In this article, we present the design of a powered knee-ankle prosthetic leg, which implements high-torque actuators with low-reduction transmissions. The transmission coupled with a high-torque and low-speed motor creates an actuator with low mechanical impedance and high backdrivability. This style of actuation presents several possible benefits over modern actuation styles in emerging robotic prosthetic legs, which include free-swinging knee motion, compliance with the ground, negligible unmodeled actuator dynamics, less acoustic noise, and power regeneration. Benchtop tests establish that both joints can be backdriven by small torques ($\sim$1-3 N$\cdot$m) and confirm the small reflected inertia. Impedance control tests prove that the intrinsic impedance and unmodeled dynamics of the actuator are sufficiently small to control joint impedance without torque feedback or lengthy tuning trials. Walking experiments validate performance under the designed loading conditions with minimal tuning. Finally, the regenerative abilities, low friction, and small reflected inertia of the presented actuators reduced power consumption and acoustic noise compared to state-of-the-art powered legs.

Although there has been recent progress in control of multi-joint prosthetic legs for rhythmic tasks such as walking, control of these systems for non-rhythmic motions and general real-world maneuvers is still an open problem. In this article, we develop a new controller that is capable of both rhythmic (constant-speed) walking, transitions between speeds and/or tasks, and some common volitional leg motions. We introduce a new piecewise holonomic phase variable, which, through a finite state machine, forms the basis of our controller. The phase variable is constructed by measuring the thigh angle, and the transitions in the finite state machine are formulated through sensing foot contact along with attributes of a nominal reference gait trajectory. The controller was implemented on a powered knee-ankle prosthesis and tested with a transfemoral amputee subject, who successfully performed a wide range of rhythmic and non-rhythmic tasks, including slow and fast walking, quick start and stop, backward walking, walking over obstacles, and kicking a soccer ball. Use of the powered leg resulted in clinically significant reductions in amputee compensations for rhythmic tasks (including vaulting and hip circumduction) when compared to use of the take-home passive leg. In addition, considerable improvements were also observed in the performance for non-rhythmic tasks. The proposed approach is expected to provide a better understanding of rhythmic and non-rhythmic motions in a unified framework, which in turn can lead to more reliable control of multi-joint prostheses for a wider range of real-world tasks.

Most robot leg designs are either based on biomimetics of humans’ or animals’ leg morphologies or on being mechanically optimized for specific task(s). In the first approach, differences between the actuation of the mechanical leg and the original biological structure usually result in inefficiencies and control malfunction, and legs in the second group are often limited to good performance for a single task and would fail when used for others. In this paper, we present a constructive framework for robot leg design, which tries to take advantage of the positive factors of both aforementioned approaches. For this purpose, we first, through selection of a template whose biological relevance for a wide range of tasks has been proven, establish a foundation on which mechanical design can be built. Then, we present a general theorem for designing a mechanism based on a template in order to maximize efficiency. In the final step and once the mechanism is designed, we address the problem of selecting the actuators and formulate it as a constrained optimization problem. In a case study with experimental walking data, we show how the mechanism design theorem and the formulated optimization problem can be used together to improve the walking energy efficiency by more than 50%. The proposed three-step approach is not limited to any template and should provide a more structured procedure for leg design, result in optimal energy economy, and maintain important bioinspired factors vital for control and versatility of legged robots.

Transfemoral amputee gait often exhibits compensations due to the lack of ankle push-off power and control over swing foot position using passive prostheses. Powered prostheses can restore this functionality, but their effects on compensatory behaviors, specifically at the residual hip, are not well understood. This paper investigates residual hip compensations through walking experiments with three transfemoral amputees using a low-impedance powered knee-ankle prosthesis compared to their day-to-day passive prosthesis. The powered prosthesis used impedance control during stance for compliant interaction with the ground, a time-based push-off controller to deliver high torque and power, and phase-based trajectory tracking during swing to provide user control over foot placement. Experiments show that when subjects utilized the powered ankle push-off, less mechanical pull-off power was required from the residual hip to progress the limb forward. Overall positive work at the residual hip was reduced for 2 of 3 subjects, and negative work was reduced for all subjects. Moreover, all subjects displayed increased step length, increased propulsive impulses on the prosthetic side, and improved impulse symmetries. Hip circumduction improved for subjects who had previously exhibited this compensation on their passive prosthesis. These improvements in gait, especially reduced residual hip power and work, have the potential to reduce fatigue and overuse injuries in persons with transfemoral amputation.

In this article, we present a new controller for stable and robust walking control of ATRIAS, an underactuated bipedal robot designed based on the spring-loaded inverted pendulum (SLIP) model. We propose a forced-oscillation scheme for control of vertical motion, which we prove to be stable and contractive. Moreover, we prove that, through some mild assumptions, the dynamics of the system can be written in a hierarchical form that decouples the stability analyses of the horizontal and vertical directions. We leverage these properties to find a stabilizing class of functions for foot placement. The torso control is also proved to be decoupled using singular perturbation theory and is stabilized through a feedback linearization controller. We also take advantage of the proposed framework’s flexibility and extend it to include a new reflex-based uneven-terrain walking control scheme. We test the controller for various desired walking speeds (0 to 2.5 m/s), for stepping up and down unexpected obstacles (15 cm), and for high-speed walking on a random uneven terrain (up to 10 cm of step-ups and step-downs and up to 1.8 m/s). The results show successful performance of the controller and its stability and robustness against various perturbations.

Although there has been recent progress in control of multi-joint prosthetic legs for periodic tasks such as walking, volitional control of these systems for non-periodic maneuvers is still an open problem. In this paper, we develop a new controller that is capable of both periodic walking and common volitional leg motions based on a piecewise holonomic phase variable through a finite state machine. The phase variable is constructed by measuring the thigh angle, and the transitions in the finite state machine are formulated through sensing foot contact together with attributes of a nominal reference gait trajectory. The controller was implemented on a powered knee-ankle prosthesis and tested with a transfemoral amputee subject, who successfully performed a wide range of periodic and non-periodic tasks, including low- and high-speed walking, quick start and stop, backward walking, walking over obstacles, and kicking a soccer ball. The proposed approach is expected to provide better understanding of volitional motions and lead to more reliable control of multi-joint prostheses for a wider range of tasks.