| Summary: | This work presents the design of the Rehab-Exos, a novel upper limb exoskeleton designed for rehabilitation purposes. It is equipped with high-reduction-ratio actuators and compact elastic joints to obtain torque sensors based on strain gauges. In this study, we address the torque sensor performances and the design aspects that could cause unwanted non-axial moment load crosstalk. Moreover, a new full-state feedback torque controller is designed by modeling the multi-DOF, non-linear system dynamics and providing compensation for non-linear effects such as friction and gravity. To assess the proposed upper limb exoskeleton in terms of both control system performances and mechanical structure validation, the full-state feedback controller was compared with two other benchmark-state feedback controllers in both a transparency test—ten subjects, two reference speeds—and a haptic rendering evaluation. Both of the experiments were representative of the intended purpose of the device, i.e., physical interaction with patients affected by limited motion skills. In all experimental conditions, our proposed joint torque controller achieved higher performances, providing transparency to the joints and asserting the feasibility of the exoskeleton for assistive applications.
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