A New Variable-Stiffness Body Weight Support System Driven by Two Active Closed-Loop Controlled Drives

Body weight support (BWS) systems are crucial in gait rehabilitation for individuals incapacitated due to injuries or medical conditions. Traditional BWS systems typically employ either static mass–rope or dynamic mass–spring–damper configurations, which can result in inadequate support stiffness, thereby leading to compromised gait training. Additionally, these systems often lack the flexibility for easy customization of stiffness, which is vital for personalized rehabilitation treatments. A novel BWS system with online variable stiffness is introduced in this study. This system incorporates a drive mechanism governed by admittance control that dynamically adjusts the stiffness by modulating the tension of a rope wrapped around a drum. An automated control algorithm is integrated to manage a smart anti-gravity dynamic suspension system, which ensures consistent and precise weight unloading adjustments throughout rehabilitation sessions. Walking experiments were performed to evaluate the displacement and load variations within the suspension ropes, thereby validating the variable-stiffness capability of the system. The findings suggest that the online variable-stiffness BWS system can reliably alter the stiffness levels and that it exhibits robust performance, significantly enhancing the effectiveness of gait rehabilitation. The newly developed BWS system represents a significant advancement in personalized gait rehabilitation, offering real-time stiffness adjustments and ongoing weight support customization. It ensures dependable control and robust operation, marking a significant step forward in tailored therapeutic interventions for gait rehabilitation.