Research Projects

EXOrem - Exoskeletons with redundant electric motors

Term, period of validity, duration: 02.2025 - 01.2025

Keywords: medical technology, active exoskeleton, electric motor

The lead partner, lead entity is AiF Projekt GmbH, which has been entrusted by the federal ministry for economy, business and climate protection.

Significant improvements to active orthoses/exoskeletons can be achieved through targeted optimization of battery-powered drives. The focus is on increasing power density, dynamics and safety. To achieve the requirements, a motor with a special two-channel design with a miniaturized feedback system is to be researched. A functional model of the motor is to be verified using a test bench and tested realistically using an active knee orthosis. To realize the project, the Centre for Reliable Mechatronic Systems at Aalen University of Applied Sciences is cooperating with Elektromotoren Fischer GmbH.

The aim of the R&D sub-project at Aalen University of Applied Sciences is the evaluation of a safe and space-optimized feedback system and the development of the control concept for the electric motor. The test bench for verifying the motor is also being developed. The degree of the sub-project is the integration of the motor into an active knee orthosis and the validation of the system using a leg simulator.

Innovative Subsea Technology for Sustainable Drinking Water Production – The SUB-CRO Research Project

The growing global demand for clean drinking water represents one of the key challenges of the 21st century. Coastal regions and arid areas in particular are increasingly dependent on efficient and sustainable technologies for seawater desalination. Against this backdrop, the research project SUB-CRO (SUBsea Control System for Reverse Osmosis Desalination Applications) is dedicated to developing a novel control and regulation system for subsea seawater desalination plants. The aim is to significantly reduce both energy consumption and environmental impact through innovative technologies.

The project is being carried out as a collaborative initiative between partners from industry and academia. Participants include Advanced Mechatronics GmbH with the subproject SUB-IRO (SUBsea Infrastructure for Reliable Reverse Osmosis), as well as the Institute for High Integrity Mechatronic Systems (ZMS) at Aalen University, which focuses on the subproject SUB-CEO (SUBsea Control and Diagnosis Algorithms for Reliable Reverse Osmosis). The consortium is complemented by the associated partner Waterise Solutions AS from Norway, which contributes extensive expertise in subsea seawater desalination and aims to support the future industrialization of the results. The total project duration is 36 months. The research project is funded by the German Federal Ministry for Economic Affairs and Energy (BMWE), with Project Management Jülich (PTJ) acting as the project sponsor.

Seawater desalination using reverse osmosis is an established process in which seawater is forced under high pressure through membranes to separate salt and other components. However, this process is highly energy-intensive: conventional land-based plants require approximately 3 to 4 kilowatt-hours per cubic meter of drinking water produced. In addition, large amounts of highly concentrated brine are generated, which is usually discharged back into the sea. SUB-CRO follows an innovative approach: relocating the desalination process to the deep sea. There, the natural ambient pressure is used to drive the water through the membranes. As a result, much of the energy-intensive pressure generation by pumps is eliminated. Only after filtration is the produced drinking water transported to the surface. The remaining brine stays in the deep sea and has a significantly lower salt concentration.

As part of the project, a demonstrator is being developed to validate the system’s functionality under near-real conditions. Building on this, field tests and industrial implementation in cooperation with Waterise Solutions AS are planned. The project makes an important contribution to the sustainable use of marine resources and addresses key objectives of the maritime research program, particularly in the areas of environmental compatibility (MARITIME.green) and economic value creation (MARITIME.value). In addition to reducing energy consumption and emissions, SUB-CRO strengthens digitalization and automation in the maritime sector and opens up new perspectives for the global drinking water supply.

With SUB-CRO, a forward-looking technological approach is being pursued that combines ecological, economic, and technical aspects. The combination of innovative subsea technology, intelligent control systems, and international collaboration has the potential to fundamentally transform seawater desalination and make a significant contribution to addressing global water scarcity.

Expansion of Subsea Research Infrastructure: The Hydraulic High-Pressure Testing System (HHPS)

With the funded project Hydraulic High-Pressure Testing System (HHPS), the Institute for High Integrity Mechatronic Systems (ZMS) at Aalen University is strategically expanding its research infrastructure in the fields of energy and subsea technology. The objective of the project is the development and implementation of a modular high-pressure test bench that enables realistic investigation of pump and valve systems under extreme conditions. The project is designed for a duration of 11 months. It is funded by the German Federal Ministry for Economic Affairs and Energy (BMWE), with Project Management Jülich (PTJ) acting as the project sponsor.

At the core of the project is a novel testing system that allows experiments with various fluids such as water, CO₂, and hydraulic fluids under partially multiphase conditions and at pressures of up to 1500 bar. This enables comprehensive testing of both active and passive subsea components. HHPS facilitates performance, leakage, and lifetime tests under conditions comparable to those encountered in real subsea applications.

Thanks to its modular architecture and intelligent interconnection of different process segments, the system offers a high degree of flexibility. It enables the verification and validation of complex electrohydraulic and electromechanical systems, including subsea high-pressure pumps, metering pumps, and safety-critical valves used in the offshore industry. A particular advantage of HHPS lies in its full compatibility with the existing ZMS research infrastructure. In particular, its integration with the subsea environmental simulator developed in the CHARISMA project opens up new possibilities for combined system testing under realistic environmental and pressure conditions. This results in a powerful overall system that allows a previously unattainable depth of analysis of mechatronic components.

The project addresses key scientific questions in the field of mechatronic high-pressure systems, including:

•             the behavior of fluids in multiphase states under high-pressure conditions,

•             the effects of phase transitions and impurities on materials and sealing systems,

•             and the reliable control and regulation of complex fluid processes.

The insights gained make a significant contribution to improving the long-term stability and operational safety of components in subsea production systems. In addition, the testing system provides a valuable platform for teaching and training young researchers by enabling hands-on experiments and student research projects.

Technologically, HHPS serves as a development and qualification platform for innovative maritime systems. The ability to flexibly simulate different fluids and test conditions significantly reduces the effort required to develop specific test setups. With HHPS, ZMS strengthens its position as a high-performance research institute in the field of reliable mechatronic systems. The new infrastructure complements existing laboratory facilities such as engine test benches, valve simulators, and the subsea environmental simulator, creating a solid foundation for future third-party funded projects, doctoral research, and international collaborations.

ISSA (Intelligent Safe Subsea Actuation)

ARKOPY - Autonomous Robotic Knee Orthosis for Training and Therapy

Duration: 08.2022 - 08.2024

Keywords: Medical Technology, Active Exoskeleton, Artificial Intelligence, Lightweight Construction

The project management organisation lent by the Ministry of Economics, Labour and Tourism Baden-Württemberg is VDI/VDE Innovation + Technik GmbH.

Mobility is the basis for an active and self-determined life. The sharp increase in physical limitations as a result of neurological damage caused by strokes and heart attacks can be countered with innovative robotic treatment methods in the form of active exoskeletons. The parameters of weight, degree of support and duration of use define the effectiveness of exoskeletons in therapy. There is a great interest among rehabilitation clinics in particularly light and at the same time powerful aids. The objective of the proposed project is an active knee orthosis with a novel innovative lightweight actuator and an AI-based control system for optimal adaptation to a wide range of users and activities. A special leg simulator will be developed to verify the functional demonstrator. This can be used to realistically model different activities, thus optimising the control algorithms and demonstrating the performance. The key to achieving this ambitious goal is a new type of biomimetic knee joint drive, which comes close to the properties of the human knee joint through the use of high-strength cables and specially shaped pulleys for an angle-dependent force transmission. In addition, an intelligent support algorithm based on machine learning is being developed. This is intended to ensure optimal support for the user during the various activities. To realise the project, Advanced Mechatronics GmbH, as a specialist in safe electronics and medical technology, is cooperating with the Institute for High Integrity Mechatronic Systems at Aalen University. The developed functional demonstrator will be validated at the end of the project at the Zihlschlacht rehabilitation clinic through a technical trial. The industrialisation of the results will be carried out by Advanced Mechatronics after the project is completed.

Sponsored by

Cyber-physical drive modules for maritime applications

The cyber-physical drive modules for maritime applications (CHARISMA) research project pursues the research and development of intelligent, highly integrated, digital, mechatronic drive modules that can be used as cyber-physical systems in marine technology.



Objective:

• Research into a suitable prognosis and health management concept to increase the availability of the modules
• Research and development of suitable motor, sensor and electronic modules
• Research and use of new materials for maritime applications
• Integration of Industry 4.0-compatible interfaces and protocols
• The modules should be usable in a wide variety of system architectures (centralised / decentralised application)
• Development of fault-tolerant low-voltage motors (up to 400 W) with high torque and large field weakening range
• Research and development of a new sensor technology
• Integration of the modules into a linear actuator with subsequent validation

Hardware integrated Motion Controller and Battery Management for high efficiency motor operation

The sub-project HIMB of the research project MIMIC (Miniaturised Integrated Motion Controller) focuses on the development of a highly efficient drive module (Miniaturised Integrated Motion Controller: Mimic) for permanently excited synchronous machines with integrated energy storage and inverter for use in industry, medical, process and marine technology.

Functions of the drive module:  

• Energy storage  
• Converter    
• Logic      
• Communication with digitalised production systems

Active exoskeleton of the lower extremities  
The research project focuses on full support of the lower extremities for rehabilitation in case of accidents, muscle diseases or partial paralysis. As a medical device, high safety and validated performance are required. A robust control system based on biomechanical sensor data is used to regulate the support.

This system is designed to:

• Provide safe support in power and speed with minimal weight
• Enable adaptive control with cloud-based data processing
• Provide faster and more personalised rehabilitation mobile health functions

In the MagNetz section of the research project, SmartPro works with the Centre for Reliable Mechatronic Systems and the qualification of electric drives, die modified with advanced magnetic materials. The focus is on the efficiency and the thermal and magnetic behaviour of the machines. Therefore, test benches for drives of different performance levels are designed and realised. Since die test benches are used as high-precision measuring instruments, a special focus is on the validation of measurements.

The test benches are used in:

• 4 quadrant load simulations (e.g. pumps, valves, fans)
• Determination of thermal contact resistance
• Verification of different commutation processes (sine-triangle, SVM, flat-top) by rapid prototyping environment
• Prognosis of the system lifetime

Smart Available Maritime Battery

The research project focuses on the development of an innovative, modular and scalable energy supply used by consumers of underwater technologies. The underwater energy supply enables the operation of different costumers at one existing supply network because the costumers are getting supplied by the energy supply. The supply network then only is needed to recharge the energy supply. This shall be achieved for a life cycle of 25 years.