Electronically controlled prosthetic knee

Abstract

The present invention relates to a variable-torque magnetorheologically actuated prosthetic knee which utilizes a plurality of interspersed and alternating rotors and stators to shear magnetorheological fluid in gaps formed therebetween. Advantageously, by operating in the “shear mode” there is substantially no or negligible fluid pressure buildup or change. Moreover, the multiple MR fluid gaps or flux interfaces desirably allow for the production of a large torque at low speed—eliminating the need for a transmission—and also for a wide dynamic torque range. One embodiment of the invention allows the rotors and / or stators to close the gaps therebetween to create a frictional torque component, thereby forming a “hybrid” braking system which provides a total torque or damping which is a combination of viscous torque and frictional torque.

Description

RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional application No. 60 / 177,108, filed Jan. 20, 2000, the entire disclosure of which is hereby incorporated by reference herein.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to prosthetic joints in general and, in particular, to controllable braking systems for prosthetic knee joints.[0004]2. Description of the Related Art[0005]Three types of variable-torque brakes have been employed in prosthetic knees in the past: (i) dry friction brakes where one material surface rubs against another surface with variable force; (ii) viscous torque brakes using hydraulic fluid squeezed through a variable sized orifice or flow restriction plate; and (iii) magnetorheological (MR) brakes or dampers where MR fluid (containing small iron particles suspended in the fluid) is squeezed through a fixed orifice or flow restriction plate, with viscosity of the fluid being varied in re...

AI Technical Summary

Benefits of technology

[0009]Accordingly it is one important advantage of the present invention to overcome some or all of the above limitations by providing a variable-torque magnetorheologically actuated prosthetic knee which utilizes a plurality of interspersed and alternating rotors and stators to shear magnetorheological fluid in gaps formed therebetween. Advantageously, by operating in the “shear mode” there is substantially no or negligible fluid pressure buildup or change. Moreover, the multiple MR fluid gaps or flux interfaces desirably allow for the production of a large torque at low speed—eliminating the need for a transmission—and also for a wide dynamic torque range. One embodiment of the invention allows the rotors and / or stators to close the gaps therebetween to create a frictional torque component, thereby forming a “hybrid” braking system which provides a total torque or damping which is a combination of viscous torque and frictional torque.

[0010]In accordance with one preferred embodiment, a magnetorheologically actuated rotary prosthetic knee is provided for precisely and rapidly controlling lower limb movement. The prosthetic knee generally comprises a substantially central core and a pair of side plates, a plurality of interspersed and alternating magnetically soft rotors and magnetically soft stators, an electromagnet positioned between the core and the rotors and stators, and a pair of bearings. The core and the side plates are formed from a magnetically soft material to create a magnetic return path. The rotors and stators are arranged so as to form a plurality of gaps therebetween. The gaps contain a magnetorheological fluid which is sheared during knee rotation. The electromagnet is responsive to an electrical signal to generate a variable magnetic field to cause a controlled change in the viscosity of the magnetorheological fluid. The bearings are in rotary communication with the rotors and a shin portion of the lower limb to transfer rotary resistive torques from the prosthetic knee to the shin portion.

[0011]In accordance with another preferred embodiment, a controllable magnetorheological brake for an artificial knee is provided to dampen knee joint rotation. The magnetorheological knee generally comprises a plurality of alternatingly arranged and spaced magnetizable rotors and magnetizable stators, a magnetorheological fluid, and a magnet. The rotors and stators are concentrically configured about a longitudinal axis of rotation of the artificial knee. The magnetorheological fluid resides in a plurality of gaps formed between the rotors and the stators. The magnet is responsive to an applied voltage and adapted to generate a variable magnetic field which passes through the rotors, the stators and the magnetorheological fluid. The shearing of the magnetorheological fluid in the gaps between the rotors and the stators creates a variable torque output which precisely controls the rotation of the artificial knee.

[0012]In accordance with yet another preferred embodiment, an electronically controlled prosthetic knee is provided for generating a wide dynamic torque range. The prosthetic knee generally comprises a plurality of rotors, a plurality of stators, and a fluid adapted to undergo a rheology change in response to an applied magnetic field. The rotors comprise a ferrous material. The rotors are rotatable and laterally displaceable about a longitudinal axis of rotation of the prosthetic knee. The stators comprise a ferrous material and are alternatingly interspersed with the rotors to form gaps therebetween. The stators are laterally displaceable about the axis of rotation of the prosthetic knee. The fluid resides in the gaps formed between the rotors and the stators. Actuation of the magnetic field generates during knee rotation a controllable variable knee damping torque.

[0013]In accordance with a further preferred embodiment, a rotary prosthetic knee for an amputee is provided. The prosthetic knee generally comprises a rotatable inner spline, a plurality of rotors engaged with the inner spline, a plurality of stators alternatingly interspersed with the rotors, an outer spline engaged with the stators, and a magnetically controlled medium residing in a plurality of sealed gaps between the rotors and the stators. The magnetically controlled medium is adapted to undergo a controlled bulk property change in response to an applied magnetic field such that the rotation of the rotors which shear the magnetically controlled medium is precisely controlled and the rotation of the prosthetic knee is variably damped to provide a substantially natural gait for the amputee.

[0014]In accordance with one preferred embodiment, a variable torque magnetorheological brake for a prosthetic knee is provided. The brake generally comprises a substantially central core, a first side plate connected to a first end of the core, a second side plate connected to a second end of the core and a rotatable and laterally displaceable blade positioned between the first side plate and the second side plate. The brake further comprises magnetorheological fluid in a pair of microgaps formed between the blade and the plates, and a magnet to generate a magnetic field such that a magnetic circuit is created through the core, the first side plate, the second side plate, the blade and the magnetorheological fluid. The microgaps have a size which is optimally minimized such that when the magnetic field has a zero value there is substantially no frictional contact between the blade and the side plates, thereby allowing the prosthetic knee to swing freely and provide a wide dynamic range.

Problems solved by technology

Though dry friction brakes can generally provide a substantial torque range for their size, undesirably, they are often difficult to control.

After extended use, the frictional pads tend to wear, thereby changing the frictional characteristics of the brake and the torque response for a given commanded torque.

Disadvantageously, this can cause unreliable damping performance, and hence adversely affect the gait of the amputee and also cause discomfort to the amputee.

Consequently, dry friction brakes may need frequent servicing and / or replacement which undesirably adds to the cost.

Under high loading conditions, viscous torque brakes are susceptible to leakage of hydraulic fluid and possibly other damage due to excessive pressure build-up.

Disadvantageously, this can result in an irreversible state, since once the brake unit is overloaded it cannot return to normal.

Therefore, such a viscous torque brake for a prosthetic joint is prone to catastrophic failure, and hence can be unreliable and detrimental to the safety of an amputee.

Disadvantageously, a MR brake operated in the “valve mode” also develops internal fluid pressure buildup, and hence is still susceptible to traditional pressure-induced failure, thereby putting the amputee at risk.

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