This paper describes the design of a powered knee- and-ankle transfemoral prosthetic leg, which implements high torque density actuators with low-reduction transmissions. The low reduction of 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 implemented in emerging robotic prosthetic legs. Such benefits include free-swinging knee motion, compliance with the ground, negligible unmodeled actuator dynamics, and greater potential for power regeneration. Benchtop validation experiments were conducted to verify some of these benefits. Backdrive and free-swinging knee tests confirm that both joints can be backdriven by small torques (~3 Nm). Bandwidth tests reveal that the actuator is capable of achieving frequencies required for walking and running. Lastly, open-loop impedance control tests prove that the intrinsic impedance and unmodeled dynamics of the actuator are sufficiently small to control joint impedance without torque feedback.

This paper presents the mechatronic design and experimental validation of a novel powered knee-ankle orthosis for testing torque-driven rehabilitation control strategies. The modular actuator of the orthosis is designed with a torque dense motor and a custom low-ratio transmission (24:1) to provide mechanical transparency to the user, allowing them to actively contribute to their joint kinematics during gait training. The 4.88 kg orthosis utilizes frameless components and light materials, such as aluminum alloy and carbon fiber, to reduce its mass. A human subject experiment demonstrates accurate torque control with high output torque during stance and low backdrive torque during swing at fast walking speeds. This work shows that backdrivability, precise torque control, high torque output, and light weight can be achieved in a powered orthosis without the high cost and complexity of variable transmissions, clutches, and/or series elastic components.