Original modular actuator design for upper extremity rehabilitation devices

In this thesis, an integrated actuator package that can be incorporated into upper limb rehabilitation robots has been designed, manufactured, and its performance has been experimentally evaluated. During the design phase, the interoperability and size/weight optimization of the BLDC motor, custom planetary gearbox, high-resolution position encoder, and multilayer PCB with continuous instantaneous direction change capability were prioritized. The gear ratio of the reducer has been optimized to support high torque production even at low speeds; mechanical parts have been produced using the 3D printing method with PLA material, ensuring assembly tolerances and strength requirements. Thanks to the triac circuit integrated into the control board, the axis rotation was completed within 30 ms after receiving the direction change command. Within the scope of performance measurements, the required output torque in durability and integration tests was consistently and repeatably achieved. Additionally, feedback control loop and speed response evaluations have shown that the proposed actuator package can operate stably and precisely in clinical rehabilitation scenarios. Thanks to its modular structure and assembly interfaces, this actuator package offers significant potential for rapid integration and long-lasting performance in rehabilitation robots.