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Proceedings of the IEEE International Conference on Mechatronics & Automation Niagara Falls, Canada July 2005 0-7803-9044-X/05/$20.00 2005 IEEEA 6DOF Rehabilitation Machine for Upper Limbsincluding Wrists Using ER ActuatorsJunji Furusho, Chengqiu Liand Yuhei YamaguchiGraduate school of EngineeringOsaka University2-1 Yamadaoka, Suita, Osaka, Japanfurushomech.eng.osaka-u.ac.jpShinya Kimura, Kenji NakayamaTakaya Katuragi and Takamichi OguriGraduate school of EngineeringOsaka University2-1 Yamadaoka, Suita, Osaka, JapanUshio Ryu and Sadami SuzukiAsahi Kasei Engineering Co., Ltd.Kohnan 4-chome, Minatoku, Tokyo, JapanAkio InoueER tec Co., Ltd.2-1-31, Sakuragaoka, Minoo, Osaka, JapanAbstractNew training methods and exercises for upperlimbs rehabilitation are made possible by application of roboticsand virtual reality technology. The technologies can makequantitative evaluations and enhance the qualitative effect oftraining. This paper deals with the development of a 6-DOFrehabilitation machine for upper limbs including wrists usingER actuators ”Robotherapist”.Index TermsRehabilitation System, Upper Limb Rehabili-tation, Wrist Rehabilitation, Robotics, ER ActuatorI. INTRODUCTIONMovements of the upper limbs, such as eating and oper-ating appliances are complicated, various and indispensablefor daily activities. It therefore is important for the aged toexercise to keep their upper limb function. Moreover, thereare many patients of paralysis caused by stroke. For example,in Japan more than two hundred and fifty thousand peoplehave stroke every year, and many of them are paralyzed.The human brain is capable of an extraordinary degree ofplasticity (self-organization), enabling learning, and leavingopen the possibility for motor recovery1. Therefore, neuro-rehabilitation for stroke-patients is effective.The physical therapy involves one-on-one interaction witha therapist who assists and encourages the patient througha number of repetitive exercises. A robotic therapist caneliminate unnecessary exertion by the therapist, quantitativelymonitor patient progress, and ensure consistency in planninga therapy program.The percentage of aged persons in society and their numberare increasing, and their physical deterioration has becomea social problem in many countries. Early detection offunction deterioration and sufficient rehabilitation training arenecessary, not only to decrease the numbers of aged who arebedridden or need nursing care, but also to enable the agedto take an active part in society.Using apparatus that applies robotic technology and vir-tual reality makes new training methods and exercises inThis work is supported by New Energy and Industrial TechnologyDevelopment Organization (NEDO) under the Ministry of Economy, Tradeand Industry of Japanrehabilitation possible2, 3. Feeding back the quantitativeevaluations to the training by a computer can enhance thequalitative effect of training. Therefore, some rehabilitationsystems using these technologies for upper limbs have beendeveloped. However, most of them apply training within atwo-dimensional horizontal plane. Many movements, how-ever, in daily activities need to move arms in a verticaldirection. A system therefore that enables exercise in three-dimensions would seem to be more effective for such train-ing. Although the MIME system 3 using PUMA-560 byVA and Stanford Univ. can give training in three-dimensions,the PUMA-560 is a robot originally developed for industrialuse and may not be sufficiently safe to train the aged and/ordisabled.Furusho, et al. of Osaka University developed two typesof 2-DOF force display systems using ER actuators4, 5,6, and have carried out clinical trials of rehabilitation forupper limbs 6. In these systems, ER actuators ensure themechanical safety. Then, Osaka University and Asahi KaseiGroup joined the 5-year NEDO Project and developed a3-D rehabilitation apparatus for upper limbs based on thisknowledge5. Then, we conducted the clinical evaluation atHyogo Medical college7.In the rehabilitation system developed in the 5-year NEDOProject, the wrist of the rehabilitation machine is not drivenby actuators and rotate freely. So, the proper rehabilitation forupper limbs including wrists can not be attained. Krebs, et al.of MIT developed a wrist robot8 for rehabilitation, and thenhave developed a 5-DOF rehabilitation system consisting ofMIT-MANUS2 and this wrist robot9.In this paper, we present the development of a 6-DOFrehabilitation machine for upper limbs including wrists usingER actuators in a project for the Practical Application ofNext Generation Robots. This machine will be exhibited atthe 2005 International Exposition held in Aichi Prefecture,Japan.1033Input RotationalCylinderER FluidElectricFieldMotorOutput RotationalCylinderOutput TorqueInput TorqueFig. 1.Conceptual Illustration of ER ActuatorFig. 2.Multi-cylindrical-type ERActuator with Output Torque inBoth-Rotational-DirectionsFig. 3.Multi-cylindrical-type ERClutchII. ER ACTUATORSER fluid is a fluid whose rheological properties can bechanged by applying an electrical field10. Fig. 1 showsthe conceptual illustration of an ER fluid actuator. TheER actuator is composed of an ER clutch and its drivemechanism consisting of a motor and a reduction-gear-unit.The rotational speed of the motor is kept constant. The outputtorque of ER actuator is controlled by the applied electricfield.The sectional view of ER actuator which is capable ofproducing output torque in both directions are given in Fig.2.The input rotational parts of Fig.2 (Part I and Part II) possesscylindrical structure. The input rotational PartI is rotatedclockwise through a gear by an electric motor, and the inputrotational Part II is rotated counterclockwise through a seriesof gears by the same motor. The input torque is transferredto the rotating cylindrical section of the output axis via theparticle-type ER fluid filled in the rotating cylinder. Boththe input axis cylinders and the output axis cylinder serve aselectrodes, and output torque is controlled by the electric fieldapplied between the electrodes. The output cylinder is madeof aluminum alloy in order to reduce the moment of inertiaof the output axis. Fig.3 shows a ER clutch with cylindricalstructure.An actuator using ER fluid is effective for human-coexistent mechatronics systems like rehabilitation systemsFig. 4.Human-Machine-Coesistent-Mechatronics (HMCM) System usingER ActuatorsFig. 5.Rehabilitation SystemNIOH-1Fig. 6.Rehabilitation SystemNIOH-2for upper limbs 4. Fig. 4 shows a conceptual illustration ofHuman-Machine-Coexistent-Mechatronics (HMCM) Systemusing ER Actuators. Merits of ER actuators in applications toHuman-Machine-Coexistent-Mechatronics (HMCM) systemare as follows:1) From the Viewpoints of the Characteristics of Opera-tion:(a) Since ER actuators have good back-drivability, theoperator can easily operate HMCM system from itsend-effector.(b) When HMCM system is driven by the operator fromits end-effector, HMCM system can be moved quicklyover the rotational speed of the input cylinder of theER clutch.2) From the Viewpoints of Performances in Force DisplaySystem:(a) Quick force response property originated from thelow inertia property of ER actuator and the rapidresponse of ER fluid make the force presentation withhigh fidelity possible.(b) Force display systems with large-force presentationability can be realized safely.1034Fig. 7.Passive-type Force Display SystemFig. 8.EMUL in RehabilitationIII. REHABILITATION ANDFORCEDISPLAYSYSTEMSUSINGER FLUIDSFurusho Lab. of Osaka University has been developingrehabilitation systems and force display systems using ERfluids since 199311.Fig. 5 shows the 2-DOF rehabilitation systems ”NIHO-1”using ER actuators shown in Fig. 24, 12. The rehabilita-tion training system was installed in a hospital for testingpurpose. 13 patients volunteered to participate in severalexperiments for evaluation of upper limbs physical capabilityand for rehabilitation training. The patients suffered fromarm paralysis due to a damaged spinal cord or clogged brainartery. Fig. 6 shows the 2-DOF rehabilitation system ”NIHO-2” using ER actuators shown in Fig. 35, 13.Fig. 7 shows a passive force display using ER brakes14.Passive force displays using brakes to present resistance forceagainst operators force are quite safe14, 15.Furusho Lab. is going to examine a passive force displayon rehabilitation for upper limbs.Fig. 8 shows the 3-D rehabilitation system for upper limbsusing ER actuators (EMUL)7. EMUL was developed in a5-year NEDO project, and evaluated for stroke-patients byusing Fugel-Meyer assessment16, Motricity Index17, andUeda Stage18 in the clinical testing. The good results wereobtained in the evaluation.Fig. 9.Hand-grip of EMULFig. 10.Drawing of the 1st PrototypeFig. 11.Movement of Link 2IV. THE1STPROTOTYPE OF6-DOF REHABILITATIONSYSTEMFig. 12.Movement of Link 3In the 3-DOF rehabilitation system (EMUL), the properrehabilitation for upper limbs including wrists can not beattained since EMUL has the free-rotation wrist as shown inFig. 9. So, we have developed a 6-DOF machine using ERactuators in a project for the Practical Application of NextGeneration Robots. In this chapter, we present the develop-ment of the 1st prototype machine using servo motors.Fig. 10 shows drawings of the 1st prototype machine. Themechanism of the prototype machine is as in the following.1) It has 2-DOF the horizontal rotation and 1-DOF for thevertical movement in the arm part.1035Fig. 13.Wrist Part and Link 3 of the 1st PrototypeFig. 14.Side View of the Link 32) Actuators and belt-pulley-reduction systems for the armmotion are set on the base in order to reduce the inertiaof the moving parts. The vertical rotation part adoptsa parallel link mechanism consisting of link 2(1) andlink 2(2) as shown in Fig. 10. This makes the gravity-effect compensation by counter-balance weight in allposture possible (see Fig. 11).3) Link-3 driven by the spatial link mechanism rotates inthe horizontal plane as shown in Fig. 12.4) Actuators for the wrist motion are mounted on link1 in order to reduce the inertia of the moving parts.The motor torques are transmitted to the wrist by usinguniversal joints, driving shafts, and wire-pulley system(see Fig. 13).5) Fig. 14 shows the wire-pulley system for the wrist. Fig.15 shows the pathways of wires for roll, pitch, yaw,(a) Roll(b) PitchFig. 15.Wires for Roll, Pitch andYaw Rotation(c) YawFig. 16.Twist of Wire-ropeFig. 17.The 6-DOF Rehabilita-tion System ”Robotherapist”Fig. 18.ER Actuatorrespectively.6) The roll motion of the wrist causes the relative rotationbetween the part A and the part B of Fig. 14. As theresult of this relative rotation, the driving wires for thepitch and yaw motions are twisted as shown in Fig.16.In order to reduce the variation of wire length causedby this roll motion, these wires are placed near the rollaxis as possible.V. 6-DOF REHABILITATIONMACHINE”ROBOTHERAPIST”Fig. 17 shows a photo of ”Robotherapist”. This systemis driven by ER actuators. Fig. 18 shows the ER actuatorfor the arm motion. The mechanism of the grip handle andthe wrist was changed to the cantilever-type from the both-Fig. 19.Wrist Part of ”Robotherapist”1036Fig. 20.Composition of 6-DOF Rehabilitation SystemFig. 21.Construction of Wrist Partside-support-type. Fig. 19 shows the mechanism of the griphandle and the wrist. Fig. 20 shows the conceptual illustrationof the total system. The gravity composition is required inthe cantilever-type grip handle, as shown in Fig. 21. Whenwe adopt such mechanism, the weight near the grip handleincreases, and the performance as a force display system andthe safety property as Human-Machine-Coexistent-system aredeteriorated. So, we placed the balance weight in the ERactuator box as shown in Fig. 22.We are developing rehabilitation training software whichrequires the dexterity of upper limbs including wrists. Fig. 23,Fig. 24 and Fig. 25 show a part of training software.Fig. 22.Arrangement of balanceweightFig. 23.Virtual HittingFig. 24.Virtual SprinkleFig. 25.Virtua WipeVI. CONSIDERATION ABOUTSAFETYA rehabilitation system for upper limbs which has largeworking area can be regarded as a kind of robots. In such ahuman-coexistent robot system where an operator must bein contact with or close to the robot, the safety-securingsystem is necessary in order that an operator can use therobot safely19. In industrial robots, an operator cannotaccess a robot except for teaching in order to avoid hazardousconditions. Fig.26 shows the structure of safety in human-coexistent robots.ER actuators have the following merits from the viewpointof safety.(a) The maximum driving speed of the output shaft of the ERactuator is restricted by the rotational speed of the input shaftof the ER clutch. Therefore, when the rotational speed of theinput shaft is set slow, HMCM systems using ER actuatorsare safe for operators.(b) The inertia of the output part can be made very small.So, in the case of unexpected accidents, the impact forcecaused by the inertia of the actuator can be reduced.Since International Safety Standards for human-coexistentrobots have not been established yet, we have no other choicebut to use the ISO and domestic standards for machinesworking close to human beings (see Table I). The developedrehabilitation system can assure these standards of Table Iby the usage of ER actuators and the mechanical design asfollows:1 The items (a) and (b) of Table I are satisfied by settingthe rotational speed of the input cylinder slow.2 The item (c) is satisfied by using a 60-watt motor forthe drive of the input rotational cylinder.3 Risk Reduction by Design (item (d) is realized bymechanical limitation of each joint, mechanical gravity-compensation and the usage of ER actuators.Safety from the viewpoint of InformationSafety from the viewpoint of Control Safety from the viewpoint of Mechanism and ActuatorsSafety from the viewpoint of Operation ConditionFig. 26.Structure for Securing Safety in Human-Coexistent RobotsVII. CONCLUSIONSWe have developed a 6-DOF rehabilitation machine forupper limbs including wrists as in the following.1) The 1st prototype machine using servo motors wasdeveloped for the purpose of confirming a novel mech-anism for the rehabilitation system.1037TABLE IINTERNATIONAL ANDDOMESTICSAFETYSTANDARDS(a) End-effector Speed is lessthan 0.25 m/sISO10218:Manipulating industrial robotsSafety(b) Low Energy PropertyISO14121:Safety of machineryPrinciples of risk as-sessment(c) Actuator Power is less than80 WJAPAN, JIS B 8433, 1983.:General Code for Safety ofIndustrial Robots(d) Risk Reduction by DesignISO12100:Safety of machineryBasic conceptsCgen-eral principles for design2) Then, the 6-DOF rehabilitation machine for upperlimbs including wrists using ER actuators ”Robothera-pist” has been developed based on the knowledge ob-tained from the development of the prototype machine.3) we are developing the rehabilitation software upperlimbs including wrists at present.REFERENCES1 Carr, Janet, and Roberta Shepherd, Neurological Rehabilitation: Opti-mizing Motor Performance, Butterworth-Heinemann, Boston, 1998.2 H. I. Krebs, B. T. Volpe, M. L. Aisen, and n. Hogan, ”Increasing produc-tivity and quality of care : Robot-aided neuro rehabilitation,”Jurnal ofRehabilitation reseach and development, vol. 37, no.6,pp.639652,2000.3 C. G. Burgar, P.S.Lum, P. C. Shor, and H. M. V. der Loos, ”Devel-opment of robots for rehabilitation therapy : The palo alto va/stanfordexperience,” Jurnal of Rehabilitation Reseach and Development, vol.37, no.6, pp.663673, 2000.4 J. Furusho and M. Sakaguchi, ”New actuators using ER fluid and theirapplications to force disply devices in virtual reality and medical treat-ments,” Proc. of the International Conferance on Electro-RheologicalFluids, Magneto-Rheological Suspensions and their Applications, 755-763, 1997 (Int. J. of modern physics B, vol.13, no. 14,15&16, pp.2151-2159, 1999).5 J. Furusho, K. Koyanagi, U. Ryu, A. Inoue, and K. Oda, ”Developmentof rehabilitation robot system with functional fluid devices for upperlimbs,”International Journal of Human-friendly Welfare Robotic System,vol. 32, no .6, pp.23-27, 2003.6 J. Furusho, ”Mechatronics system using ER fluids (review paper),”J.of Japan Hydraulics and Pneumatic Society,vol. 32, no .6, pp.390-395,2001,(In Japanese)7 J. Furusho, K. Koyanagi, Y. Imada, Y. Fujii, K. Nakanishi, K. Domen,K. Miyakoshi, U. Ryu, S. Takenaka, A, Inoue, A 3-D Rehabilitationsystem for Upper Limbs Developed in a 5-year NEDO Project and itsClinical Testing, ICORR2005, in press.8 J. Celestino, H. I. Kreb