This paper deals with the design of an optimal cable-driven parallel robot (CDPR) for upper limb rehabilitation. The robot’s prescribed workspace is identified with the help of an occupational therapist based on three selected daily life activities, which are tracked using a Qualisys motion capture system. A preliminary architecture of the robot is proposed based on the analysis of the tracked trajectories of all the activities. A multi-objective optimization process using the genetic algorithm method is then performed, where the cable tensions and the robot size are selected as the objective functions to be minimized. The cables tensions are bounded between two limits, where the lower limit ensures a positive tension in the cables at all times and the upper limit represents the maximum torque of the motor. A sensitivity analysis is then performed using the Monte Carlo method to yield the optimal design selected out of the non-dominated solutions, forming the obtained Pareto front. The robot with the highest robustness toward the disturbances is identified, and its dexterity and elastic stiffness are calculated to investigate its performance.

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