Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI

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Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
sensors
Article
Force-Moment Sensor for Prosthesis Structural
Load Measurement
Md Rejwanul Haque , Greg Berkeley and Xiangrong Shen *

 Department of Mechanical Engineering, The University of Alabama, Tuscaloosa, AL 35401, USA
 * Correspondence: xshen@eng.ua.edu; Tel.: +1-205-348-6743

 Abstract: Measurement of prosthesis structural load, as an important way to quantify the interaction
 of the amputee user with the environment, may serve important purposes in the control of smart
 lower-limb prosthetic devices. However, the majority of existing force sensors used in protheses are
 developed based on strain measurement and thus may suffer from multiple issues such as weak
 signals and signal drifting. To address these limitations, this paper presents a novel Force-Moment
 Prosthesis Load Sensor (FM-PLS) to measure the axial force and bending moment in the structure of
 a lower-limb prosthesis. Unlike strain gauge-based force sensors, the FM-PLS is developed based on
 the magnetic sensing of small (millimeter-scale) deflection of an elastic element, and it may provide
 stronger signals that are more robust against interferences and drifting since such physical deflection
 is several orders of magnitude greater than the strain of a typical load-bearing structure. The design of
 the sensor incorporates uniquely curved supporting surfaces such that the measurement is sensitive
 to light load but the sensor structure is robust enough to withstand heavy load without damage.
 To validate the sensor performance, benchtop testing of the FM-PLS and walking experiments of a
 FM-PLS-embedded robotic lower-limb prosthesis were conducted. Benchtop testing results displayed
 good linearity and a good match to the numerical simulation results. Results from the prosthesis
 walking experiments showed that the sensor signals can be used to detect important gaits events
 such as heel strike and toe-off, facilitating the reliable motion control of lower-limb prostheses.

 Keywords: force-moment sensor; loadcell; prosthesis load measurement

Citation: Haque, M.R.; Berkeley, G.;
Shen, X. Force-Moment Sensor for
Prosthesis Structural Load
 1. Introduction
Measurement. Sensors 2023, 23, 938.
https://doi.org/10.3390/s23020938 Human walking is a cyclic movement that involves coordinated reciprocating motion
 of two legs. Despite the continuous forward motion of the upper body, each leg’s motion
Academic Editors: Maria de
 pattern is essentially discrete, with vastly different dynamic behaviors across different
Fátima Domingues, Hugo Plácido
 phases in a single gait cycle [1]. During the swing phase, the leg joints (especially the
da Silva and Damla Turgut
 knee) display low impedance, generating a pendulum-like swing motion to reposition
Received: 2 December 2022 the leg in front of the upper body to prepare for the next heel strike. During the stance
Revised: 6 January 2023 phase, the leg joints display much elevated impedance, preventing the leg from buckling
Accepted: 10 January 2023 under the load imposed by the body weight. For individuals living with lower-limb losses,
Published: 13 January 2023 restoring the locomotive functions require their prosthetic devices to replicate the dynamic
 characteristics of the biological legs, especially the significant differences between the stance
 and swing phases.
 Leg prostheses, in the early stage of prosthetics development, was simple, purely
Copyright: © 2023 by the authors.
 mechanical devices with very limited capability of regulating joint behavior. With the
Licensee MDPI, Basel, Switzerland.
 technological advances in actuation, electronics, and control, micro-processor-controlled
This article is an open access article
 (MPC) knee prostheses were developed and entered clinical practice, for example, Ottobock
distributed under the terms and
 C-Leg [2] and Ossur Rheo Knee [3]. Typical MPC prostheses regulate joint-resistance during
conditions of the Creative Commons
Attribution (CC BY) license (https://
 different gait phases with hydraulic or pneumatic circuits, and some also provide swing
creativecommons.org/licenses/by/
 assistance using mechanical springs [4]. Unlike the control of upper-limb prostheses [5],
4.0/).
 realizing such functionality in leg prostheses requires accurate and reliable detection of gait

Sensors 2023, 23, 938. https://doi.org/10.3390/s23020938 https://www.mdpi.com/journal/sensors
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
Sensors 2023, 23, 938 2 of 18

 phases in real-time, which is usually conducted through the measurement of prosthesis
 structural load (e.g., using a sensorized pylon in the C-Leg). More recently, powered robotic
 lower-limb prostheses started to emerge, including the Vanderbilt Leg [6,7], MIT ankle-foot
 prostheses [8], Ossur PowerKnee [9], Open Source Leg [10], and Utah Leg [11]. With
 their capability of providing actively-powered joint action, the importance of prosthesis
 structural load is further highlighted, not only for the determination of the gait phase,
 but also for the quantification of the prosthetic leg load-bearing for more sophisticated
 functions (e.g., to trigger the sit-to-stand assistance when an amputee shifts load to his/her
 leg prosthesis [12]).
 For load measurement, the most extensively used method is strain measurement.
 Strain gauges can be firmly attached to the load-bearing structure to measure the underlying
 micro-scale deflection, which correlates to the magnitude to the applied load [13]. Strain
 gauge-based load measurement has been applied to orthopedics since the 1970s [14], and it
 still remains as a major approach for the prosthesis structural load measurement. Strain
 gauges can be attached to structural components (e.g., pylons), or a dedicated structure
 can be designed and instrumented to form a force sensor (i.e., load cell). For example, Sup
 et al. developed a 3-axis socket load cell for the control of an early version of the Vanderbilt
 Leg in which regions of compression and tension were defined in a double-cross structure
 for strain measurement [6]. Despite the maturity of such a technique, the weak signals
 generated by strain gauges are susceptible to interferences, and signal drift may also occur
 and affect the consistency of the measurement. An alternative approach, similar to the
 strain gauge method, is the force-sensing resistor (FSR)-based load sensing [15]. FSRs can
 be placed under the prosthetic feet [16,17] or embedded in the prosthesis structure [18]
 for load sensing, but due to their unsatisfactory measurement accuracy and consistency,
 FSR signals use has largely been limited to the detection of gait events (e.g., heel strike) for
 phase transition.
 The most recent progress in the area was the structural deflection-based prosthesis
 load sensing. Instead of using strain gauges to measure micro-scale deflection, this new
 sensing approach is based on the measurement of much larger (typically millimeter-scale)
 deflection of load-bearing structures. A typical example is the instrumented pyramid
 adapter developed by Gabert and Lenzi [19], which incorporates a cantilever beam-type
 structure as the load-sensing element. By using two magnetic sensors to measure the
 displacements of the two ends of the cantilever beam, this new sensor is able to provide
 robust sensing of the axial force and bending moment in the sagittal plane. However, the
 cantilever beam structure needs to be accurately machined with high-performance metal
 (titanium in the prototype), resulting in a high cost of manufacturing. Another example
 is the parallelogram load cell developed for the Vanderbilt Leg [7], which also provides
 reliable load measurement through a parallelogram-configured deformable structure. As
 its major weaknesses, this load cell only measures the axial force (not the bending moment),
 and it is relatively heavy due to the use of a coil spring as the elastic element.
 Motivated by the weaknesses of existing prosthesis load sensors and sensing ap-
 proaches, we developed a novel prosthesis load sensor, namely Force-Moment Prosthesis
 Load Sensor (FM-PLS), to provide reliable measurement of the axial force and bending
 moment in a lower-limb prosthesis with a simple, lightweight, and inexpensive sensor pack-
 age. Compared with the strain gauge-based load sensors, the FM-PLS provides stronger
 signals, more robust against interferences. Compared with the recent large structural
 deformation-based sensors, the FM-PLS is mechanically simpler and less expensive to
 manufacture. Specifically, compared with the recent work by Gabert and Lenzi [19], the
 FM-PLS uses a dedicated elastic element to measure the load (axial force and bending
 moment) through its deflection, which is easy and less expensive to manufacture since
 no high-accuracy machining is needed. Further, with the use of the curved supporting
 surfaces of the mounting blocks (upper and lower), the deflection of the elastic member
 can be modulated such that the sensor has high sensitivity when light load is applied while
 still being able to endure heavy load without damage.
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
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 surfaces of the mounting blocks (upper and lower), the deflection of the elastic member
Sensors 2023, 23, 938 3 of 18
 can be modulated such that the sensor has high sensitivity when light load is applied
 while still being able to endure heavy load without damage.
 This paper details the development of this FM-PLS sensor along with the related re-
 sults This paperthrough
 obtained details the developmentanalysis
 finite-element of this FM-PLS sensor along
 and experimental with the
 testing. related
 The paperresults
 is or-
 obtained through finite-element analysis and experimental testing. The paper
 ganized as follows: Section 2 presents the overview of the FM-PLS design and develop- is organized
 as follows:
 ment, Section
 including 2 presents
 sensing theand
 principle overview of the
 electronic FM-PLS design
 components; Sectionand development,
 3 presents the ex-
 including sensing principle and electronic components; Section 3 presents the
 perimental procedure while Section 4 presents the results to validate the performance experimental of
 procedure
 the FM-PLS; while Section
 Section 4 presents
 5 presents the results to
 the discussion; validate
 and Sectionthe performancethe
 6 summarizes of conclusions.
 the FM-PLS;
 Section 5 presents the discussion; and Section 6 summarizes the conclusions.
 2. Design and Development of the FM-PLS
 2. Design and Development of the FM-PLS
 2.1. Functioning
 2.1. Functioning Mechanism
 Mechanism of of FM-PLS
 FM-PLS
 The functioning
 The functioning mechanism
 mechanism of the FM-PLS
 of the FM-PLS is is based
 based on on two-stage
 two-stage transduction:
 transduction: (1) (1)
 Displacement due the deformation of elastic element by applied force or bending moment,
 Displacement due the deformation of elastic element by applied force or bending moment,
 and (2)
 and (2) Magnetic
 Magnetic fieldfield transduction
 transduction due due to to change
 change in in distance
 distance between
 between the the magnet
 magnet andand
 magnetic field transducer.
 magnetic field transducer.
 The key
 The key component
 component of of 1st-stage
 1st-stage transduction
 transduction is is aa flat
 flat carbon
 carbon fiber
 fiber or
 or fiberglass
 fiberglass piece,
 piece,
 which serves as the elastic element to deform under load.
 which serves as the elastic element to deform under load. Each end of this elastic Each end of this elastic element
 element
 is rigidly
 is rigidly attached
 attached to to aa curved
 curved mounting
 mounting block block in in aa cantilever
 cantilever beam-like
 beam-like configuration,
 configuration, as as
 shown in
 shown in Figure
 Figure 1. 1. Under
 Under an an axial
 axial force,
 force, the the left
 left and
 and right
 right ends
 ends experience
 experience symmetric
 symmetric
 deflections (i.e., ∆x ∆x22););under
 ∆x11 == ∆x underaa bending
 bending moment,
 moment, the the left and right ends experience
 asymmetric deflections
 deflections (i.e.,
 (i.e.,∆x∆x1 ≠ 6=
 1 ∆x 2∆x
 ) (Figure
 2 ) 1B).
 (Figure As
 1B). such,
 As any combination
 such, any combination of theofaxial
 the
 force and bending moment can be measured by independently
 axial force and bending moment can be measured by independently measuring the small measuring the small de-
 flections at at
 deflections thethe
 leftleft
 and right
 and rightends
 ends(∆x(∆x
 1 and
 1 and ∆x2∆x
 ). 2 ).

 Figure 1. Functioning
 Functioningmechanism
 mechanismofofthe FM-PLS:
 the (A)(A)
 FM-PLS: schematic of the
 schematic sensor
 of the structure,
 sensor andand
 structure, (B) de-
 (B)
 flections under axial force and bending moment.
 deflections under axial force and bending moment.

 The deflection
 deflectionof ofthe
 theelastic
 elasticmember
 memberchanges
 changes the relative
 the distance
 relative between
 distance betweenthethe
 magnets
 mag-
 and the magnetic field sensors located on top/bottom of the magnets. Since
 nets and the magnetic field sensors located on top/bottom of the magnets. Since the mag- the magnetic
 flux
 neticdensity is a function
 flux density of distance
 is a function from the
 of distance frommagnet, magnetic
 the magnet, flux density
 magnetic measured
 flux density by
 meas-
 the
 uredmagnetic field transducers
 by the magnetic changeschanges
 field transducers due to the
 duechange of distance
 to the change by applying
 of distance force.
 by applying
 The output
 force. of the magnetic
 The output field transducer
 of the magnetic is voltage.
 field transducer is Thus, theThus,
 voltage. appliedtheforce is sensed
 applied force as
 is
 the voltage by the transducer through two-stage transductions.
 sensed as the voltage by the transducer through two-stage transductions.
 Both
 Both stages
 stages ofof the
 the transduction
 transduction principle
 principle have
 have aa substantial
 substantial impact
 impact onon its
 its capacity
 capacity to
 to
 measure
 measure force and bending moment. To establish the relationship between applied force
 force and bending moment. To establish the relationship between applied force
 and
 and magnetic
 magnetic field
 field sensor
 sensor voltage
 voltage output,
 output, analyses
 analyses (either
 (either simulation
 simulation or or mathematical)
 mathematical)
 have
 have been
 been carried
 carried out in multiple
 out in multiple stages.
 stages. The
 The elastic
 elastic member
 member between
 between thethe upper
 upper and
 and lower
 lower
 blocks works as a cantilever beam. Hence the deflection of the elastic member
 blocks works as a cantilever beam. Hence the deflection of the elastic member is a function is a function
 of the active length of the cantilever beam. This sensor design adopts a curved surface for
 both upper and lower blocks (as shown in Figure 1) which modulates the active length
 of the elastic member and thus controls the deflection. That means this feature makes the
 sensor sensitive at low force while still withstanding heavy load without damage.
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
Sensors 2023, 23, x FOR PEER REVIEW 4 of 17
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 of the active length of the cantilever beam. This sensor design adopts a curved surface for
 of the upper
 both active and
 length of the
 lower cantilever
 blocks beam.
 (as shown inThis sensor
 Figure design
 1) which adopts a the
 modulates curved
 activesurface
 lengthforof
Sensors 2023, 23, 938 both upper and lower blocks (as shown in Figure 1) which modulates the active 4 ofof
 length 18
 the elastic member and thus controls the deflection. That means this feature makes the
 the elastic
 sensor member
 sensitive andforce
 at low thus whilecontrols
 stillthe deflection. heavy
 withstanding That means this feature
 load without damage.makes the
 sensorThe sensitive at low force while still withstanding heavy load
 second stage of transduction relies on the amount of magnetic flux measured by without damage.
 The
 The second
 the magnetic second stage
 stage
 field of
 of transduction
 sensor. transduction
 Although the relies
 relies on
 on the
 magnetic amount
 thefield
 amount of
 of magnetic
 to theflux
 magnetic
 is related flux measured
 from by
 measured
 distance by
 the
 the
 the magnetic
 magnetic
 magnet, field
 field sensor.
 the magnetic sensor.
 fieldsAlthough
 around the
 Although athe magnetic
 magnetic
 magnet are field
 field is
 is related
 related
 not uniform intoallthe
 to the distance
 distanceThe
 directions. from the
 frommag-
 the
 magnet,
 magnet,
 netic fieldthedepends
 magnetic
 magnetic on fields
 fields aroundfactors
 around
 numerous a amagnet
 magnet are
 are not
 including not uniform
 uniform
 the shape in the
 in of
 all all directions.
 directions.
 magnet,The The
 the mag-
 magnetic
 distance
 netic
 field field
 depends depends
 on on
 numerousnumerousfactors factors
 including including
 the the
 shape ofshape
 the
 between the poles, as well as the specific position around the magnet. The magnet used of the
 magnet, magnet,
 the the
 distance distance
 between
 between
 the poles,
 in the the
 sensor poles,
 as well asas
 design the well
 can beasconsidered
 specific the specific
 position position
 around
 as the around
 magnet.
 the cylindrical the
 The
 bar magnet.
 magnet
 magnet The
 usedmagnet
 whose in the
 two used
 sensor
 opposite
 in the
 design sensor
 can be design can
 considered be considered
 as the cylindricalas the cylindrical
 bar magnet bar
 whose
 faces are the two poles. The magnetic field distribution around a cylindrical bar magnetmagnet
 two whose
 opposite two opposite
 faces are the
 two
 [20] poles.
 faces are be
 can The
 twomagnetic
 theshown poles.
 in theThe field distribution
 magnetic
 Figure 2. around a cylindrical
 field distribution around a bar magnetbar
 cylindrical [20]magnet
 can be
 shown
 [20] canin bethe Figure
 shown in 2.
 the Figure 2.

 Figure 2. Magnetic field distribution of a cylindrical bar magnet.
 Figure 2.
 Figure Magnetic field
 2. Magnetic field distribution
 distribution of
 of aa cylindrical
 cylindrical bar
 bar magnet.
 magnet.
 The magnetic flux density at a distance d (as shown in Figure 3), in the axial direction,
 The magnetic
 magnetic flux
 flux density
 density at
 at aadistance
 distance dd(as
 (asshown
 shown inFigure Figure 3), inthe
 theaxial
 axialdirection,
 direction,
 can The
 be expressed as Equation (1) [21], where H is the in thickness3),ofinthe magnet, r is the
 can
 can be expressed
 be expressed as Equation
 as Equation (1) [21], where H is the thickness of the magnet, rr is
 is the
 the
 radius of the magnet and Br is(1)
 the[21], where
 radial H is theofthickness
 component of theflux
 the magnetic magnet,
 density in the
 radius
 radius of the magnet and B r is the radial component of the magnetic
 of the magnet and Br is the radial component of the magnetic flux density in the flux density in
 axial direction.
 the axial direction.
 axial direction.  
 Br H+ d d 
 B =  −√ 
 
 (1)
 (1)
 2 √ 2 + 
 
 2
 q
 2 r d 2 (1)
 r +
 ( H + d ) 
 
 √ 

 Figure 3.3. The
 Figure Themagnetic
 magneticfluxfluxdensity of of
 density a cylindrical barbar
 a cylindrical magnet (radius
 magnet r andr and
 (radius thickness H) inH)
 thickness theinaxial
 the
 Figure
 axial 3. The
 direction magnetic
 at a flux
 distance
 direction at a distance d. density
 d. of a cylindrical bar magnet (radius r and thickness H) in the
 axial direction at a distance d.
 2.2. Overview of the Design
 The main design objective of the FM-PLS was to measure the axial force and bending
 moment simultaneously while minimizing the mechanical complexity.
 The FM-PLS consists of four main structural components and two sets of sensing
 components. The structural components are: (1) Elastic member, (2) Upper mounting block,
 (3) Lower mounting block, and (4) Detachable adapter, as shown in Figure 4. The elastic
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
2.2. Overview of the Design
 The main design objective of the FM-PLS was to measure the axial force and bending
 moment simultaneously while minimizing the mechanical complexity.
Sensors 2023, 23, 938 The FM-PLS consists of four main structural components and two sets of sensing 5 of 18

 components. The structural components are: (1) Elastic member, (2) Upper mounting
 block, (3) Lower mounting block, and (4) Detachable adapter, as shown in Figure 4. The
 elastic
 member member is the sensor’s
 is the sensor’s core structural
 core structural component
 component whichwhich is mounted
 is mounted to thetoupper
 the upper
 and
 and
 lowerlower
 blockblock on each
 on each end.end. By measuring
 By measuring the upper
 the upper and and lower
 lower blocks
 blocks relative
 relative displace-
 displacement
 (determined
 ment by theby
 (determined elastic deflection
 the elastic of the member),
 deflection the axialthe
 of the member), force andforce
 axial bending moment
 and bending
 can be determined
 moment accordingly.
 can be determined The mating
 accordingly. Thesurface
 matingofsurface
 the lower/upper block with
 of the lower/upper the
 block
 elasticthe
 with member is curvedistocurved
 elastic member modulate the deflection
 to modulate of the elastic
 the deflection member.
 of the elastic member.

 Figure 4. Detail design of the FM-PLS sensor: (A) Exploded view, and (B) FM-PLS sensor with di-
 Figure 4. Detail design of the FM-PLS sensor: (A) Exploded view, and (B) FM-PLS sensor
 mensions.
 with dimensions.

 The
 The sensing
 sensingcomponents
 componentsconsist of of
 consist magnetic field
 magnetic sensors
 field and and
 sensors magnets. For theFor
 magnets. meas-
 the
 urement of the deflections, a miniature magnet is embedded on each end of the elastic
 measurement of the deflections, a miniature magnet is embedded on each end of the elastic
 element, andaamagnetic
 element, and magneticsensor
 sensor is embedded
 is embedded in the
 in the freefree
 end end of each
 of each curved
 curved mounting
 mounting block,
 measuring the change of the magnetic field due to the movement of the corresponding
 magnet. As such, the magnet sensors’ signals serve as indirect measurements of the
 force/moment applied to the sensor.
 Note that each magnetic sensor is embedded in a small, printed circuit board (PCB),
 which also includes the signal conditioning circuit. As such, the output signals of the FM-
 PLS can be directly routed to the prosthesis microcontroller as a plug-n-play component.
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
block, measuring the change of the magnetic field due to the movement of the correspond-
 ing magnet. As such, the magnet sensors’ signals serve as indirect measurements of the
 force/moment applied to the sensor.
Sensors 2023, 23, 938 Note that each magnetic sensor is embedded in a small, printed circuit board (PCB), 6 of 18
 which also includes the signal conditioning circuit. As such, the output signals of the FM-
 PLS can be directly routed to the prosthesis microcontroller as a plug-n-play component.
 Further, the standard pyramid connector is mounted to the top of the FM-PLS, and a
 Further, the standard pyramid connector is mounted to the top of the FM-PLS, and a
 detachable mounting channel is added at the bottom of the sensor to allow the sensor to
 detachable mounting channel is added at the bottom of the sensor to allow the sensor to
 be mounted to a lower-limb prosthesis using the threaded holes for the standard pyramid
 be mounted to a lower-limb prosthesis using the threaded holes for the standard pyramid
 connector (i.e., attach the mounting channel to the prosthesis using the existing mounting
 connector (i.e., attach the mounting channel to the prosthesis using the existing mounting
 holes for the pyramid connector; subsequently, attach the rest of the sensor to the mount-
 holes for the pyramid connector; subsequently, attach the rest of the sensor to the mounting
 ing channel; finally, mount the pyramid connector to the top of the sensor). As such, the
 channel; finally, mount the pyramid connector to the top of the sensor). As such, the
 FM-PLS can be easily integrated into the prosthesis structure without affecting the stand-
 FM-PLS can be easily integrated into the prosthesis structure without affecting the standard
 ard connection interface, essentially forming a sensorized pyramid connector (similar to
 connection interface, essentially forming a sensorized pyramid connector (similar to [19]).
 [19]). To facilitate the sensor’s practical use in lower-limb prostheses, a pair of slotted bars
 To facilitate the sensor’s practical use in lower-limb prostheses, a pair of slotted bars are
 are added
 added onon each
 each side
 side to to limit
 limit thethe extension
 extension when
 when a pulling
 a pulling force
 force is applied
 is applied (e.g.,
 (e.g., during
 during the
 the
 swing). The elastic member is made of E-fiberglass/epoxy with 67% fiber volumeratio
 swing). The elastic member is made of E-fiberglass/epoxy with 67% fiber volume ratio
 (GC-67-UB,
 (GC-67-UB,PolyOne
 PolyOneCorporation,
 Corporation,Ohio, Ohio,USA)
 USA)while
 whilethe
 therest
 restofofthe
 thestructural
 structuralcomponents
 components
 are
 are made of 7075 aluminum. Finally, a 3D-printed cover (made with PLAPlastic)
 made of 7075 aluminum. Finally, a 3D-printed cover (made with PLA Plastic)isisadded
 added
 totoencapsulate the entire sensor and protect the interior components for its future
 encapsulate the entire sensor and protect the interior components for its future practical practical
 use.
 use.The
 The3D3Ddimensions
 dimensionsofofthe theFM-PLS
 FM-PLSsensor
 sensorare
 are90
 90mm
 mm××6464mm mm×× 2525mmmm(without
 (withoutthe the
 pyramid adapter), as shown in the Figure 4B. The prototype of
 pyramid adapter), as shown in the Figure 4B. The prototype of the FM-PLS sensor the FM-PLS sensor is
 is shown
 shown in Figure
 in Figure 5. 5.

 Figure
 Figure5.5.Prototype
 Prototypeofofthe
 theFM-PLS
 FM-PLSsensor
 sensor(left)
 (left)and
 andFM-PLS
 FM-PLSfitted
 fittedon
 ona arobotic
 roboticprosthesis.
 prosthesis.

 2.3.Electrical
 2.3. ElectricalComponents
 Components
 AAcustom-printed
 custom-printed circuit
 circuit board
 board (PCB)
 (PCB)waswasdesigned
 designedand developed
 and developed to house
 to housethe mag-
 the
 netic field sensor along with other electronic components necessary for the
 magnetic field sensor along with other electronic components necessary for the force/mo- force/moment
 transduction
 ment andand
 transduction signal conditioning.
 signal conditioning.TheThe
 AD22151
 AD22151 (Analog
 (Analog Devices,
 Devices, Inc.,
 Inc.,Wilmington,
 Wilming-
 ton, MA, USA) was used as the magnetic field sensor. The schematic diagramofofthe
 MA, USA) was used as the magnetic field sensor. The schematic diagram thePCB
 PCBis
 shown in Figure 6 (top right) while in Figure 6 (bottom right) shows the
 is shown in Figure 6 (top right) while in Figure 6 (bottom right) shows the PCB layout. PCB layout. Two
 identical, small PCBs (18 mm × 18 mm) were made for each side
 Two identical, small PCBs (18 mm × 18 mm) were made for each side of the FM-PLS. Theof the FM-PLS. The
 PCBsare
 PCBs aremounted
 mountedon onthe
 theupper
 upperandandlower
 lowerblock
 blocksuch
 suchthat
 thatthe
 theAD22151
 AD22151sensor
 sensorstays
 stayson
 on
 top/bottom of the magnet. Both boards are connected by electrical wires
 top/bottom of the magnet. Both boards are connected by electrical wires to share the to share the power
 supply as well as to facilitate the access of both sensor signals from one PCB. The sensor
 signal can be read in real-time using Analog-to-Digital Converter (ADC) interface.
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
Sensors 2023, 23, x FOR PEER REVIEW 7 of 17

 Sensors 2023, 23, 938 power supply as well as to facilitate the access of both sensor signals from one7PCB.
 of 18 The

 sensor signal can be read in real-time using Analog-to-Digital Converter (ADC) interface.

 Figure 6. Section
 Figure 6. Sectionview
 viewofofthe
 theFM-PLS
 FM-PLS showing placement
 showing placement ofof electrical
 electrical component
 component and and magnet
 magnet (left);(left);
 TheThe
 electrical circuit diagram (top right) and custom-printed circuit board (bottom right).
 electrical circuit diagram (top right) and custom-printed circuit board (bottom right).

 2.4.2.4. Finite Element Analysis
 Finite Element Analysis
 To determine the structural displacement, Finite Element Analysis (FEA) was con-
 To determine the structural displacement, Finite Element Analysis (FEA) was con-
 ducted using Ansys Mechanical (Ansys Inc., Canonsburg, PA, USA) under various loading
 ducted using Only
 conditions. Ansys theMechanical (Ansys
 elastic member and Inc., Canonsburg,
 upper/lower PA,blocks
 mounting USA) were
 under various load-
 considered
 ingasconditions.
 they are the primary contributors of the displacement study. The analysis waswere
 Only the elastic member and upper/lower mounting blocks consid-
 further
 ered as theyby
 simplified are the primary
 considering bothcontributors of the
 blocks to be rigid, displacement
 as they are connectedstudy. Thestructural
 to other analysis was
 further simplified
 components of theby considering
 prosthesis both
 and thus theblocks to bearerigid,
 deflections as they
 negligible are connected
 compared to other
 to that of the
 elastic member. The elastic member was composed of 33,299 quadratic tetrahedrals
 structural components of the prosthesis and thus the deflections are negligible compared and ma-
 terialof
 to that properties formember.
 the elastic E-fiberglass/epoxy
 The elasticwith 67% fiber
 member wasvolume ratio (GC-67-UB,
 composed PolyOne tet-
 of 33,299 quadratic
 Corporation, Avon Lake, OH, USA) were assigned and summarized in Table 1. With the
 rahedrals and material properties for E-fiberglass/epoxy with 67% fiber volume ratio (GC-
 symmetry of the assembly, only half of the components in their longitudinal direction were
 67-UB, PolyOne Corporation, Avon Lake, OH, USA) were assigned and summarized in
 considered and symmetric boundary conditions were applied to the appropriate surfaces.
 Table
 The1.mounting
 With theblocks
 symmetrywere of the assembly,
 constrained to theonly half
 elastic of the by
 member components in their longitu-
 line body connections
 dinal
 representing the low alloy steel fasteners of the assembly. Finally, the adjoiningapplied
 direction were considered and symmetric boundary conditions were surfacesto the
 appropriate surfaces.
 of the elastic member The
 to mounting blocks
 the respective were constrained
 mounting to the elastic
 blocks were allowed member
 to freely by line
 slide in
 body connections
 contact representing
 but penetration the low
 was penalized to alloy steel
 achieve fasteners
 accurate of the assembly.
 deformations Finally, the
 of the assembly.
 adjoining surfaces of the elastic member to the respective mounting blocks were allowed
 Table 1. The material properties of the elastic member.
 to freely slide in contact but penetration was penalized to achieve accurate deformations
 of the assembly.Orthotropic Elasticity
 Young’s modulus X direction 5.8 × 106 psi
 Table 1. TheYoung’s
 material properties
 modulus of the elastic member.
 Y direction 1.5 × 106 psi
 Young’s modulus Z direction 1.5 × 106 psi
 Orthotropic Elasticity
 Poisson’s Ratio XY 0.3
 Young’sPoisson’s
 modulus X direction
 Ratio YZ 5.8
 0.3× 106
 psi
 Poisson’s Ratio XZ 0.3
 Young’s modulus Y direction 1.5 × 106
 psi
 Shear Modulus XY 6 × 105 psi
 Young’sShear
 modulus Z
 Modulus YZdirection 4.2 1.5 psi
 × 10×5 10
 psi
 6

 Poisson’s Ratio XZ
 Shear Modulus XY 5
 6 × 10 0.3
 psi
 Poisson’s Ratio YZ 0.3
 Poisson’s
 The maximum Ratio
 force wasXZ chosen as 5000 N in the analysis which is0.3
 more than six times
 of average Shear
 humanModulus
 adult weight.
 XY Figure 7 the displacement of the elastic member at the
 6 × 105 psi
 location of the magnet by varying the axial force from 0 N to 5000 N. This was achieved
 Shear Modulus YZ 4.2 × 105 psi
 over 14 linearly incremented steps in a quasistatic fashion. The figure shows that the trend
 Shear Modulus XZ 6 × 105 psi
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
Sensors 2023, 23, x FOR PEER REVIEW 8 of 17

 The maximum force was chosen as 5000 N in the analysis which is more than s
 times of average human adult weight. Figure 7 the displacement of the elastic member
 The of
 the location maximum
 the magnetforcebywas chosen
 varying theasaxial
 5000force
 N infrom
 the analysis
 0 N to 5000which N.isThis
 morewas than six
 achieve
 Sensors 2023, 23, 938 times of average human adult weight. Figure 7 the displacement of
 over 14 linearly incremented steps in a quasistatic fashion. The figure shows that the tren the elastic member
 8 of 18 at
 thedisplacement
 of the location of the ismagnet by varying
 nonlinear as thethe
 loadaxial force from
 increases; 0 N tothe
 rather 5000 N. This was achieved
 displacement gradient
 over 14 linearly incremented steps in a quasistatic fashion. The figure shows that the trend
 decreasing as the load increases. The von mises stress of the FEA is shown in Figure 8. Th
 of of
 thethe
 displacement
 displacementisisnonlinear
 nonlinear asas the load
 load increases;
 increases;rather
 ratherthethe displacement
 displacement gradient is
 gradient
 maximum stress as
 is decreasing on the elastic member is mises
 153.71 MPa, which isis lower than the tensi
 decreasing as the the
 loadload increases.
 increases. TheThe von
 von mises stressstressofofthe
 the FEA is
 FEA shown
 shown in
 in Figure
 Figure8.8. The
 strength
 Theof
 maximum thestress
 maximum elastic
 onmember,
 stress on the
 the meaning
 elastic
 elastic member
 member itisis
 withstands MPa,heavy
 153.71 MPa,
 153.71 which
 whichisload
 lower without
 is lower the damage.
 thanthan tensile
 the tensile
 strength
 strength ofofthe
 theelastic
 elastic member,
 member, meaning
 meaningit it
 withstands heavy
 withstands loadload
 heavy without damage.
 without damage.
 1.6
 1.6
 1.4
 1.4
 1.2
 1.2
 Displacement (mm)

 Displacement (mm)

 1
 1

 0.8
 0.8

 0.6 0.6

 0.4 0.4

 0.2 0.2

 0 0
 0
 0 10001000 2000
 2000 3000
 3000 4000
 4000 5000
 5000
 Force (N)
 Force (N)
 Figure 7. FEA result: displacement of the elastic element under axial load. The displacement has
 Figure 7.calculated
 FEA
 Figure
 been result:
 7. FEA displacement
 result:
 at the
 displacementof
 location of the
 of the elasticelement
 the elastic
 magnet. element under
 under axial axial load.
 load. The The displacement
 displacement has h
 been calculated at the location of the
 been calculated at the location of the magnet. magnet.

 Figure 8. FEA: stress on the elastic element by applying 5000 N axial load.
 Figure 8. FEA: stress on the elastic element by applying 5000 N axial load.
 3. Experimental Validation
 3.1. Benchtop Testing
 Figure 8. FEA: stress on the elastic element by applying 5000 N axial load.
 The goal of the benchtop testing was to monitor the loading response of the FM-PLS
 using an off-the-shelf loadcell as a reference measure. A testing setup was custom designed
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
using an off-the-shelf loadcell as a reference measure. A testing setup wa
 signed and fabricated for the benchtop testing of the FM-PLS in different lo
 tions. The setup consists of a stationary support plate, moveable mounting p
Sensors 2023, 23, 938 cylindrical support bars, as shown in Figure 9. An off-the-shelf prosthetic 9 of 18 foo
 to the movable mounting plate through the prosthetic load sensor to be teste
 the experiments). The moveable mounting plate with four through-holes
 and fabricated for the benchtop testing of the FM-PLS in different loading conditions. The
 bearings installed),
 setup consists slides
 of a stationary along
 support four
 plate, cylindrical
 moveable mountingsupport
 plate, and bars (serving as ve
 four cylindrical
 rails).
 support This
 bars,ensures
 as shownthe prosthetic
 in Figure foot can move
 9. An off-the-shelf upwards
 prosthetic or downwards
 foot is mounted to the wh
 movable mounting plate through the prosthetic load sensor to be tested (FM-PLS in the
 horizontal. To apply a pushing force, a lead screw assembly is used to expand
 experiments). The moveable mounting plate with four through-holes (with sleeve bearings
 between the stationary
 installed), slides support
 along four cylindrical platebars
 support and the moveable
 (serving mounting
 as vertical sliding plate. To
 rails). This
 ground
 ensures thetruth measurement
 prosthetic foot can moveof the applied
 upwards load while
 or downwards (anyremaining
 combination of the ax
 horizontal.
 To apply a pushing force, a lead screw assembly is used to expand the distance between
 bending moment), an off-the-shelf load cell (ELPF-500-T3E, Measuremen
 the stationary support plate and the moveable mounting plate. To provide the ground
 Hampton, VA, USA)
 truth measurement supports
 of the applied loadthe
 (anyprosthetic
 combination foot
 of thefrom underneath
 axial force and bending at a sele
 corresponding to theload
 moment), an off-the-shelf desired loading condition.
 cell (ELPF-500-T3E, Measurement InSpecialties,
 this experiment,
 Hampton, VA, the loadc
 USA) supports the prosthetic foot from underneath at a selected position corresponding
 tioned at three locations underneath the foot piece, which are: (1) aligned w
 to the desired loading condition. In this experiment, the loadcell was positioned at three
 the FM-PLS,
 locations (2) atthethe
 underneath footheel
 piece,of the are:
 which prosthetic
 (1) alignedfoot, and (3)
 with center atFM-PLS,
 of the the toe(2)(ballat joint
 thetic
 the heelfoot,
 of theas shownfoot,
 prosthetic in Figure
 and (3) at9.the toe (ball joint) of the prosthetic foot, as shown
 in Figure 9.

 Figure 9. FM-PLS benchtop testing setup.
 Figure 9. FM-PLS benchtop testing setup.

 3.2. Testing with Prosthesis
 The FM-PLS was fitted with a prototype knee prosthesis to evaluate its
 FM-PLS was interfaced with the prosthesis main controller unit to feed the s
 to the controller. The prosthesis controller uses finite-state impedance contro
Force-Moment Sensor for Prosthesis Structural Load Measurement - MDPI
Sensors 2023, 23, 938 10 of 18

Sensors 2023, 23, x FOR PEER REVIEW

 3.2. Testing with Prosthesis
 The FM-PLS was fitted with a prototype knee prosthesis to evaluate its performance.
 which was
 FM-PLS the interfaced
 real-timewithdetection of important
 the prosthesis gaitunit
 main controller events
 to feedisthe
 crucial. FM-PLS sig
 sensor signals
 to
 used in this experiment to identify those important gait events for theforcontroll
 the controller. The prosthesis controller uses finite-state impedance control strategy,
 which the real-time detection of important gait events is crucial. FM-PLS signals will be
 An able-bodied male participant (31 years old, 175 cm, and 70 kg) particip
 used in this experiment to identify those important gait events for the controller.
 study. An able-bodied
 An able-bodied prosthesis
 male participant (31 testing-adapter was70used
 years old, 175 cm, and to attach the
 kg) participated in prost
 subject. The experimental setup is shown in Figure 10. The participant walked
 this study. An able-bodied prosthesis testing-adapter was used to attach the prosthesis
 to the subject. The experimental setup is shown in Figure 10. The participant walked
 mill at two different speeds (1 mph and 2 mph) while a total of 94 walking
 on a treadmill at two different speeds (1 mph and 2 mph) while a total of 94 walking
 recorded.
 cycles The duration
 were recorded. of theofexperiment
 The duration the experiment waswas338
 338 ss and
 and aatotal
 total
 of of 173,160 sa
 173,160
 taken. were taken.
 samples

 Figure
 Figure 10.10. Prosthesis
 Prosthesis fitted
 fitted with thewith thesensor
 FM-PLS FM-PLS sensor
 prototype. prototype.
 4. Results
 4. Results
 4.1. Benchtop Testing vs. Numerical Simulation
 4.1.The
 Benchtop Testing
 results of vs. Numerical
 the benchtop Simulation
 testing while placing the off-the-shelf loadcell underneath
 of the prosthetic foot as a reference measure are shown in Figure 11. Both heel side
 and toeThesideresults
 magnetic offlux
 thesensor
 benchtop testing
 responses while placing
 are depicted while thethe off-the-shelf
 off-the-shelf loadcell
 loadcell
 of the
 was prosthetic
 (1) aligned footofasthea FM-PLS
 with center reference measure
 (shown in Figureare shown
 9, left column),in(2)Figure 11.ofBoth he
 at the heel
 the prosthetic foot (shown in Figure 9, middle column), and (3) at the ball
 toe side magnetic flux sensor responses are depicted while the off-the-shelf lo of the prosthetic
 foot (shown in Figure 9, right column).
 (1) aligned with center of the FM-PLS (shown in Figure 9, left column), (2) at
 the prosthetic foot (shown in Figure 9, middle column), and (3) at the ball of th
 foot (shown in Figure 9, right column).
 Based on the FEA, Figure 12 shows the change of relative distance betwee
 net and the magnetic field transducer with respect to the change of axial force,
 their 4th-order polynomial fitting. As shown in this figure, the 4th-order polyno
 can express the force-distance relationship with good accuracy. The coefficien
 order polynomial model are as follows: 4.8069× 10−10, −2.8442× 10−7 6.9600× 10
 and 3.9971.
Sensors 2023, 23, x FOR PEER REVIEW 11 of 17
 Sensors 2023, 23, 938 11 of 18

 Figure
 Figure11.11.
 Benchtop
 Benchtoptesting
 testing results: referencemeasure,
 results: reference measure, heel
 heel side
 side andand toe side
 toe side magnetic
 magnetic flux sensor
 flux sensor
 responses
 responses while
 whilethethe
 off-the-shelf
 off-the-shelfloadcell
 loadcellwaswas (A)
 (A) aligned
 aligned with center of
 with center of the
 theFM-PLS
 FM-PLS(shown
 (showninin Fig-
 ureFigure
 9, left9,column), (B) at
 left column), the
 (B) at heel of the
 the heel prosthetic
 of the foot
 prosthetic foot(shown
 (shownin in Figure
 Figure 9,9, middle
 middlecolumn),
 column), and (C)
 and
 at the ball of the prosthetic foot (shown in Figure 9, right column).
 (C) at the ball of the prosthetic foot (shown in Figure 9, right column).

 Figure 13 (left) illustrates the change in magnetic flux density with respect to the rel-
 ative axial distance between the magnet and the magnetic flux transducer. By combining
 the force-distance relationship expressed by the 4th-order polynomial model and the dis-
Sensors 2023, 23, 938 12 of 18
R PEER REVIEW 12 of 17

 Based on the FEA, Figure 12 shows the change of relative distance between the magnet
 and the magnetic field transducer with respect to the change of axial force, along with their
 field relation was 4th-order
 established, as shown
 polynomial fitting. Asinshown
 Figure 13 (right).
 in this figure, theSince thepolynomial
 4th-order voltage model
 output canof
 the magnetic flux express
 density thetransducer
 force-distanceis proportional
 relationship to the
 with good magnetic
 accuracy. field, the
 The coefficients force-mag-
 of the 4th-order
 polynomial model are as follows: 4.8069 × 10 −10 , −2.8442× 10−7 6.9600× 10−5 , −0.01139,
 netic field model can be converted to the force-voltage output model.
 and 3.9971.
 Average distance of the magnet from encoder (mm)

 Figure 12. The change of 12.
 Figure relative distance
 The change between
 of relative distancethe magnet
 between and the
 the magnet andmagnetic field
 the magnetic field transducer
 transducer
 with respect to the change of axial
 with respect force and
 to the change their
 of axial force4and
 th -order polynomial
 their 4th-order fitting.
 polynomial fitting.

 Figure 13 (left) illustrates the change in magnetic flux density with respect to the
 relative axial distance between the magnet and the magnetic flux transducer. By combining
 the force-distance relationship expressed by the 4th-order polynomial model and the
 distance-magnetic flux density relationship given by Equation no. (1), the force-magnetic
 field relation was established, as shown in Figure 13 (right). Since the voltage output of the
 magnetic flux density transducer is proportional to the magnetic field, the force-magnetic
 field model can be converted to the force-voltage output model.
Aver
 Sensors 2023, 23, 938 13 of 18
 Figure 12. The change of relative distance between the magnet and the magnetic field transducer
 with respect to the change of axial force and their 4th-order polynomial fitting.

Sensors 2023, 23, x FOR PEER REVIEW 13 of 17
 Figure 13.
 Figure 13. The
 The change
 change of magnetic flux
 of magnetic density with
 flux density with respect
 respect to
 to the
 the relative
 relative distance
 distance between
 between the
 the
 magnet and
 magnet and the
 the magnetic
 magneticfield
 fieldtransducer
 transducer(left).
 (left).The
 Thechange
 changeofofmagnetic
 magnetic flux
 flux density
 density with
 with respect
 respect to
 to axial force (right).
 axial force (right).
 When the off-the-shelf loadcell is positioned at the center, the applied load on the
 When the off-the-shelf loadcell is positioned at the center, the applied load on the
 FM-PLS can be considered as the axial force. Figure 14 shows the experimentally meas-
 FM-PLS can be considered as the axial force. Figure 14 shows the experimentally measured
 ured FM-PLS
 FM-PLS sensor
 sensor readings
 readings while while theforce
 the axial axial force
 was was gradually
 gradually increased
 increased from from
 0 to 650 0 to 650
 N. The
 N. figure
 The figure also shows
 also shows the simulated
 the simulated sensor(based
 sensor reading reading
 on(based on simulation)
 numerical numerical simulation)
 for the
 for similar
 the similar axial
 axial force. force.
 Average sensor reading (mV)

 Figure 14.14.
 Figure Comparison
 Comparisonofofsensor
 sensor readings fromnumerical
 readings from numerical simulation
 simulation andand benchtop
 benchtop testing
 testing of theof the
 FM-PLS during
 FM-PLS the
 during theaxial
 axialforce
 force change.
 change.

 Figure 15 shows the scatter plot of the reference force (measured by the off-the-shelf
 loadcell) versus the FM-PLS signals in the benchtop testing, along with the linear regres-
 sion fitting. The fitting has an R-square value of 0.9802 and a root-mean-squared-error
 (RMSE) of 28.59 N.
Figure 14. Comparison of sensor readings from numerical simulation and benchtop testing
Sensors 2023, 23, 938 FM-PLS during the axial force change. 14 of 18

 Figure 15 shows the scatter plot of the reference force (measured by the off-th
 Figureversus
 loadcell) 15 shows theFM-PLS
 the scatter plot of the in
 signals reference force (measured
 the benchtop testing,byalong
 the off-the-shelf
 with the linear r
 loadcell) versus the FM-PLS signals in the benchtop testing, along with the linear regression
 sion fitting. The fitting has an R-square value of 0.9802 and a root-mean-squared
 fitting. The fitting has an R-square value of 0.9802 and a root-mean-squared-error (RMSE)
 (RMSE)
 of 28.59 N.of 28.59 N.

 700

 600

 500
 Measured force (N)

 400

 300

 200

 100

 0
 0 100 200 300 400 500 600 700
 Reference force (N)
 Figure15.
 Figure 15.Linear
 Linear regression
 regression of unfiltered
 of the the unfiltered data from
 data taken taken
 thefrom the FM-PLS
 FM-PLS sensor andsensor and refere
 reference
 the-shelf loadcell.
 off-the-shelf loadcell.

 4.2. Testing with Prosthesis
 The results of the prosthesis treadmill walking experiments are shown in Figure 16,
 which shows the FM-PLS sensor response during a complete gait cycle along with the
 relative knee angle measured from the knee prosthesis encoder. A complete walking gait
 cycle consists of the stance phase (~60% of the cycle) and the swing phase (~40% of the
 cycle). The stance phase starts with heel contact and ends at toe-off. Hence the average
 sensor reading of the FM-PLS started to increase at the beginning of the cycle (i.e., heel
 contact), which is clearly visible from the data shown in Figure 16. A threshold of 1890 mV
 was empirically selected based on the data for the heel strike detection, and the prosthesis
 controller switches to the stance phase when the sensor reading is greater than the threshold.
 Conversely, the sensor reading drops immediately after the toe-off, which is also obvious
 from the result. The threshold for the toe-off was selected as 1895 mV, below which the
 controller switches to the swing phase. Both of these thresholds were successfully used by
 the controller for the seamless switching between stance and swing phases without any
 misdetection during the prosthesis walking.
thesis controller switches to the stance phase when the sensor reading is greater than the
 threshold. Conversely, the sensor reading drops immediately after the toe-off, which is
 also obvious from the result. The threshold for the toe-off was selected as 1895 mV, below
 which the controller switches to the swing phase. Both of these thresholds were success-
Sensors 2023, 23, 938fully used by the controller for the seamless switching between stance and swing phases 15 of 18

 without any misdetection during the prosthesis walking.

 16. FM-PLS
 Figurewalking
 Figure 16. FM-PLS test:walking test: knee
 knee angle (top angle (top
 figure), averagereading
 figure), sensor
 average sensor reading
 (middle(middle figure),
 figure),
 and sensor
 and sensor reading reading(bottom
 difference difference (bottom figure).
 figure).
 5. Discussion
 5. Discussion
 A novel FM-PLS was designed, developed, and tested in this study. The sensor is
 A novelcompact
 FM-PLS was
 and designed,The
 lightweight. developed,
 height of theand tested
 device in this
 is only study.
 25 mm, Thevery
 adding sensor
 smallisbuild
 compact andheight
 lightweight. The height
 to the prosthesis of the
 when device is
 attached. Theonly 25 mm,
 unique adding very
 functioning small build
 mechanism (magnetic
 height to thesensing of millimeter-scale
 prosthesis when attached.deflection of an elastic
 The unique element) makes
 functioning the device
 mechanism more robust
 (magnetic
 against interferences
 sensing of millimeter-scale and drifting.
 deflection The sensor
 of an elastic does not
 element) require
 makes the highly
 deviceaccurate placement
 more robust
 of magnets as the sensor can easily tolerate misalignment.
 against interferences and drifting. The sensor does not require highly accurate placement
 As shown in the benchtop testing results in Figure 11, the FM-PLS is sensitive at light
 of magnets as the sensor can easily tolerate misalignment.
 load, which makes it competitive for prosthesis control applications with its capability
 of reliably detecting the initiation and ending of ground contact. Although the sensor
 is sensitive at light load, it can still withstand heavy load (5000 N axial force) without
 structural failure, supported by the FEA analysis shown in Figure 7. The benchtop testing
 results validated the theoretical analysis by demonstrating similar shapes of the axial load
 vs. sensor response curve and the axial load vs. magnetic flux curve, as shown in Figure 13.
 The prosthesis testing data shows that this device can reliably detect the stance phase
 and swing phase. The sensor signal started to rise immediately after the heel contact and
 drops after the toe-off as shown in Figure 15. Additionally, sensor signals were used by the
 prosthesis finite-state controller to successfully trigger the stance and swing phase, which
 shows great potential of this sensor for real-time powered prosthesis control.
 Different from the traditional strain gauge-based force sensors, the FM-PLS load
 sensing is based on the millimeter-scale deflection of an elastic element, which is several
 orders of magnitude greater than the strain in a typical load-bearing structure. As such, the
Sensors 2023, 23, 938 16 of 18

 FM-PLS is expected to provide stronger signals that are more robust against interferences
 and drifting. Due to the limitation of experimental conditions, the authors were not able
 to conduct long-term experiments to validate such a hypothesis. Such experiments are
 planned as an important part of the future work for further validating and improving the
 sensor performance.
 When compared against similar millimeter-scale deflection-based load sensing ap-
 proaches (e.g., [19]), the unique design of the FM-PLS incorporates a dedicated elastic
 element to measure the load (axial force and bending moment) through its deflection,
 which is easy and less expensive to manufacture since no high-accuracy machining is
 needed. The cost of the mechanical and electrical components was ∼$1000, which may
 further decrease in future mass production. As such, it may become a building block for the
 future of low-cost, lower-limb prostheses to benefit more amputees in their daily life. On
 the other hand, because of this dedicated elastic element, the FM-PLS sensor is also slightly
 bigger and heavier than other state-of-the-art prosthetic load sensors (e.g., [19]). With
 respect to the sensing performance, the RMSE calculated from the FM-PLS experimental
 data was 28.59 N and the R-value was 0.9802, while the corresponding values in [19] were
 60 N and 0.990, respectively. As such, the FM-PLS performance, based on the available
 experimental data, is comparable to similar sensors, and a more detailed comparison can
 be conducted when more data become available.
 Finally, future work is planned to further validate and improve the performance
 of the proposed FM-PLS sensor. For the validation of the FM-PLS sensor performance,
 the authors plan to test the sensor with more sophisticated commercial testing machines
 to obtain more data on the sensing accuracy, repeatability, and sensor durability. The
 authors also plan to incorporate the sensor into a robotic lower-limb prosthesis to test its
 performance in the desired use conditions and characterize the sensor’s reliability and
 the signals robustness against interferences and drifting. To further improve the sensor
 performance, structural design may be further improved to reduce the sensor dimensions
 and improve the sensitivity. Further, wireless communication interface (such as Bluetooth)
 and an onboard battery may also be introduced to convert the FM-PLS into a wireless
 sensor, enabling it to serve new applications beyond prosthesis control (gait data collection,
 activity recognition, etc.).

 6. Conclusions
 This article presents a novel force/torque sensor named FM-PLS. Unlike existing
 strain gauge-based loadcells, the FM-PLS is based on the measurement of millimeter-
 scale deflection of an elastic element. The much more significant deflection (compared
 with the strain of a typical load-bearing structure) may generate stronger sensor signals
 more robust against interferences and drifting. The design incorporates unique, curved
 supporting blocks, which modulate the deflection of the elastic member and thus make
 the measurement sensitive at light load while withstanding heavy load without damage.
 The FM-PLS prototype is compact and lightweight. With its standard mechanical interface
 and embedded electronic circuits, the sensor can be easily incorporated into a smart or
 robotic prosthesis and supply the important structural load information to the prosthesis
 control system. For the analysis of the sensing mechanism, a two-stage transduction model
 was established to describe the relationship between the applied force/moment and the
 output signals. The benchtop testing results match well with the model-driven predictions.
 To validate its performance, experiments were conducted on a custom testing setup, and
 the sensor signals displayed a good match to the readings of an off-the-shelf loadcell, as
 demonstrated by the R-square value of 0.9802 and the RMSE of 28.59 N. Additionally,
 the sensor was validated through robotic prosthesis walking experiments, and the results
 showed that the proposed FM-PLS can reliably detect important gait events such as heel
 strike and toe-off, providing important real-time information to support the intelligent
 motion control of smart prostheses.
Sensors 2023, 23, 938 17 of 18

 Author Contributions: Conceptualization, M.R.H. and X.S.; Design and Development, M.R.H. and
 X.S.; data collection, M.R.H. and G.B.; writing—original draft preparation, M.R.H.; writing—review
 and editing, X.S.; supervision, X.S. All authors have read and agreed to the published version of the
 manuscript.
 Funding: This research was funded by National Science Foundation, grant numbers 1351520
 and 1734501.
 Data Availability Statement: The data that support the findings of this study are available from the
 corresponding author, XS, upon reasonable request.
 Conflicts of Interest: The authors declare no conflict of interest.

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