Experimental test platform for exoskeleton joint motors based on a ZYNQ heterogeneous system-on-chip architecture

Exoskeleton joint motors are required to operate under complex conditions, such as variable loads, frequent start–stop motions, and external disturbances. These conditions necessitate high dynamic control performance and rapid response capability. However, conventional motor testing systems mostly rely on discrete hardware architectures and external data acquisition devices, resulting in low integration levels, limited real-time performance, and challenges in the synchronous measurement of multiple parameters. To address these issues and enable the accurate evaluation of steady-state and dynamic performance indicators for exoskeleton joint motors, this study designs a highly integrated, real-time experimental platform based on a ZYNQ heterogeneous system-on-chip (SoC) system.

The performance test platform is developed based on the ZYNQ-7010 SoC using a hardware–software codesign approach. The ARM processing system facilitates test management, parameter configuration, communication, and data processing, while the programmable logic implements high-speed synchronous torque- and speed-frequency-signal acquisition, analog signal sampling, and dynamic loading signal generation. A drag-type experimental structure is constructed by coaxially coupling the experimental exoskeleton joint motor with the load motor through a torque sensor, allowing simulation of typical operating conditions encountered in exoskeleton applications. An equal-precision frequency measurement algorithm is implemented in programmable logic to ensure accurate frequency acquisition over a wide dynamic range. Meanwhile, a direct digital synthesis–based method is adopted to generate controllable and repeatable dynamic loading signals. Based on relevant national standards, experimental procedures are established to evaluate the torque and speed ripple coefficients, control accuracy, and step response time.

The experimental results demonstrate that (1) an embedded measurement and control hardware system based on the ZYNQ-7010 is designed and implemented, integrating high-precision frequency signal acquisition interfaces with a measurement range of 1 Hz–1 MHz, analog signal acquisition modules, and dynamic load simulation output modules; (2) a drag-type physical test platform for exoskeleton joint motors is constructed to simulate various typical load conditions encountered during actual motion processes and support coordinated multiparameter testing; (3) platform-level implementation and validation are conducted across key performance indicators, including torque and speed ripple coefficients, control accuracy, and step response time, with data-update periods ranging from 1 to 500 ms, based on a hardware-software codesign approach and in accordance with relevant national and industry standards for testing exoskeleton joint motors.