Design and Development of a Novel Sensorized Orthosis for Orthopedic Rehabilitation

Abstract

This thesis presents the design, development, and implementation of a novel sensorized orthosis for orthopedic rehabilitation. The system addresses the lack of quantitative feedback in traditional passive braces by integrating compact sensing and data communication modules into a lightweight and modular structure. An absolute rotary encoder and two six-axis IMUs were employed to measure knee joint angle and motion dynamics in real time. The embedded controller, based on an ESP32-S3 microcontroller, supports high-frequency data acquisition, local microSD logging, and wireless communication with the ROS 2 framework, enabling both offline analysis and interactive applications.

The system was designed as a fully independent and non-invasive add-on to a commercial postoperative brace, maintaining clinical compatibility while adding sensing capability. The complete system weighs approximately 180 grams and allows rapid attachment and removal without altering the brace’s mechanical properties. Experimental validation confirmed stable and synchronized sensor performance, accurate joint-angle estimation, and reliable differentiation between correct and incorrect rehabilitation motions.

The integration of the existing Unity3D-based rehabilitation game with the proposed system successfully validated its feasibility and immense potential in intelligent, interactive rehabilitation. This system bridges the technological gap between conventional orthopedic braces and intelligent robotic rehabilitation devices, establishing a solid foundation for achieving intelligent, quantitative, and personalized rehabilitation assessment and training.