Exoskeleton fit evaluation system and method

1. A method of performing a fit test on a wearable pneumatic exoskeleton system coupled to a user:

coupling the wearable pneumatic exoskeleton system to legs of a user, the wearable pneumatic exoskeleton system comprising:

a left and right pneumatic leg actuator unit respectively associated with a left and right leg of the user, the left and right pneumatic leg actuator units each including:

a rotatable joint configured to be aligned with a rotational axis of a knee of the user wearing the pneumatic exoskeleton system,

an upper arm coupled to the rotatable joint and extending along a length of an upper leg portion above the knee of the user wearing the pneumatic exoskeleton system,

a lower arm coupled to the rotatable joint and extending along a length of a lower leg portion below the knee of the user wearing the pneumatic exoskeleton system, and

an inflatable bellows actuator defining a bellows cavity, the inflatable bellows actuator configured to extend along a length of the bellows actuator when pneumatically inflated by introducing pneumatic fluid into the bellows cavity and configured to actuate the upper arm and lower arm;

a pneumatic system configured to introduce pneumatic fluid to the bellows actuators of the pneumatic leg actuator units to independently actuate the bellows actuators, and

an exoskeleton computing device including:

a plurality of sensors,

a memory storing at least a fit test program, and

a processor configured to execute the fit test program to control the pneumatic system; and

executing the fit test program by the processor to cause pneumatic exoskeleton system to:

generate a fit testing position indication instructing the user to assume a seated position with the knees of the user in a bent position;

determining that the user has assumed the seated position with the knees of the user in a suitable bent position;

actuating the right pneumatic leg actuator unit with the user remaining in the seated position with the knees of the user in the suitable bent position;

determining a first configuration of the upper arm and lower arm of the right pneumatic leg actuator unit during the actuating of the right pneumatic leg actuator unit, with the user remaining in the seated position with the knees of the user in the suitable bent position, the determining of the first configuration based at least in part on data obtained from a subset of the plurality of sensors;

determining a second configuration of the upper arm and lower arm of the right pneumatic leg actuator unit during the actuating of the right pneumatic leg actuator unit, with the user remaining in the seated position with the knees of the user in the suitable bent position, the determining of the second configuration based at least in part on data obtained from the subset of the plurality of sensors;

determining a change in configuration based at least in part on a difference between the first and second configuration;

determining that the change in configuration corresponds to an improper fit of the right pneumatic leg actuator unit to the right leg of the user; and

generating an improper fit indication that indicates improper fit of the right pneumatic leg actuator unit to the right leg of the user.

2. The method of claim 1 , wherein executing the fit test program by the processor further causes pneumatic exoskeleton system to, after generating the improper fit indication that indicates improper fit of the right pneumatic leg actuator unit to the right leg of the user:

actuating the left pneumatic leg actuator unit with the user remaining in the seated position with the knees of the user in the suitable bent position;

determining a first configuration of the upper arm and lower arm of the left pneumatic leg actuator unit during the actuating of the left pneumatic leg actuator unit, with the user remaining in the seated position with the knees of the user in the suitable bent position, the determining of the first configuration based at least in part on data obtained from a subset of the plurality of sensors;

determining a second configuration of the upper arm and lower arm of the left pneumatic leg actuator unit during the actuating of the left pneumatic leg actuator unit, with the user remaining in the seated position with the knees of the user in the suitable bent position, the determining of the second configuration based at least in part on data obtained from the subset of the plurality of sensors;

determining a change in configuration based at least in part on a difference between the first and second configuration;

determining that the change in configuration corresponds to an improper fit of the left pneumatic leg actuator unit to the left leg of the user; and

generating an improper fit indication that indicates improper fit of the left pneumatic leg actuator unit to the left leg of the user.

3. The method of claim 1 , wherein determining the change in configuration based at least in part on the difference between the first and second configuration comprises: determining a displacement angle of one or both of the upper arm and lower arm of the right pneumatic leg actuator unit.

4. The method of claim 1 , wherein the right pneumatic leg actuator upper arm and lower arm are coupled to the right leg of the user via a respective plurality of couplers of a set of couplers, with each of the couplers of the set of couplers including a strap that surrounds a portion of the right leg of the user; and

wherein the improper fit indication that indicates improper fit of the right pneumatic leg actuator unit to the right leg of the user further includes an indication of one or more of the couplers of the set of couplers being improperly secured to the right leg of the user and an indication that the other couplers of the set of couplers are properly secured to the right leg of the user.

5. The method of claim 1 , wherein actuating the right pneumatic leg actuator unit with the user remaining in the seated position with the knees of the user in the suitable bent position comprises: actuating with an increasing pulsing force applied by the right pneumatic leg actuator unit at a defined frequency, starting from an initial torque until a maximum torque threshold is reached; and

wherein the determining the change in configuration based at least in part on the difference between the first and second configuration is based on a difference in configuration at the initial torque compared to a configuration at the maximum torque threshold; and

wherein the increasing pulsing force applied by the right pneumatic leg actuator unit is applied at a fixed frequency, a variable frequency, or a random frequency.

6. The method of claim 1 , wherein actuating the right pneumatic leg actuator unit with the user remaining in the seated position with the knees of the user in the suitable bent position comprises two or more cycling repetitions of:

increasing force applied by the right pneumatic leg actuator unit in a first direction until a first maximum torque threshold is reached; and

increasing force applied by the right pneumatic leg actuator unit in a second direction that is opposite of the first direction until a second maximum torque threshold is reached.

7. A method of performing a fit test on a leg actuator unit coupled to a user, the method comprising:

coupling the leg actuator unit to a leg of a user, the leg actuator unit comprising:

a joint configured to be aligned with a knee of the leg of the user wearing the leg actuator unit;

an upper arm coupled to the joint and extending along a length of an upper leg portion above the knee of the user wearing the leg actuator unit;

a lower arm coupled to the joint and extending along a length of a lower leg portion below the knee of the user wearing the leg actuator unit; and

an actuator configured to actuate the upper arm and lower arm;

actuating the leg actuator unit;

determining a first configuration of the upper arm and lower arm of the leg actuator unit generated during actuating the leg actuator unit;

determining a second configuration of the upper arm and lower arm of the leg actuator unit during actuating the leg actuator unit;

determining a change in configuration based at least in part on the difference between the first and second configuration;

determining that the change in configuration corresponds to an improper fit of the leg actuator unit to the leg of the user; and

generating an improper fit indication that indicates improper fit of the leg actuator unit to the leg of the user.

8. The method of claim 7 , wherein the determining the change in configuration based at least in part on the difference between the first and second configuration comprises: determining a displacement angle of one or both of the upper arm and lower arm of the leg actuator unit.

9. The method of claim 7 , wherein the actuating the leg actuator unit comprises: increasing force applied by the leg actuator unit, starting from a first torque and increasing to a second torque that is greater than the first torque; and

wherein the determining the change in configuration based at least in part on the difference between the first and second configuration is based on a difference in configuration between respective configurations generated by the first torque and the second torque.

10. The method of claim 9 , wherein the increasing force is applied as a pulsing force at a defined frequency, including one of a fixed frequency, a variable frequency, and a random frequency.

11. The method of claim 9 , wherein the increasing force is applied as a constant force.

12. The method of claim 7 , wherein the actuating the leg actuator unit comprises:

increasing force applied by the leg actuator unit in a first direction until a first torque threshold is reached; and

increasing force applied by the leg actuator unit in a second direction that is opposite of the first direction until a second torque threshold is reached.

13. A method of performing a fit test on an actuator unit coupled to a user, the method comprising:

actuating the actuator unit;

determining a first configuration of the actuator unit generated during the actuating the actuator unit;

determining a second configuration of the actuator unit generated during the actuating the actuator unit;

determining a change in configuration of the actuator unit based at least in part on the difference between the first and second configuration; and

determining that the change in configuration corresponds to an improper fit of the actuator unit to the user,

wherein the actuating the actuator unit comprises changing force applied by the actuator unit, including a first torque and a second torque that is greater than the first torque; and

wherein the determining the change in configuration based at least in part on the difference between the first and second configuration is based on a difference in configurations generated by the first torque and the second torque.

14. The method of claim 13 , wherein the changing force applied by the actuator unit is applied as a pulsing force.

15. The method of claim 13 , wherein the changing force is applied by the actuator unit is applied as a constant changing force.

16. The method of claim 13 , wherein the actuating the actuator unit comprises:

applying force by the actuator unit in a first direction; and

applying force by the actuator unit in a second direction that is opposite of the first direction.

17. The method of claim 13 , further comprising generating an improper fit indication that indicates improper fit of the actuator unit to the user including an indication of a specific portion of the actuator unit being improperly fit to the user.

18. The method of claim 13 further comprising limiting a capability of the actuator unit in response to the determining that the change in configuration corresponds to an improper fit of the actuator unit to the user.