A Knee–Ankle–Foot Orthosis to Assist the Sound Limb of Transfemoral Amputees

As a consequence of limb loss, trans-femoral amputees exert 60% additional knee extension torque and 50% more plantar flexion torque in the healthy limb compared to non-amputees. In this paper, we developed an active knee–ankle–foot orthosis (KAFO) designed to assist the healthy leg of trans-femoral amputees in activities of daily living, such as walking, ascending/descending stairs, and transitioning from sit-to-stand with adequate range of motion, speed, and peak torque. Our KAFO was designed to exceed the performance of similar assistive devices reported in literature in terms of: 1) portability; 2) power; 3) compliance; and 4) versatility. It is based on one-degree-of-freedom active series-elastic actuators in both the knee and ankle, with an additional passive degree of freedom at the ankle level to allow natural inversion/eversion. The knee module consists of a worm-gear surrounded by two pre-compressed springs. The ankle actuator relies on a mechanically adjustable compliance system combined with a 4-bar linkage transmission. The actuators were designed to optimize the torque output at the joints while fulfilling low-power requirements. This novel KAFO is controlled with a three-layer structure. The optimized low level, based on a closed-loop torque controller, has adequate performances for the targeted application. The device is also shown to fulfill the three pre-defined functional requirements for all locomotion modes.