Biomechanics-Informed Mechatronics Design of Comfort-Centered Portable Hip Exoskeleton: Actuator, Wearable Interface, Controller

Exoskeletons can improve human mobility, but discomfort remains a significant barrier to their widespread adoption. This paper presents a comfort-centered mechatronics design of portable hip exoskeletons, comprising of three factors: (i) actuation, (ii) wearable interface, (iii) and assistive controller. We introduced an analytical multibody model to predict the human-exoskeleton contact forces during gait. Informed by this model, we designed a wearable interface that significantly improved the three considered objective metrics: (i) undesired contact forces at the wearable interface, (ii) wobbling, and (iii) metabolic reduction, and also the post-test evaluation via a System Usability Scale questionnaire as a subjective metric. Our experiments with two exoskeleton controllers (gait-based and reinforcement learning-based) demonstrated that the design of the wearable physical interface has a greater impact on reducing metabolic rate and minimizing wobbling than the choice of controller. Our actuation design method leads to highly backdrivable, lightweight quasi-direct drive actuators with high torque tracking performance. By leveraging this wearable design, we achieved up to 60% reduction in undesired contact forces, and a 74% reduction in exoskeleton wobbling in the frontal axis compared to a traditional configuration. Additionally, the net metabolic cost reduction was 18% compared to the no exoskeleton condition.