory, the device was found to convert 26.6% of input translational work as rotational work, accounting for 63.1% of modeled rotational work. Through human subject testing, the device was found to function inconsistently due to the large impact loadings associated with human gait. In order to achieve proper functionality with human gait, design modifications to the energy storage and release devices are recommended

Bio-inspired knee joint: Trends in the hardware systems development

The knee joint is a complex structure that plays a significant role in the human lower limb for locomotion activities in daily living. However, we are still not quite there yet where we can replicate the functions of the knee bones and the attached ligaments to a significant degree of success. This paper presents the current trend in the development of knee joints based on bio-inspiration concepts and modern bio-inspired knee joints in the research field of prostheses, power-assist suits and mobile robots. The paper also reviews the existing literature to describe major turning points during the development of hardware and control systems associated with bio-inspired knee joints. The anatomy and biomechanics of the knee joint are initially presented. Then the latest bio-inspired knee joints developed within the last 10 years are briefly reviewed based on bone structure, muscle and ligament structure and control strategies. A leg exoskeleton is then introduced for enhancing the functionality of the human lower limb that lacks muscle power. The design consideration, novelty of the design and the working principle of the proposed knee joint are summarized. Furthermore, the simulation results and experimental results are also presented and analyzed. Finally, the paper concludes with design difficulties, design considerations and future directions on bio-inspired knee joint design. The aim of this paper is to be a starting point for researchers keen on understanding the developments throughout the years in the field of bio-inspired knee joints

A Generalized Method for Predictive Simulation-Based Lower Limb Prosthesis Design

Lower limb prostheses are designed to replace the functions and form of the missing biological anatomy. These functions are hypothesized to improve user outcome measures which are negatively affected by receiving an amputation – such as metabolic cost of transport, preferred walking speed, and perceived discomfort during walking. However, the effect of these design functions on the targeted outcome measures is highly variable, suggesting that these relationships are not fully understood. Biomechanics simulation and modeling tools are increasingly capable of analyzing the effects of a design on the resulting user gait. In this work, prothesis-aided gait is optimized in simulation to reduce both muscle effort and peak loads on the residual limb using a generalized prosthesis model. Compared to a traditional revolute powered ankle joint model, a two degree-of freedom generalized model reduced muscle activations by 50% and peak loads by 15%. Simulated prosthesis behaviors corresponding to the optimal gait patterns were translated into a two degree-of-freedom ankle-foot prosthesis design with powered bidirectional linear translation and plantarflexion. The prototype is capable of delivering up to 171 N-m of plantarflexion torque and 499 N of translation force, with 15° dorsi-/35° plantarflexion and 10 cm translation range of motion. The mass and height of the ankle-foot are 2.29 kg and 19.5 cm, respectively. The mass of the entire system including the wearable offboard system is 8.58 kg. This platform is designed to emulate the behavior of the simulated prosthesis, as well as be configurable to emulate alternate behaviors obtained from simulations with different optimization objectives. The prototype is controlled to replicate simulated walking patterns using a high level finite state controller, mid-level stiffness controller, and low level load controller. Closed loop load control has bandwidth of 15 Hz in translation and 7.2 Hz in flexion. Load tracking during walking with a single able-bodied human subject ranges from 93 to 159 N in translation and 4.6 to 21.3 N-m in flexion. The contribution of this work is to provide a framework for predictive simulation-based prosthesis design, evidence of its practical implementation, and the experimental tools to validate future predictive simulation studies