ArticleScientific reports2026
Design, control, and computational validation of a mechanically decoupled 3-DOF ankle rehabilitation device.
Article in Scientific reports, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
This paper presents the design methodology, kinematic analysis, finite element structural validation, and closed-loop computational simulation of a novel 3-degree-of-freedom (3-DOF) ankle-foot rehabilitation exoskeleton. The proposed exoskeleton addresses the simultaneous rehabilitation of dorsiflexion/plantarflexion (DF/PF), abduction/adduction (AB/AD), and inversion/eversion (INV/EV) in a seated configuration suited to patients with weight-bearing restrictions. Three NEMA 23 stepper motors independently actuate each axis through custom two-stage spur gear transmissions, achieving positive torque margins of + 6%, + 35%, and + 25% and sub-degree angular resolution. Full kinematic decoupling between all three axes is established through two independent architectural strategies. A finite element analysis (FEA) conducted on all four critical Al 6061-T6 structural components confirms safety factors between 2.82 and 4.87 under worst-case loading. A closed-loop PID control framework with adaptive range-of-motion (ROM) regulation, simulated in MATLAB/SIMULINK, demonstrates tracking performance characterised by maximum overshoots of 0.02°-0.12°, settling times of 3.7-7.8 s, and steady-state errors below ± 0.04° across all nine simulation scenarios. The results confirm the mechanical feasibility, structural integrity, and control effectiveness of the proposed exoskeleton as a viable platform for multi-DOF seated ankle rehabilitation.
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