These slides use concepts from my (Jeff Funk) course entitled analyzing hi-tech opportunities to analyze rapid improvements in the economic feasibility of robotic exoskeletons. These exoskeletons can be worn by workers in harmful environments and physically disabled people. By sensing a person’s nerve impulses, these exoskeletons can activate motors that help people move and lift heavy objects. Improvements in biosensors, ICs, materials, batteries, and other components have enabled dramatic reductions in cost and weight, and improvements in response time

1. Opportunities in
Robotic Exoskeletons
Hybrid Assistive Limb SUIT
(MT5009)
Group Members:
Phyoe Kyaw Kyaw
A0098528M
Khin Sandar
A0049731A
Mohammad Khalid
A0098544R
Wang Juan
A0098515W
Yuanbo Li (Michael)
A0119085A
Zhongze Chen (Frank)
A0119239B
1

2. CONTENTS

Introduction

How it Works

Applications
 Evolution of Hybrid Assistive Limb (HAL)

Developments of the HAL suits

Future improvements for the HAL suits
 Robotics Market
 Future Entrepreneurial Opportunities
 Summary and Conclusion
2

3. INTRODUCTION
 Founded in 24 June 2004
 Headquarters in Tsukuba, Ibaraki, Japan
 R&D of equipment & systems in medical, rehabilitation,
elderly assistance, rescue support, heavy labor supports in
factories and plants. Production, lease, sales and support of
HAL.
 Well known for Hybrid Assistive Limb (HAL-5) suit
Hybrid Assistive Limb (HAL) Suit
Prof. Yoshiyuki Sankai
(山海 嘉之)
University of Tsukuba, Japan
Founder of Cyberdyne
Systems Corporation
 A cyborg-type robot that can supplement, expand or
improve physical capability.
Source: Cyberdyne Corporation, www.cyberdyne.jp

4. HAL IN THE NEWS AND PUBLICATIONS

5. HOW IT WORKS: HYBRID CONTROL SYSTEM
Hybrid Control System (Cybernic Autonomous Control + Bio-Cybernic Control)
Cybernic Autonomous Control System
Two control algorithms to provide physical
support to wearers in various conditions.
Bio-Cybernic Control System
Control system that sense wearer’s motion
and activities using bioelectrical signal
including myoelectricity
Wearer receives physical support directly
from the bioelectrical signals driven motors

6. HOW IT WORKS: BIO-CYBERNIC CONTROL
1. Brain sends ‘Myoelectrical’ signal to muscles.
2. Bioelectrical
sensor detects the
signal and activates
Biocybernic Control
3. Biocybernic
Control reads
data and activates
the suit’s motors

7. APPLICATIONS
 Next generation rehabilitation
o Enhance and support physical capabilities of
the user.
o Accelerate wearer’s daily activities and
improve recovery.
o Support self-physical training
 Disaster Relief activities
o Rescue support at disaster sites
o Accelerate disaster recovery activities
and save lives
o Lifting heavy obstacles, victims and
elderly
o Disaster cleanup
7

8. APPLICATIONS
 Heavy industries
o Support carrying heavy machines and
parts
o Reduce injury due to improper
handling of heavy items
o Help ease the workers and increase
productivity
• Hospitals and nursing homes
o Improves the mobility of elderly and
disabled
o Carry patients effortlessly by nurses
and hospital staffs
o Nurse-free walking and other physical
activities

9. APPLICATIONS: DEMO
9

10. APPLICATIONS
 For robot-assisted therapy: Testing on stroke patients shows that robotassisted therapy is as good as intensive comparison therapy.
Statistical Analysis on HAL vs. other care for the recovery of stroke patients
Reference: The New England Journal of Medicine, Downloaded from nejm.org on August 25, 2013.

11. CONTENTS

Introduction

How it Works

Applications

Evolution of Hybrid Assistive Limb (HAL)

Improvements of the HAL suits

Future improvements for the HAL suits
 Robotics Market
 Future Entrepreneurial Opportunities
 Summary and Conclusion
11

12. EVOLUTION OF HAL SUITS
Discovery
- Mapping out
neurons
governing leg
movement
1993
Designs and Creation
- Prototype hardware
design, HAL-3
- Attached to computer
1996
Design and Creation
- Prototype HAL-1
- Support only lower
half limb
1997
Technology and Designs
- Prototype hardware
designs, HAL-5
- Attached computer
directly to the suit for
limb control system
1999
2003
2005
Safety and Conformance
- certified for European
Conformity (EC
Certificate) in Medical
Device Directive (MDD)
2011
2012
Scale and Weight
Commercialization
Scale and Weight
- Released HAL-5 - Commercialized
- Released HAL-3
Prototype for Trail HAL-5 to hospitals
Prototype for Trial
- Waist strapped
and rehab centers
- Backpack battery
battery and
- Operate in
and weighted 22kg
weighted 10kg
Fukushima cleanup

13. HAL IMPROVEMENTS MADE
350
300
1200
300
1000
1000
Suit Weight (Kg)
Operating Time (mins)
Weight Lifting (kg)
250
800
240
800
200
600
160
150
500
400
100
50
60
60
50
30
23
0
70
200
20
15
0
HAL-3
(1999)
HAL-5
(2005)
HAL-5
(2008)
HAL-5
(2011)
200
0
Response Time (ms)

14. IMPROVEMENTS: HAL-3 TO HAL-5A
 Comparison of HAL-3 VS HAL-5 Type A
Suit Type
HAL-3 (1999-2005)
HAL-5 Type A (2005)
Weight
(Lower Body)
22kg
15kg
Power Storage
Lead-Acid
Rechargeable Battery
Li-Poly Battery
Rechargeable battery
< 60 mins
< 160 mins
Operating
time
Improvement (%)
HAL 3
(1999-2005)
32% weight
reduction
266% more
operating time
Motions
Daily Activities (sitting down and standing up from
a chair, walking, climbing up and down stairs)
Operation
Cybernic
Autonomous Control
(CAC)
Hybrid Control System
(CAC + Bio-Cybernic
Control)
Processing
Microcontroller
Microprocessor
Tungsten /
Aluminum
Nickel molybdenum and
aluminum alloy
10% more
Strength/Weight
University Research
Clinical Trial
First Clinical
Trail with HAL
Construction
(S/W)
Price
53% faster
response time
HAL 5-A
(2005)

15. IMPROVEMENTS – BIOELECTRICAL SENSING
Bio-Cybernic Control System
- HAL exoskeleton moves
according to the thoughts of its
wearer.
- Muscle movements are based on
nerve signals sent from the brain
to the muscles – signals that are
registered in very weak traces on
the surface of the skin.
- HAL identifies these signals
using a sensor, sends a signal to
the suit’s power unit and
computer control the movement
of the robotic limbs along with
the human limbs

16. IMPROVEMENTS: HAL-5A TO HAL-5C
HAL 5-A
(2005)
 Comparison of HAL-5 Type A VS HAL-5 Type B VS HAL-5 Type C
Suit Type
HAL-5 Type B
(2008)
Weight
HAL 5-B
(2008)
HAL-5 Type A
(2005 – Ref)
Lower body 15kg
Full Body Weight
(< 23kg)
Power
Storage
Li-Poly
Rechargeable
battery
HAL-5 Type C
(2011)
Full Body Weight
(<20 kg)
13% weight
reduction
Li-Ion Battery Rechargeable battery
Operating
time
Approx. 2 hrs 40
mins
Motions
Daily Activities (sitting down and standing up from a chair,
walking, climbing up and down stairs)
Operation
Agility
HAL 5-C
(2011)
Improvement
(%)
Approx. 3 hrs
166% more
operating time
Hybrid Control System (CAC +Bio-Cybernic Control)
N/A
Hold and lift heavy
objects up to 60 kg
Processing
Microprocessor
Construction
(S/W)
Nickel molybdenum, aluminum alloy
Price (Lease)
Approx. 5 hrs
Clinical Trial
Hold and lift heavy
objects up to 70 kg
Intel Atom
USD 2,500/mth
16% more
agility to lift
6% more
response time
Carbon Magnesium
Alloy
Nil
USD 2,300/mth
5% lower lease
price

17. DEVELOPMENT – RESPONSE TIME
1. Natural movement
2. Avoid accident
3. Move faster
3
2.5
2.5
2.4
2
1.5
1.8
1.6
1.5
1.8
1.8
1.7
1.5
Up to
7.5X
1
1
0.8
0.5
Reduce
Response
Time
0.5
0.2
0.15
0.1
0
Microcontroller
(1999-2005)
Microprocessor
(2005-2008)
Intel Atom (20082011)
Intel Atom (2011Present)
Intel Atom (Future)
HAL 3
HAL 5 (2005)
HAL 5 (2008)
HAL 5 (2011)
HAL 5 (FG)
Response Time (s)
http://www.cpu-world.com/info/Intel/Intel_Atom.html
Frequency (GHz)
TDP (Watt)
Factor affecting in Response time are classified as
1. Software algorithm, 2. Processor speed, 3. Sensor’s
sensitivity and its feedback.

18. DEVELOPMENT – WEIGHT LIFTING
1. Possible more applications that
require heavy lifting such as
heavy labour industry,
warehouse, rescue, nursing, etc.
80
70
Up to
60
Kg
2.6X
50
More weight
can be lifted
40
30
20
10
0
Lower Limb
Lower and Upper
Limb
Full Body Suit
Full Body Suit
HAL 3
HAL 5 (2005)
HAL 5 (2008)
HAL 5 (2011)
Agility (kg)
Source: Cyberdyne, Japan, www.cyberdyne.jp

19. DEVELOPMENT – MATERIAL
950
1.5 X
Reduce
Weight*
10%
Up
S/W
Hal 3
(50kg)
450
300
Hal 5 (2011)
(15kg)
Hal 5 (2005 – 2008)
(23kg)
1. Quicker Mobility
2. Needs less motor torque
to drive the body
3. Easy to wear
http://helix.gatech.edu/Classes/ME4182/2000S1/Webs/reg_mech/prod/materials/strengthvsdensity.html
* Maintain Strength to Weight Ratio

20. DEVELOPMENT – MATERIAL
IMPROVEMENT IN WEIGHT OF
HAL SUIT AND STRENGTH/WEIGHT RATIO
60
20.2
20
50
1. Quicker Mobility
2. Needs less motor torque
to drive the body
3. Lighter to make a suit
and easy to wear
40
30
20
19.8
19.6
19.4
19.2
19
18.8
10
18.6
0
18.4
1
HAL-3
(Tg-Al Alloy)
2
HAL-5
(2005)
Ni-Mo-Al Alloy
Weight (Kg)
Source: Cyberdyne, Japan, www.cyberdyne.jp
3
HAL-5
(2008)
Ni-Mo-Al Alloy
Strength/Weight (Mpa/Kg)
4
HAL-5
(2011)
C-Mg Alloy

21. DEVELOPMENT – ENERGY STORAGE
Comparison of Energy Density for battery materials
Battery storage used for HAL
160
350
120
5X
Energy density (Wh / kg)
Hal-5 C
(2011)
Energy
Density
100
5X
250
Operating
Time
200
Hal-5 B
(20052008)
80
Up to
300
Up to
Operating time (min)
140
150
100
60
50
40
20
0
Hal-3
(19992005)
HAL-3
0
lead acid
Ni-Iron
NiCa
NiMH
li-ion
li-polymer
1. More usage time and less charging
2. Compact and portable battery pack is possible
3. Improve suit’s form factors
Source: http://blog.genport.it/?p=133
HAL-5 B
HAL-5 C

22. CONTENTS

Introduction

How it Works

Applications

Evolution of Hybrid Assistive Limb (HAL)

Improvements of the HAL suits

Future improvements for the HAL suits
 Robotics Market
 Future Entrepreneurial Opportunities
 Summary and Conclusion
22

23. FUTURE IMPROVEMENT OF HAL SUITS
Strength/Weight
Berkeley Lower Extremity
Exoskeleton (BLEEX)
Future HAL
Rewalk
HAL 5 (2011)
HAL 5 (2005)
Current Standing of HAL suit and expectation for future HAL

24. FUTURE IMPROVEMENT OF HAL SUITS
Low Cost
Material
Enhanced
Sensor
Performance
Low Cost
Production
Cost
Improve
Operating
Time (Power
Storage)
Performance
Consideration for Our Next Generation Hal Suit for future opportunities of HAL
Market
Opportunities,
Market Shares
and Types of
Applications

25. PERFORMANCE IMPROVEMENT – POWER
STORAGE
Current situation:
• Battery pack weighs 3kg.
• Continuous usage lasts less than 3
hours.
• Battery type: Lithium-Ion
Alternatives in the future
(7-10 years later)
•
IMPROVE
OPERATING
TIME
Li-S Prototype
Lithium-Sulphur (Li-S) Batteries
http://www.wfs.org/blogs/len-rosen/energy-update-lithiumsulfur-batteries-waste
http://www.barnardmicrosystems.com/L4E_batteries.htm

26. PERFORMANCE IMPROVEMENT – POWER
STORAGE
High Energy Density in Li-S enables HAL
more operating time for less weight (Wh/Kg)
Future HAL
(Li-S)
Current HAL
(Li-Ion)
Source: Tarascon, J , 2010. Key Challenges in future Li-battery research.
Philosophical Transactions of the Royal Society 368: 3227-3241

27. PERFORMANCE IMPROVEMENT – POWER
STORAGE
Future HAL
Up to
x2
Energy
Density
Future Opportunities for Future
Applications for HAL with
• Higher power and energy density
• Lighter and longer cycle times
• Cost effective and competitive
• Easy to Manufacture for
productivity
Current HAL
http://www.barnardmicrosystems.com/L4E_batteries.htm

28. PERFORMANCE IMPROVEMENT – RESPONSE TIME
Current situation:
•
•
Slow synchronization between limb nerve, motion sensor
and driver.
Room for improvement in speed of signal processing and
energy consumption from the processor
Alternatives in the future
•
•
Shrink, SoC Atom Processor for low
cost, power consumption with
multi-core processing capability.
Scaling in Bioelectronic IC
fabrication enables packing of
transistors required in a single IC
and creates additional room for
other components.
Sensors
Enhanced
Sensor
Performance

29. FUTURE PERFORMANCE IMPROVEMENT –
RESPONSE TIME
Pack more cores into a single SoC
(low power and heat, high speed processing)
2010
2008
2011
2013
2014 and beyond
Intel’s Future Atom Architecture
Future Opportunities for Future
Applications for HAL with
•
•
•
Low power multicore processor
enables quicker response time
for lag free movement
Help synchronization quicker
Reduce in Chip size enable low
energy consumption and space
required
Source: http://www.extremetech.com/computing/116561-the-death-of-cpu-scaling-from-one-core-to-many-and-why-were-still-stuck

30. PERFORMANCE IMPROVEMENT – RESPONSE TIME WITH
SCALING BIOELECTRICAL (MUSCLE) SENSOR ICS
Muscle Sensor v1
(HAL-5A)
Muscle Sensor v2
(HAL-5B)
Scaling Pack more transistors into a
single IC and thus increase freq.
(speed), allow low power and heat
9
Dimension (inxin)
8
Function of BioElectronic sensor IC
Future Opportunities
for Future
Applications for HAL
with
•
•
6
Up to
5
2X
4
Size and
Power
3
2
•
1
0
Lower power
consumption
Reduce no. of ICs
and size of sensor
create extra room
for other
components
Improve gain
setting for better
sensor accuracy
and response time
Muscle sensor v1
Muscle sensor v2
Muscle sensor v3
HAL 5 (2005)
HAL 5 (2008)
60
Gain Setting (kW)
50
Voltage Used (V)
7
Muscle Sensor v3
(HAL-5C)
Price (USD)
40
30
Up to
20
4X
10
Gain
Setting
0
Muscle sensor v1
Muscle sensor v2
Muscle sensor v3
HAL 5 (2005)
HAL 5 (2008)
HAL 5 (2011)
HAL 5 (2011)
http://www.scribd.com/doc/123001077/Advancer-Technologies-Muscle-Sensor-v2-Manual

31. FUTURE TRENDS FOR MEMS SENSOR
http://www.siliconsemiconductor.net/article/72615MEMS-Chip-business-to-double-by-2013.php
Source: MEMS market grows as prices decline, http://www.digikey.com/supply-chain-hq/us/en/articles/ semiconductors/
mems-market-grows-as-prices-decline/1058

32. ENTREPRENEUR OPPORTUNITIES WITH
LOW COST MATERIAL
Current situation:
• Base material used:
• Carbon Magnesium alloy
- Weighted 15kg
- US $40-65/kg
LOW COST
MATERIAL
• Base material cost:
• Approx. US $600-975/suit
Alternatives in the future
• Magnesium Reinforced Polycarbonate
• US$20-50/kg, Est. US$300-750/suit
• Pro: Low Cost Material
Future Opportunities for Future
Applications for HAL with
- Reduction in cost creates greater
market share
- Polycarbonate enable easy molding
for quick production and increase
productivity

33. COST REDUCTION IMPROVEMENTS – MATERIAL
Other material consideration for suit and casing given the cost vs. strength chart
below:
Future
Now
Polycarbonate, aluminum
or magnesium alloys
seems more viable material
to strike a balance between
cost and strength.
http://www.thenakedscientists.com/HTML/articles/article/steeling-the-show/

34. Prices of HAL 5 Half Suit VS Full Suit
HAL 5 – Half Suit
HAL 5 – Full Suit
- Indicative prices for Hospitals and Rehab centers. Leasing option is available
from US$2,300 per month.
- At this moment, can’t be bought-off the shelf.
34
http://news.cnet.com/8301-27083_3-20043544-247.html
http://www.theaustralian.com.au/news/world/robots-to-the-rescue-as-an-aging-japan-looks-for-help/story-e6frg6so-1226494698495

35. CONTENTS

Introduction

How it Works

Applications

Evolution of Hybrid Assistive Limb (HAL)

Improvements of the HAL suits

Future improvements for the HAL suits
 Robotics Market
 Future Entrepreneurial Opportunities
 Summary and Conclusion
35

36. ROBOTICS MARKET
1. Service Robots
-
For domestic tasks
Entertainment
Handicap assistance
Personal transportation
Home security
Medical robots
Defense, rescue & security applications
Humanoids
http://www.ifr.org/service-robots/statistics/
2. Industrial Robots
-
Manufacturing
Line assembly
Bio-industrial
In 2012, about 3 million service robots
for personal and domestic use were
sold, 20% more than in 2011. The value
of sales increased to US$1.2 billion.

37. ROBOTICS MARKET
Current applications of HAL:
- Eldercare and rehabilitation
- Disaster relief
- Heavy industries
Future
Forecast US$51.7b market size
for service & personal robotics
- Consumer robotics, entertainment, leisure, military
Worldwide Robotics Market Growth
1. Product Strategy
• Upper, Lower, Full Body,
Rescue & Recovery
2. Pricing Strategy
• Lease < US$2000/mth
3. Target Market
• US, EU and Japan
4. Sales Strategy
• Rental to Hospitals, clinics,
Rescue agencies, heavy
labour industries and
Rehab Centres

38. FUTURE ENTREPRENEUR OPPORTUNITY
HAL-assisted Rehab Centers / Hospitals
•
•
Patients with physical, developmental conditions.
Eldercare
Training for Hal-Therapists
•
•
New training programs & centers for therapists to
use HAL-equipment.
Also available to HAL suit customers
Manufactures and Suppliers
•
Increase demand to produce more
materials, components and integration
parts.

39. FUTURE ENTREPRENEUR OPPORTUNITY
Mobile HAL suit charging stations
•
Consumers can charge suit or exchange/purchase
battery packs.
Robot variations for games, sports
•
Create new market segments for sports
and games.
Software Development Firms and Developers
•
Creates apps ecosystem for better Hal suit software like
brain-wave control, healthcare feedback, etc.
Heavy-lifting services
•
Existing movers, product assembly lines & warehousing
using the HAL suit.

40. SUMMARY - ROADMAP OF HAL
Business Market
(Int.)
(Ext.)
Drivers
2005
2011
Trends: Growth of global ageing population and disabilities
Market: Japan Domestic Hosipitals and Rehabitilitation Centre
R&D by Tsukuba University
Founded Cyberdyne in 2008,
Produced 500 units per annum
Product
Full-body
Support Suit
Single
Joint Suit
Technology
HAL-5 (2011)
Time
Trends: Need for Heavy Labour and Rescue Works
Market: Heavy industries and Tough labour works
2016
Global
Market
Collaborate with Intel Inc, Medical Industries in Europe,
Heavy industries in Japan Domestic and Global Market
HAL-5 (2011-2013)
HAL-7 (2016)
HAL-5 (2005)
Regional
Joint Suit
Battery
Used
R&D
Present
Sensors/
Processor
Material
Hardware
Software
Li-Poly Op: 2 hr 40mins
Li-Ion Op: Up to 3hrs
Acceleration/COG/Angular Sensors/
Muscle Sensor v1, Microprocessor
Acceleration/COG/Angular /Bioelectrical
(Muscle Sensor v3)/COP Sensors/Intel Atom (Z540)
Nickel molybdenum and aluminum alloy
Uppler/Lower Limb Suit
Hi Capacity Li-Ion Op: Up to 4hrs
Full-body Support Suit
Carbon Magnesium Alloy
Tungsten Made Suit
Heavy Industry Suit
Lithium-Sluphur
Li-Ion Op: > 5hrs
MEMS sensors /
Bay Trail Processors
Magnesium Reinforced
Polycarbonate
Polycarbonate Suit
Cybernic Autonomous Control (CAC) + Hybrid Control System (CAC +Bio-Cybernic Control)

41. CONCLUSION
• HAL suit – The leader in robotics exoskeleton
• Showed improvements and commitment to the success of the product.
• Developments in key areas that will impact the performance and cost of
the HAL suit.
• Growing trend in robotics market.
• Entrepreneurship opportunities

42. Lets have
Q & A…

43. REFERENCES
[1] F. Ichihashi, Y. Sankai, S. Kuno, Development of Secure Data Management Server for e-
Health Promotion System, International Journal of Sport and Health Science,Vol.4, pp. 617627, 2006
[2] H. Toda, T. Kobayakawa, Y. Sankai, A multi-link system control strategy based biologilcal
movement, Advanced Robotics, vol.20 no.6, pp. 661-679, 2006
[3] H. Toda, Y. Sankai: Three-dimensional link dynamics simulator base on N-single-particle
movement, Advanced Robotics, vol. 19, no. 9, pp. 977-993, 2006
[4] H. Kawamoto, Y. Sankai: Power assist method based on phase sequence and muscle force
condition for HAL, Advanced Robotics, vol.19, no.7, pp. 717-734, 2005
[5] S. Lee, Y. Sankai: Virtual Impedance Adjustment in Unconstrained Motion for Exoskeletal
Robot Assisting Lower Limb, Advanced Robotics, vol.19, no.7, pp. 773-795, 2005
[6] K. Suzuki, G. Mito, H. Kawamoto, Y. Hasegawa and Y. Sankai: Intention-based walking
support for paraplegia patients with Robot Suit HAL, Advanced Robotics, vol. 21, no. 12, pp.
1441 – 1469, 2007