The ankle joint of a powered ankle-foot orthosis (PAFO) is a prominent component, as it must withstand the dynamic loading conditions during its service time, while delivering all the functional requirements such as reducing the metabolic effort during walking, minimizing the stress on the user's joint, and improving the gait stability of the impaired subjects. More often, the life of an AFO is limited by the performance of its joint; hence, a careful design consideration and material selection are required to increase the AFO's service life. In the present work, a compact AFO joint was designed based on a worm gear mechanism with steel and brass counterparts due to the fact of its large torque transfer capability in a single stage, enabling a compact joint. Further, it provided an added advantage of self-locking due to the large friction that prevents backdrive, which is beneficial for drop-foot recovery. The design was verified using nonlinear finite element analysis for maximum torque situations at the ankle joint during normal walking. The results indicate stress levels within its design performance; however, it is recommended to select high-grade structural steel for the ankle shaft as the highest stresses in AFO were located on it.
Keywords: ankle joint torque; ankle–foot orthosis (AFO); finite element analysis (FEA); mechanical design; worm gear.