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.

ARKOPY - Autonomous Robotic Knee Orthosis for Training and Therapy

Term, period of validity, duration: 08.2022 - 08.2024

Keywords: medical technology, active exoskeleton, artificial intelligence, lightweight construction

The lead partner, lead entity is VDI/VDE Innovation + School of Engineering GmbH, which is entrusted by the Ministry of Economy, Business, Labor and Tourism of Baden-Württemberg.

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 weighting, degree of support and duration of use determine the effectiveness of exoskeletons in therapy. There is great interest among rehabilitation clinics in particularly lightweight yet powerful means of assistance. The aim of the proposed project is an active knee orthosis with a novel, innovative lightweight actuator and AI-based control for optimal adaptation to a wide range of users and activities. A special leg simulator is being developed to verify the functional demonstrator. This will allow different activities to be simulated realistically, enabling the control algorithms to be optimized and performance to be proven. The key to achieving this ambitious goal is a new type of biomimetic knee joint drive that comes close to the properties of the human knee joint by using high-strength cables and specially shaped pulleys for 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 users, readers during the various activities. To realize the project, Advanced Mechatronics GmbH, a specialist in safe electronics and medical technology, is cooperating with the Centre for Reliable Mechatronic Systems at Aalen University of Applied Sciences. The functional demonstrator developed will be validated at the end of the project at the Zihlschlacht Rehabilitation Clinic through technical testing. The industrialization of the results will be carried out by Advanced Mechatronics after project completion.

Cyber-physical drive modules for maritime applications

The CHARISMA research project is pursuing 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 prognostics 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 minutes
• The modules should be able to be used in a wide variety of system architectures (centralized / decentralized application)
• Development of fault-tolerant low-voltage motors (up to 400 W) with high torque and a wide field weakening range
• Research and development of a new type of 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 HIMB sub-project of the MIMIC (Miniaturized Integrated Motion Controller) research project aims to develop a highly efficient drive module (Miniaturized Integrated Motion Controller: Mimic) for permanently excited synchronous machines with integrated energy storage and inverter for use in industry, medicine, process and marine technology.

Functions of the drive module:

• Energy storage
• inverter
• Control logic
• Communication with digitalized production systems

Active Lower Limb Exoskeleton

The research project aims to provide full support for the lower limbs for rehabilitation purposes in the event of accidents, muscle diseases or partial paralysis. As a medical device, special requirements are placed on safety and validated functionality. Reliable control based on biomechanical sensor data is used to ensure support.

The aims of the system are

• Support for force and speed with minimal weighting
• Adaptive control through cloud-based data handling
• Faster and personalized rehabilitation through mobile health functionality

In the MagNetz sub-area of the university-wide SmartPro research project, the Centre for Reliable Mechatronic Systems is responsible for qualifying electric drives that have been modified using state-of-the-art magnetic materials. In addition to efficiency, the focus is on their thermal and magnetic behavior. For this purpose, test benches are designed and implemented for motors of various power ratings. Due to the usefulness of the test benches as high-precision measuring devices, a special focus is placed on the validation of the measurements. The test benches are used in

• 4 quadrant load simulations (e.g. pumps, valves, fans)
• Determination of thermal contact resistances
• Verification of different commutation methods (sine-delta, SVM, flat-top) in a rapid prototyping environment
• Forecasting the service life

Smart Available Maritime Battery

As part of the research project, an innovative, modular, scalable energy supply for consumers in the field (of) underwater technology is being developed. The underwater energy supply allows the operation of various contracting parties on an existing supply network, as the consumers are fed directly from the energy supply and the supply network is only required for recharging the energy supply. This is to be achieved for a service life of 25 years.

ISSA (Intelligent Safe Subsea Actuation)