This paper proposed a novel design using a torsion spring mechanism with a single fluidic muscle actuator (FMA) to drive a joint with one degree-of-freedom (DOF) through a steel wire and a proportional pressure regulating valve (PRV). We developed a 4-DOF wearable upper-limb rehabilitation assistance exoskeleton system (WURAES) that is suitable for assisting in the rehabilitation of patients with upper-limb injuries. This system is safe, has a simple mechanism, and exhibits upper-limb motion compliance. The developed WURAES enables patients with upper-limb musculoskeletal injuries and neurological disorders to engage in rehabilitation exercises. Controlling the joint is difficult because of the time-varying hysteresis properties of the FMA and the nonlinear motion between standard extension and flexion. To solve this problem, a proxy-based output feedback sliding mode control (POFSC) was developed to provide appropriate rehabilitation assistance power for the upper-limb exoskeleton and to maintain smooth and safe contact between the WURAES and the patient. The POFSC enables the overdamped dynamic of the WURAES to recover motion to be aligned with the target trajectory without a significant error overshoot caused by actuator saturation. The experimental results indicate that the proposed POFSC can control the designed WURAES effectively. The POFSC can monitor the exoskeleton system’s total disturbance and unknown state online and adapt to the exterior environment to enhance the control capability of the designed system. The results indicate that a single FMA with a torsion spring module exhibits a control response similar to a dual FMA configuration.

An innovative wearable upper-limb power-assist exoskeleton system (UPES) was designed for laborers to improve work efficiency and reduce the risk of musculoskeletal disorders. This novel wearable UPES consists of four joints, each comprising a single actuated pneumatic muscle actuator (PMA) and a torsion spring module driven via a steel cable. Unlike most single-joint applications, where dual-PMAs are driven by antagonism, this design aims to combine a torsion spring module with a single-PMA via a steel cable for a 1-degree of freedom (1-DOF) joint controlled by a proportional-pressure regulator. The proposed four driving degrees of freedom wearable UPES is suitable for power assistance in work and characterizes a simple structure, safety, and compliance with the motion of an upper limb. However, due to the hysteresis, time-varying characteristics of the PMA, and non-linear movement between joint flexion and extension, the model parameters are difficult to identify accurately, resulting in unmeasurable uncertainties and disturbances of the wearable UPES. To address this issue, we propose an improved proxy-based sliding mode controller integrated with a linear extended state observer (IPSMC-LESO) to achieve accurate power-assisted control for the upper limb and ensure safe interaction between the UPES and the wearer. This control method can slow the underdamped dynamic recovery motion to tend the target trajectory without overshoots from large tracking errors that result in actuator saturation, and without deteriorating the power assist effect during regular operation. The experimental results show that IPSMC-LESO can effectively control a 4-DOF wearable UPES, observe the unknown states and total disturbance online of the system, and adapt to the external environment and load changes to improve system control performance. The results prove that the joint torsion spring module combining the single-PMA can reduce the number of PMAs and proportional-pressure regulators by half and obtain a control response similar to that of the dual-PMA structure.