Design and Benchmarking of a Two Degree of Freedom Tendon Driver Unit for Cable-Driven Wearable Technologies

Exosuits have recently been developed as alternatives to rigid exoskeletons and are increasingly adopted for both upper and lower limb therapy and assistance in clinical and home environments. Many cable-driven exosuits have been developed but little has been published on their electromechanical designs and performance. Therefore, this paper presents a comprehensive design and performance analysis of a two degree of freedom tendon driver unit (TDU) for cable-driven wearable exosuits. Detailed methodologies are presented to benchmark the functionality of the TDU. A static torque output test compares the commanded and measured torques. A velocity control test evaluates the attenuation and phase shift across velocities. A noise test evaluates how loud the TDU is for the wearer under different speeds. A thermal stress test captures the cooling performance of the TDU to ensure safe operation at higher loads. Finally, a battery endurance test evaluates the runtime of the TDU under various loading conditions to inform the usable time. To demonstrate these tests, a modular TDU system for cable-driven applications is introduced, which allows components such as motors, pulleys, and sensors to be adapted based on the requirements of the intended application. By sharing detailed methodologies and performance results, this study aims to provide a TDU design that may be leveraged by others and resources for researchers and engineers to better document the capabilities of their TDU designs.