Impedance MPC with Patient-Torque Estimation for Knee Rehabilitation Exoskeletons

Abstract: Knee rehabilitation exoskeletons must enforce a prescribed joint trajectory while remaining safely compliant with involuntary spasm and voluntary patient effort-objectives in tension for any fixed-gain impedance controller. We present an Impedance Model Predictive Control framework for knee rehabilitation exoskeletons, demonstrated on a series-elastic-actuator (SEA) platform: an algebraic feedforward reduces the knee dynamics to a constant-coefficient scalar double integrator, and a receding-horizon quadratic program (QP) computes corrective torques while enforcing hard range-of-motion, torque, and velocity limits (ISO 13482). A Kalman disturbance state driven by direct SEA-based torque sensing (the series-elastic spring deflection measured through the elastic element - an intrinsic, EMG-free patient-torque estimate, not a separate load cell) gives a nominal offset-free guarantee and, via its sign and the desired-motion direction, sensorless Assist-as-Needed. The constant state matrix permits offline precomputation of the QP cost inverse, enabling 500 Hz operation with a multi-step horizon. Across seven-controller benchmarks (sinusoidal tracking, isometric hold), the 500 Hz Kalman MPC is offset free 0.1 mrad RMS, 0.1 mrad steady-state, 0.2 mrad peak under 15 Nm spasm, versus a 515 mrad steady-state offset for classical impedance at the same stiffness - the direct-measurement channel converging the estimate near-immediately (within a few sampling periods). Without the estimator it realizes a classical impedance (4.8 mrad RMS, 8.3 mrad steady-state). All MPC variants meet the 87 mrad clinical criterion; no classical controller does. The architecture is formulated for the 20 DOF MyoSuite myoLeg via coupling-aware per-joint QPs.