Active-passive robotic exoskeleton systems, appendage and joint units, modular motor units, and methods for making the same

An exoskeleton system comprising:

• an exoskeleton frame including an articulating joint and appendage (J&A) unit with a joint assembly, the J&A unit configured to attach to an appendage of a user;
• and
• a motor unit including:
• a motor support structure including a motor plate removably mounted to the J&A unit;
• an electric motor mounted to the motor support structure and operable to produce a motor output torque;
• a motor attachment device selectively connectable to the electric motor and drivingly connected to the joint assembly to transmit thereto the motor output torque received from the electric motor;
• an electromagnetic (EM) clutch assembly mounted to the motor support structure in serial power-flow communication between the electric motor and the motor attachment device, the EM clutch assembly being selectively actuable to drivingly connect the electric motor to the motor attachment device and thereby transmit the motor output torque to the joint assembly;
• and
• a motor unit housing attached to the motor support structure and containing therein the EM clutch assembly.

A method of assembling a motor unit for an exoskeleton system, the exoskeleton system having an exoskeleton frame including an articulating joint and appendage (J&A) unit with a joint assembly, the J&A unit configured to attach to an appendage of a user, the method comprising:

• assembling a motor support structure including a motor plate configured to mount to the joint assembly;
• attaching an electric motor to the motor support structure, the electric motor being operable to produce a motor output torque;
• attaching, in a selectively connectable manner, a motor attachment device to the electric motor, the motor attachment device being configured to drivingly connect to the joint assembly and transmit thereto the motor output torque received from the electric motor;
• attaching an electromagnetic (EM) clutch assembly to the motor support structure in serial power-flow communication between the electric motor and the motor attachment device, the EM clutch assembly being selectively actuable to drivingly connect the electric motor to the motor attachment device and thereby transmit the motor output torque to the joint assembly;
• and
• attaching a motor unit housing to the motor support structure such that the motor unit housing contains therein the EM clutch assembly.