Design and Validation of a Pancake Style Planetary Gearbox for an Eddy Current-Based Wearable Gait Training Robot

Eddy current brakes have been recently used for functional resistance training in individuals with neurological and orthopaedic disorders. These devices consist of a gearbox, a conductive disc, and permanent magnets that can be moved relative to the disc to alter resistance. However, current devices use a commercial planetary gearbox with a tall profile that sticks out from the leg, which affects wearability. This is coupled with the large system inertia, which together impedes potential device transition to clinical and in-home use. In this study, we developed a low-profile, pancake-style planetary gearbox that greatly reduces the protrusion of the device from the leg. We performed a design analysis and optimization to minimize the thickness and inertia of the device while ensuring that it could withstand the maximum expected torque (50 Nm). We then performed human subjects experiments to examine the effectiveness of our new design for functional resistance training. The results indicated that all leg muscles showed a significant increase in activation during resisted conditions. There were also significant after-effects on medial hamstring activation. These results indicate that the new design is a feasible method for functional resistance training and may have a potential clinical value in gait rehabilitation.