DSO-VSA: a Variable Stiffness Actuator with Decoupled Stiffness and Output Characteristics for Rehabilitation Robotics

Stroke-induced motor impairment often results in substantial loss of upper-limb function, creating a strong demand for rehabilitation robots that enable safe and transparent physical human-robot interaction (pHRI). Variable stiffness actuators are well suited for such applications. However, in most existing designs, stiffness is coupled with the deflection angle, complicating both modeling and control. To address this limitation, this paper presents a variable stiffness actuator featuring decoupled stiffness and output behavior for rehabilitation robotics. The system integrates a variable stiffness mechanism that combines a variable-length lever with a hypocycloidal straight-line mechanism to achieve a linear torque-deflection relationship and continuous stiffness modulation from near zero to theoretically infinite. It also incorporates a differential transmission mechanism based on a planetary gear system that enables dual-motor load sharing. A cascade PI controller is further developed on the basis of the differential configuration, in which the position-loop term jointly regulates stiffness and deflection angle, effectively suppressing stiffness fluctuations and output disturbances. The performance of prototype was experimentally validated through stiffness calibration, stiffness regulation, torque control, decoupled characteristics, and dual-motor load sharing, indicating the potential for rehabilitation exoskeletons and other pHRI systems.