Adaptive, Bidirectional, 2 kW DC-DC Boost Converter Module
The boost converter module enables higher peak power in wearable robotic devices without substantially increasing device mass by generating a higher voltage for the servo drive from a smaller, lighter battery pack. It boosts the voltage from a 5-8 cell (18-30V) Li-ion battery up to 60 V, with a peak output power of 2.0 kW and peak efficiency of 94% at 800 W output. The module measures 78 x 43 x 12mm and weighs 55 g, achieving a peak power density of 50 W/cm3 by exploiting the inherently pulsed demands of human movement. To support activities that regenerate energy, such as ramp descent, the converter operates bidirectionally, seamlessly reversing power flow to maintain output voltage regulation. A passthrough mode bypasses the converter entirely during low-demand periods to preserve battery life, while enabling rapid transitions to boost operation when required.
Battery Management and Charging System
The boost converter module enables higher peak power in wearable robotic devices without substantially increasing device mass by generating a higher voltage for the servo drive from a smaller, lighter battery pack. It boosts the voltage from a 5-8 cell (18-30V) Li-ion battery up to 60 V, with a peak output power of 2.0 kW and peak efficiency of 94% at 800 W output. The module measures 78 x 43 x 12mm and weighs 55 g, achieving a peak power density of 50 W/cm3 by exploiting the inherently pulsed demands of human movement. To support activities that regenerate energy, such as ramp descent, the converter operates bidirectionally, seamlessly reversing power flow to maintain output voltage regulation. A passthrough mode bypasses the converter entirely during low-demand periods to preserve battery life, while enabling rapid transitions to boost operation when required.
Custom Embedded Systems
Our powered prostheses and exoskeletons include custom embedded electronic systems designed for the tight space constraints of these devices. The circuits boards include a PIC32 microcontroller for low-level control and a Raspberry Pi CM4 embedded computer for high-level control, data logging, and wireless communication. Inrush protection enables hot-plugging of Li-ion battery packs, and per-connector power protection isolates sensors faults to prevent system resets. Shown is the circuit board used in the Direct Ball Screw Drive Knee Prosthesis.