Upper extremity injuries caused by trauma and repetitive movements are common among elderly individuals, manual labor workers, and athletes. A traditional rehabilitation program to restore range of motion and strength consists of massage, physiotherapy, and mechanotherapy. Although a great variety of commercial devices is available, the majority lack sensorization for performance monitoring. This paper presents a sensor-integrated rotating crank mechanism for upper limb rehabilitation by comparing the performance of three motor configurations and by validating the system's capability through quantitative motion parameters during exercise. Three prototype configurations were developed and tested. The first prototype (V0) was tested in passive mode without motor activation, then the stepper motor in (V1) was activated, and testing was carried out in semi-active mode. The third prototype (V3) was designed and tested in motorized mode. A 6-axis IMU sensor was integrated onto the crank to capture acceleration and orientation data. Testing was conducted with six volunteers (3 male, 3 female, aged 21-26 years) performing exercises in both horizontal and sagittal planes. The V0 configuration demonstrated predictable motion patterns with an acceleration magnitude ranging from approximately 9 to 13 m/s². Sagittal plane rotation exhibited higher variability with the range 5-20 m/s² due to gravitational effects. The V2 configuration introduced vibration and irregularities in motion smoothness with a magnitude acceleration range of 12 to 13.5 m/s². The most consistent performance was demonstrated by the brushless DC motor system (V3) with stable acceleration profiles (7-18 m/s² horizontal, 4-20 m/s² vertical). Acquired data revealed gender-related differences in peak acceleration, where male volunteers exhibited higher acceleration peaks, especially in the sagittal plane, where the Az component reached up to 25 m/s², whereas female volunteers showed lower and smoother acceleration profiles. The sensor-integrated system provided a reliable method for acquiring quantitative performance metrics, establishing a viable foundation for monitoring rehabilitation progress.
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Design Improvements and Experimental Characterization of a Sensored Rotating Crank for Arm Exercise
Published:
07 May 2026
by MDPI
in The 3rd International Electronic Conference on Machines and Applications
session Mechatronics/Electromechatronics
Abstract:
Keywords: motion assisting devices; arm rehabilitation; rotating crank mechanism; IMU sensor; motion analysis
