Bowden Cables Research Articles

Soft ankle exoskeleton to counteract dropfoot and excessive inversion.

Wearable exoskeletons are emerging technologies for providing movement assistance and rehabilitation for people with motor disorders. In this study, we focus on the specific gait pathology dropfoot, which is common after a stroke. Dropfoot makes it difficult to achieve foot clearance during swing and heel contact at early stance and often necessitates compensatory movements. We developed a soft ankle exoskeleton consisting of actuation and transmission systems to assist two degrees of freedom simultaneously: dorsiflexion and eversion, then performed several proof-of-concept experiments on non-disabled persons. The actuation system consists of two motors worn on a waist belt. The transmission system provides assistive force to the medial and lateral sides of the forefoot via Bowden cables. The coupling design enables variable assistance of dorsiflexion and inversion at the same time, and a force-free controller is proposed to compensate for device resistance. We first evaluated the performance of the exoskeleton in three seated movement tests: assisting dorsiflexion and eversion, controlling plantarflexion, and compensating for device resistance, then during walking tests. In all proof-of-concept experiments, dropfoot tendency was simulated by fastening a weight to the shoe over the lateral forefoot. In the first two seated tests, errors between the target and the achieved ankle joint angles in two planes were low; errors of <1.5° were achieved in assisting dorsiflexion and/or controlling plantarflexion and of <1.4° in assisting ankle eversion. The force-free controller in test three significantly compensated for the device resistance during ankle joint plantarflexion. In the gait tests, the exoskeleton was able to normalize ankle joint and foot segment kinematics, specifically foot inclination angle and ankle inversion angle at initial contact and ankle angle and clearance height during swing. Our findings support the feasibility of the new ankle exoskeleton design in assisting two degrees of freedom at the ankle simultaneously and show its potential to assist people with dropfoot and excessive inversion.

Process improvement in Zamak injection machines for automotive component fabrication

Die casting processes are nowadays widely used in the industry and differentiate from metal casting from the high-speed and pressure applied to inject the metal into the cavity. Due to this procedure, the produced parts manage to acquire better mechanical characteristics, dimensional precision, and smaller roughness. Due to the automation possibility, and mould coating possibilities, the process becomes cost competitive at significant production rates. However, to assure proper functioning and extended life of die casting equipment, it is necessary to continuously control the process variables, undertake maintenance, and implement process improvement actions to the production lines. The objective of the present work is to improve the efficiency of a Zamak die cast injection line for cable terminals used in Bowden or control cables for the automotive industry. By reducing wear and number of failures of standard components in this production line, and thus by diminishing the stoppage and replacement costs, it becomes possible to improve the current process. By applying specific improvements to the injection subset, heating element, and pump, including geometry modifications to the injection elements and respective interactions, heat treatments, higher power resistor, and groove/ring system in the pumps’ piston, a significant process improvement was accomplished by the proposed and tested modifications, leading to reduction of failures and operational costs, and consequently higher competitiveness of the process.

A 4-DOF Exosuit Using a Hybrid EEG-Based Control Approach for Upper-Limb Rehabilitation.

Rehabilitation devices, such as traditional rigid exoskeletons or exosuits, have been widely used to rehabilitate upper limb function post-stroke. In this paper, we have developed an exosuit with four degrees of freedom to enable users to involve more joints in the rehabilitation process. Additionally, a hybrid electroencephalogram-based (EEG-based) control approach has been developed to promote active user engagement and provide more control commands.The hybrid EEG-based control approach includes steady-state visual evoked potential (SSVEP) paradigm and motor imagery (MI) paradigm. Firstly, the rehabilitation movement was selected by SSVEP paradigm, and the multivariate variational mode decomposition (MVMD) and canonical correlation analysis (CCA) method was used for SSVEP EEG recognition; then, the motion intention was obtained by MI paradigm, and the convolutional neural network (CNN) and long short-term memory network (LSTM) were used to build a CNN-LSTM model for MI EEG recognition; finally, the recognition results were translated into control commands of Bowden cables to achieve multi-degree-of-freedom rehabilitation.Experimental results show that the average classification accuracy of the CNN-LSTM model reaches to 90.07% ± 2.23%, and the overall accuracy of the hybrid EEG-based control approach reaches to 85.26% ± 1.95%. The twelve subjects involved in the usability assessment demonstrated an average system usability scale (SUS) score of 81.25 ± 5.82. Additionally, four participants who underwent a 35-day rehabilitation training demonstrated an average 10.33% increase in range of motion (ROM) across 4 joints, along with a 11.35% increase in the average electromyography (EMG) amplitude of the primary muscle involved.The exosuit demonstrates good accuracy in control, exhibits favorable usability, and shows certain efficacy in multi-joint rehabilitation. Our study has taken into account the neuroplastic principles, aiming to achieve active user engagement while introducing additional degrees of freedom, offering novel ideas and methods for potential brain-computer interface (BCI)-based rehabilitation strategies and hardware development.Clinical impact: Our study presents an exosuit with four degrees of freedom for stroke rehabilitation, enabling multi-joint movement and improved motor recovery. The hybrid EEG-based control approach enhances active user engagement, offering a promising strategy for more effective and user-driven rehabilitation, potentially improving clinical outcomes.Clinical and Translational Impact Statement: By developing an exosuit and a hybrid EEG-based control approach, this study enhances stroke rehabilitation through better user engagement and multi-joint capabilities. These innovations consider neuroplasticity principles, integrating rehabilitation theory with rehabilitation device.

Research on Bowden Cable–Fabric Force Transfer System Based on Force/Displacement Compensation and Impedance Control

Bowden cable–fabric is a key force transfer device for flexible exoskeletons, and its precise control of force/displacement is a significant factor in the human–machine interaction of flexible exoskeletons. In this paper, a force/displacement control method based on friction compensation and impedance control was proposed based on a flexible Bowden cable–fabric force transfer testbed system. First, a set of in vitro experimental platforms simulating Bowden cable–fabric force transfer was built according to a typical flexible exoskeleton force transfer system, and following the walking gait of lower limbs, the expected force and knee joint motion were set. Secondly, the Bowden cable–fabric force transfer friction model was constructed as the basis of the system’s force transfer compensation. In addition, the stiffness model of Bowden cable–fabric and the lower leg movement model were established and combined with impedance control to realize the precise control of system displacement. Finally, the damping and stiffness parameters suitable for the system were obtained through the impedance control simulation. In terms of the experiment, an in vitro Bowden cable–fabric force transfer experimental platform was built, and the expected force with the input peak value of 40 N, 50 N, and 60 N was set. Through the friction and position compensation model of Bowden cable–fabric force transfer and impedance control, the relative root-mean-square errors of the output force and expected force were obtained as 2.53%, 2.16%, and 2.07%, respectively. Therefore, the effectiveness of the proposed method is verified, which provides a foundation for the engineering application of flexible exoskeletons.

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

With a view to maintaining the competitiveness required by the market, the automotive industry strongly encourages its suppliers to develop new production methods and technologies capable of reducing the costs of produced products, ensuring the necessary quality, and increasing flexibility, with a view to responding more easily to the customization of the products that the market increasingly demands. The main goal of this work was to increase the flexibility and productivity of equipment capable of producing the first subset that constitutes the product commonly known as the Bowden cable. To this end, the design science research methodology was used, which was understood as the most effective in describing scientific work related to the improvement of existing systems. Bowden cables are cables that activate various devices in the car, such as opening doors, moving window glasses, and adjusting some car seats, among others. The work consisted of integrating several operations usually carried out for the manufacture of the referred subset, reducing logistics operations and manual work, increasing operator safety, and increasing the production rate and flexibility of the equipment, by reducing the setup time. For this purpose, new mechanical concepts were developed, and automation was applied, which resulted in a completely new concept, able to fulfill all the objectives initially set. It should be noted here that the new equipment allowed a production rate of 1140 p/h, when the initial objective was 1100 p/h; it requires an investment of only around EUR 55,000 (easy return on investment), occupies only 11.6 m2, and has reinforced safety systems to avoid workers’ injuries, an aspect that is very important in this type of equipment, where operators deal with cutting systems and high temperatures. The dissemination of this concept could help other researchers to easily find solutions to certain problems that they face in the development of modern equipment. The main contributions of this paper are the novel concepts created to overcome some process difficulties, which can be used for a wide range of other processing situations with similar difficulties. The solutions proposed allow a decrease in the cycle time, present high flexibility, save workshop space, and are affordable in terms of global cost.

Feasibility Study of Joint Exoskeleton Device Without Bowden Cables Based on Highly Integrated Wireless Fluxgate Sensor

Feasibility Study of Joint Exoskeleton Device Without Bowden Cables Based on Highly Integrated Wireless Fluxgate Sensor

CURER: A Lightweight Cable-Driven Compliant Upper Limb Rehabilitation Exoskeleton Robot

Upper limb exoskeletons show promise for improving functionalities required for stroke patients. Despite recent progress, most of current upper limb rehabilitation devices are still bulky, heavy, and less compliant to be applied. This article presents a cable-driven compliant upper limb rehabilitation exoskeleton robot (CURER) with a lightweight frame and comfortable human–robot interaction. A modular series elastic actuator (SEA) was designed to provide controlled torque for each active robotic joint, and Bowden cables were applied to transfer controlled torque to distal joints. A six-bar double parallelogram mechanism was designed to implement 3 active degrees of freedom (DOFs) of a shoulder. An actuated elbow with 1 DOF and a wrist with a passive DOF were also developed for CURER. The anthropomorphic shoulder, elbow, and wrist joints can minimize misalignment between human upper limbs and the robot. The length of anthropomorphic arm was adjustable for a wide range of users. It can apply up to a 33 N·m torque in shoulder flexion/extension, abduction/adduction, intra/extra rotation, and elbow flexion/extension, with a range of 7.6–8.0 Hz position bandwidth in each actuation. CURER has a large range of motion and can provide accurate torque control for stroke patients’ requirements. Besides, a comprehensive rehabilitation strategy including robot-in-charge mode and human-in-charge mode was developed for different recovery stages. Experiments carried out on CURER actuation units demonstrated good position and impedance control performance. Finally, a virtual reality training system was developed to assist the subjects to accomplish upper limb rehabilitation efficiently.

Design Methodology and Experimental Study of a Lower Extremity Soft Exosuit

Flexibility and light weight have become the development trends in the field of exoskeleton research. With high movement flexibility, low movable inertia and excellent wearable comfort, such a type of system is gradually becoming an exclusive candidate for applications such as military defense, rehabilitation training and industrial production. In this paper, aiming at assisting the walking of human lower limbs, a soft exosuit is investigated and developed based on the considerations of fabric structure, sensing system, cable-driven module, and control strategy, etc. Evaluation experiments are also conducted to verify its effectiveness. A fabric optimization of the flexible suit is performed to realize the tight bond between human and machine. Through the configuration of sensor nodes, the motion intention perception system is constructed for the lower limb exosuit. A flexible actuation unit with a Bowden cable is designed to improve the efficiency of force transmission. In addition, a position control strategy based on division of the gait phase is applied to achieve active assistance during plantar flexion of the ankle joint. Finally, to verify the assistive effectiveness of the proposed lower extremity exosuit, experiments including a physiological metabolic test and a muscle activation test are conducted. The experiment results show that the exosuit proposed in this paper can effectively reduce the metabolic consumption and muscle output of the human body. The design and methodology proposed in this paper can be extended to similar application scenarios.

A modular cable-driven humanoid arm with anti-parallelogram mechanisms and Bowden cables

A modular cable-driven humanoid arm with anti-parallelogram mechanisms and Bowden cables

A novel passive shoulder exoskeleton for assisting overhead work.

Shoulder exoskeletons (SEs) can assist the shoulder joint of workers during overhead work and are usually passive for good portability. However, current passive SEs face the challenge that their torque generators are often attached to the human arm, which adds a significant amount of weight to the user's arms, resulting in additional energy consumption of the user. In this paper, we present a novel passive SE whose torque generator is attached to the user's back and assists the shoulder joint through Bowden cables. Our approach greatly reduces the weight on the user's arms and can accommodate complex shoulder joint movements with simple and lightweight mechanical structure based on Bowden cables. In addition, to match the nonlinear torque requirements of the shoulder joint, a unique spring-cam mechanism is proposed as the torque generator. To verify the effectiveness of the device, we conducted a usability test based on muscle activations of 10 healthy subjects. When assisting overhead work, the SE significantly reduced the mean and maximum electromyography signals of the shoulder-related muscles by up to 25%. The proposed SE contributes to further research on passive SE design to improve usability, especially in terms of reducing weight on human arms.

Development of Soft Exoskeleton Rehabilitation Device with Bowden Cables Supports Natural Ankle Movements

Development of Soft Exoskeleton Rehabilitation Device with Bowden Cables Supports Natural Ankle Movements

A Novel Robotic Exoskeleton for Finger Rehabilitation: Kinematics Analysis.

A novel robotic exoskeleton for fingers rehabilitation is developed, which is driven by linear motors through Bowden cables. For each finger, in addition to three links acting as phalanxes, two more links acting as knuckles are also implemented. Links are connected through passive joints, by which translational and rotary movements can be realized simultaneously. Either flexion or extension motion is accomplished by one cable of adequate stiffness. This exoskeleton possesses good adaptability to finger length of different subjects and length variations during movement. The exoskeleton's kinematics model is built by the statistics method, and piecewise polynomial functions (PPF) are chosen to describe the relationship between motor displacement and joint variables. Finally, the relationship between motor displacement and the finger's total bending angle is obtained, which can be used for rehabilitation trajectory planning. Experimental results show that this exoskeleton achieves nearly the maximum finger bending angle of a healthy adult person, with the maximum driving force of 68.6 N.

Design and Validation of a Lightweight Soft Hip Exosuit With Series-Wedge-Structures for Assistive Walking and Running

To overcome the limitations of a traditional soft hip exosuit directly driven by Bowden cables or winding belts at two points, in this article, we propose a new soft hip exosuit design concept based on series-wedge-structures for energy-efficient walking and running during daily activities for elderly individuals. The series-wedge-structure is designed to improve the comfort of the wearer–exosuit interface and to passively adapt to the user's body curvature, with no hindrance during movement. The design and function, including the series-wedge-structure belt, series elastic cable drive actuator, and control scheme, are described. The presented soft exosuit, which is lightweight (1.4 kg) and comfortable, provides assistive torque for hip flexion by folding series-wedge-structures driven by Bowden cables. The series-wedge-structure-based hip exosuit adopts single actuation coupled to the Bowden cable pull mechanism with a series elastic actuator to drive both hip flexions based on the out-of-phase nature of the human legs during walking and running. The exosuit performance test results show that the proposed exosuit improves the comfort of the wearer–exoskeleton interface by minimizing the shear force and maximizing the exosuit–skin interaction force contact area. Three healthy subjects walked at a fixed speed of 1.25 m/s and ran at a fixed speed of 2.2 m/s while wearing the proposed exosuit with/without assistance and without wearing the exosuit to evaluate the biomechanical and physiological effects of the proposed exosuit assistance on locomotion. The metabolic rate with exosuit assistance was reduced by 10.9% for walking and by 6.2% for running compared with not wearing the exosuit.

Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry

Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line.

Design of a Spiral Double-Cutting Machine for an Automotive Bowden Cable Assembly Line

The manufacture of automotive components requires innovative technologies and equipment. Due to the competitiveness in the sector, the implementation of automatic and robotic equipment has been vital in its development to produce the largest number of products in the shortest amount of time. Automation leads to a significant reduction in defects and enables mass production and standardization of the final product. This work was based on the need of an automotive components’ company to increase the rate of spiral cable cutting, used as protection for Bowden (control) cables. Currently, this component, used in automotive systems, is processed with simple cutting machines and cleaning machines. Based on the design science research (DSR) methodology, this work aims to develop a machine capable of performing the cutting and cleaning of two spiral cables simultaneously and automatically. The development of this machine was based on existing machines, and the biggest challenge was the implementation of a double-cutting system. The designed machine met the initial requirements, such as enabling the simultaneous cut of two spirals, being fully automatic, doubling the output over the current solution, and fully complying with the current legislation.

Reimagining Prosthetic Control: A Novel Body-Powered Prosthetic System for Simultaneous Control and Actuation

Globally, the most popular upper-limb prostheses are powered by the human body. For body-powered (BP) upper-limb prostheses, control is provided by changing the tension of (Bowden) cables to open or close the terminal device. This technology has been around for centuries, and very few BP alternatives have been presented since. This paper introduces a new BP paradigm that can overcome certain limitations of the current cabled systems, such as a restricted operation space and user discomfort caused by the harness to which the cables are attached. A new breathing-powered system is introduced to give the user full control of the hand motion anywhere in space. Users can regulate their breathing, and this controllable airflow is then used to power a small Tesla turbine that can accurately control the prosthetic finger movements. The breathing-powered device provides a novel prosthetic option that can be used without limiting any of the user’s body movements. Here we prove that it is feasible to produce a functional breathing-powered prosthetic hand and show the models behind it along with a preliminary demonstration. This work creates a step-change in the potential BP options available to patients in the future.

Force Transmission Analysis and Optimization of Bowden Cable on Body in a Flexible Exoskeleton.

The Bowden cable is a significant force transmission equipment for a flexible exoskeleton. However, the previous researches of Bowden cable had emphasized on the data from experimenting test board, instead of on human body, which produced the inaccurate assisting analysis of the flexible exoskeleton. In this paper, a flexible exoskeleton for assisting knee extension was proposed, which provided an on-body condition. Then, the friction force and its influencing factors between the wire rope and sheath of the Bowden cable from the motor to the anchor of knee have been analyzed. The segment models of force transmission with the concern of three kinds of friction modes were established, and the relationship between various lengths and bending angles of Bowden cable was fitted to the equations of curve. Furthermore, the association rule between the force transmission and the lengths of Bowden cable was obtained, based on which, the optimal force transmission efficiency was 78.68% when the length value of the Bowden cable was 475 mm. A flexible exoskeleton prototype was assembled; then, the experiments with force transmission and metabolic cost have been developed. The results showed that the force transmission efficiency had strong association with the lengths of Bowden cable, instead of the transmission velocities. Furthermore, this knee assistance exoskeleton reduced the net metabolic cost of the testees during walking. These experiments results corroborated the force transmission modeling and simulation of the Bowden cable on body we proposed in this paper.

Design and Control of a Flexible Exoskeleton to Generate a Natural Full Gait for Lower-Limb Rehabilitation

Abstract Strokes caused by cerebrovascular diseases often result in severe damage to locomotion, movement, and cognitive functions. Rehabilitation is an effective way to regain locomotion ability in daily life. However, there are mismatching biological joints, non-full rehabilitation gaits, and indirect joint feedback among conventional exoskeletons or devices. Hence, this paper proposed a novel flexible Bowden cable driving exoskeleton to achieve natural full walking gaits utilizing direct lower-limb movement feedback. First, complete flexible joint rotation kinematics was proposed by using a pair of agonism–antagonism flexible Bowden cables. Then, a personalized rehabilitation walking gait and feedforward proportional-integral-differential controller were adopted to drive the lower limbs to realize complete joint movement and natural full gait locomotion. Finally, a prototype was designed to verify the effectiveness. Mannequin and human tests were conducted, and the results show that the real walking gait is consistent with the reference natural human gait and that assistive torque was applied to humans to reduce muscle activation without significantly changing the foot pressure.

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

The automotive industry is one of the driving forces of the global industry; thus, it is a very competitive sector which creates a constant need for process improvement, regarding productivity, quality, and flexibility. Automation has proven to be a viable solution for these production problems, with the rising adoption of these automated system by companies that try to design and implement more flexible systems, while reducing costs and improving process quality. Furthermore, the use of automation reduces the manpower factor and its associated variability. In the present work, a new concept for a Bowden cable production process is presented by employing the design science research (DSR) methodology. The project starts with the analysis of the previous production concept, determining possible problems and improvements, as well as setting objectives/requirements for a possible new concept/equipment. This information was used to develop a new automated Bowden cable production equipment, implementing several changes to the old concept and filling a gap in the literature in this field. The developed system was implemented and tested. A considerable reduction in cycle time was registered by 25%, which resulted in an increase of 30% in process productivity.

A new approach to increase the environmental sustainability of the discharging process in the over-injection of conduits for bowden cables using automation

The industry of automotive components is highly competitive. Polymer injection, used to over-mould conduits, is used to produce the necessary connections between the end of the Bowden cables and the car parts where they need to be assembled. Depending on the vehicle or the use, there will be a different connection of the conduit. The industry continuously looks for greener and more sustainable solutions. This study presents a strategy to save energy in polymer over-injection moulding. The developed concept consists of replacing the previous moulding system by a custom automatic one, using two more compact injection machines and automation, allowing for increased productivity and sustainability, all while retaining operators’ jobs. An application of the novel methodology is presented, reporting an energy consumption reduction of about 80% and an increase of 12% in production rate. With this work, the benefits of automation for overcoming sustainability and productivity problems are highlighted. Furthermore, the developed strategy may be applied to other production processes, regarding the injection of small parts in large quantities for a variety of materials.