System Implementation

Project Progress & Assembly Documentation

Electronics & PCB Design

PCB Design Layout — Figure 1: Custom PCB designed for sensor integration and power distribution

Testing & Validation

Treadmill Testing Setup — Figure 2: Human subject testing on treadmill for gait validation

Mechanical Test Bench — Figure 3: Benchtop mechanical testing rig for transmission efficiency validation

Full System Assembly

Complete Exoskeleton Assembly — Figure 4: Fully assembled AXilles ankle exoskeleton system

Subsystem Components

**Figure 5: Back Brace Assembly**
Motor mounting and cable routing system

Waist Mounting Detail — **Figure 6: Waist Mount Detail**
Lightweight frame with integrated electronics

Foot Assembly Mechanism — **Figure 7: Foot Assembly**
Ankle joint mechanism with embedded sensor suite

Build Process Timeline

Phase 1: CAD Finalization & Manufacturing

We began this semester by finalizing the CAD model and system architecture, then commenced sheet metal part production and 3D printing of structural components.

Initial Assembly Phase 1 — Figure 8: Initial mechanical assembly – view 1

Initial Assembly Phase 2 — Figure 9: Initial mechanical assembly – view 2

CAD Model and Parts Layout — Figure 10: CAD model verification and component layout planning

Phase 2: Electronics Integration

We implemented a standardized wiring color code for all sensor and power connections to ensure consistency and facilitate troubleshooting:

SDA (Data): Yellow
SCL (Clock): White
VCC (Power): Red
GND (Ground): Black

Sensor Wiring — Figure 11: IMU sensor wiring with color-coded connections

Electronics Harness — Figure 12: Complete sensor harness assembly

Phase 3: Electronics Enclosure

The electronics enclosure was designed with aggressive weight optimization while maintaining structural integrity and thermal management capabilities.

3D Printed Enclosure — Figure 13: Weight-optimized electronics enclosure

Component Installation — Figure 14: Jetson Orin Nano and sensor integration

Power Distribution Wiring — Figure 15: Completed power distribution system with buck-boost converters

Phase 4: Force Sensor Integration

Force Sensitive Resistors (FSRs) were prepared with integrated 10kΩ voltage divider resistors and carefully embedded into the shoe insole for ground contact detection.

FSR Preparation — Figure 16: FSR with soldered voltage divider circuit

FSR Installation Underside — Figure 17: FSRs embedded on insole underside (heel and toe positions)

FSR Wire Routing — Figure 18: Signal wires routed through discreet side channel for minimal interference

Phase 5: Final Ankle Assembly

Current Ankle Assembly State — Figure 19: Current state of ankle assembly with integrated sensors and mechanical coupling

Assembly process continues with control system integration and validation testing.