Design and Development of Self Physiotherapy Arm

Abstract

The design of an upper limb rehabilitation robot for post-stroke patients is considered a benchmark problem regarding improving functionality and ensuring better human–robot interaction (HRI). Existing upper limb robots perform either joint-based exercises (exoskeleton-type functionality) or end-point exercises (end-effector-type functionality). Patients may need both kinds of exercises, depending on the type, level, and degree of impairments. This work focused on designing and developing a four-degrees-of-freedom (DoFs) upper-limb rehabilitation exoskeleton called ‘self-exercising physiotherapy arm’ that functions as both exoskeleton and end-effector types device. Furthermore, HRI can be improved by monitoring the interaction forces between the robot and the wearer. Existing upper limb robots lack the ability to monitor interaction forces during passive rehabilitation exercises; measuring upper arm forces is also absent in the existing devices. This research work aimed to develop an innovative tensorized upper arm cuff to repetitive movements of upper arm. A control technique was implemented for both joint-based and end-point exercises.

Introduction

The project focuses on designing a self-physiotherapy upper limb rehabilitation arm for post-stroke patients, orthopedic patients, and individuals with sedentary or stressful work habits. The device aims to improve functionality and human–robot interaction (HRI) by providing both joint-based (exoskeleton) and end-point (end-effector) exercises, catering to different levels and types of impairment.

Objective

To create a flexible, adaptive rehabilitation arm that allows maximum degrees of freedom, accommodates different heights and sizes, and aids in faster recovery and stress reduction for patients.

Methodology

1. Mechanical Design & Fabrication: Constructed doctor and patient arm setups with MS pipes and aluminum links.

2. Circuit Development: Designed using Proteus software.

3. Interfacing Components: Motors and electrical components integrated with the arm.

4. Prototype Development: Functional prototype with 3–4 degrees of freedom.

5. Testing & Validation: Ensured correct motion and therapeutic effectiveness.

Working Principle

• Motors at each joint lift and move the patient’s arm according to controller signals.

• Provides multiple degrees of freedom for comprehensive exercise.

• Designed to fit various body sizes and deliver controlled, safe motion.

• Reduces recovery time and alleviates stress for users.

Construction Highlights

• Structure: MS pipe frame with aluminum links.

• Motors: High-torque gear motors for joint movement.

• Power Supply: Battery or SMPS.

• Safety Features: Limit switches restrict joint movement to safe angles.

• Fasteners: Ensure stability and proper assembly.

Literature Reference

• hCAAR (2014): Home-based computer-supported arm rehabilitation system.

• Tone-Aligning End-Effector (2023): Design and characterization for precise arm exercises.

Future Scope

1. AI-Based Adaptive Therapy: Automatically adjust exercises based on patient progress.

2. AR/VR Integration: Immersive and motivating rehab exercises.

3. Tele-Rehabilitation: Remote monitoring and guidance by doctors.

4. Advanced Sensors: EMG, grip force, and motion tracking for precise feedback.

5. Gamification & Mobile App: Interactive exercises and progress tracking.

Conclusion

This work presents the design and functionality of a motion-assisting device for arm exercises with portability characteristics, easy use even in home environments, and low cost, with features that are designed for use especially by elderly people not necessarily in rehabilitation therapies. The device is based on the structure and functionality of a sensorized crank that can rotate in a range suitable for a user’s conditions. The device can have servomotor-assisted operation or a crank movement driven solely by the user during operation. The major innovative feature can be recognized in the structural and functional simplicity designed for autonomous but also monitored use of arm exercises to train the the mobility of its articulations by elderly users.

References

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Copyright

Copyright © 2025 Mrs. Radhika Suraj Ghat, Ms. Shravani Appaso Kamate, Ms. Soudamini Sarjeroa kasote, Ms. Shreya Sambhaji Koli, Ms. Radhika Raju Mathapati. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.