Active-Assistive Control Based on Dynamic Moving Window for Trajectory Tracking of an Upper Limb Exoskeleton in Assisted Rehabilitation

Rehabilitation robotics faces the challenges of aligning engineering design with patient-specific needs. Most existing controllers in rehabilitation robots often constrain motion to fixed paths or provide only passive guidance, limiting user engagement and adaptability. This study proposes a novel active-assistive mode controller that integrates a virtual tunnel-based force generation mechanism with a dynamic moving-window technique for tracking activities of daily living (ADL) trajectories. Unlike conventional impedance controllers, the proposed method dynamically adjusts the virtual tunnel in real time, permitting voluntary upper-limb movement within a safe operational range while preventing excessive deviation. The system was implemented on a wearable two-degree-of-freedom (DOF) upper-limb exoskeleton equipped with drive and integrated sensor units. Experimental results demonstrated that decreasing the guidance force (Fgf) increased tracking errors, from 1∘ at 100% Fgf to 5∘ at 30% Fgf, indicating greater voluntary participant motion. Peak actuator torques correspondingly decreased from 14.75 to 13.43 Nm (elbow) and from 4.14 to 2.48 Nm (wrist), confirming the controller’s capability to modulate robotic assistance according to user effort. Tests with 30 healthy participants demonstrated the effectiveness of guidance along predefined ADL trajectories, validating the controller’s potential for patient-centered rehabilitation.