As the world population continues to age, the demand for treatment and rehabilitation of long-term age-related ailments will rise. Healthcare technology must keep up with this demand, and existing solutions must become more readily available to the populace. Conditions such as impairment due to stroke currently take months or years of physical therapy to overcome, but rehabilitative exoskeletons can be used to greatly extend a physical therapist’s capabilities.

In this thesis, a rehabilitative knee exoskeleton was designed which is significantly lighter, more portable and less costly to manufacture than existing designs. It accomplishes this performance by making use of high-powered and weight-optimized brushless DC (BLDC) electric motors designed for drones, open-source hardware and software solutions for robotic motion control, and rapid prototyping technologies such as 3D printing and laser cutting.

The exoskeleton is made from a series of laser cut aluminum plates spaced apart with off-the-shelf standoffs. A drone motor with a torque of 1.32 Nm powers an 18.5:1 reduction two-stage belt drive, giving a maximum torque of 24.4 Nm at the output. The bearings for the belt drive are installed into 3D printed bearing mounts, which act as a snug intermediary between the bearing and the aluminum plate. The system is powered off a 24 volt, 1,500 MAh lithium battery, which can provide power for around an hour of walking activity.

The exoskeleton is controlled with an ODrive motor controller connected to a Raspberry Pi. Hip angle data is provided by an IMU, and the knee angle is provided by an encoder on the output shaft. A compact Rotary Series Elastic Actuator (cRSEA) device is mounted on the output shaft as well, to accurately measure the output torque going to the wearer. A Proportional-Derivative (PD) controller with feedforward relates the input current with the output torque. The device was tested on a treadmill and found to have an average backdrive torque of 0.39 Nm, significantly lower than the current state of the art. A gravity compensation controller and impedance controller were implemented to assist during swing and stance phases respectively. The results were compared to the muscular exertion of the knee measured via Electromyography (EMG).