FEM-Based Modelling and AI-Enhanced Monitoring System for Upper Limb Rehabilitation

The integration of physical modelling, artificial intelligence (AI), and embedded electronics represents a promising direction in the development of intelligent systems for rehabilitation monitoring. Most existing approaches, however, treat biomechanical simulation and sensor-based AI separately, without leveraging their potential synergy. This study introduces a hybrid framework for upper limb rehabilitation that combines finite element modelling (FEM), AI-based trend classification, and a custom-designed electronic system for real-time signal acquisition and wireless data transmission. A mechanical model, developed in COMSOL 6.2 Multiphysics, simulates the interaction between a robotic glove and a deformable latex sphere. The latex material is described using a two-parameter Mooney–Rivlin hyperelastic formulation to capture large nonlinear deformations under realistic contact conditions. The high-fidelity simulation data are used to validate the signal acquisition chain and to train a supervised AI algorithm capable of classifying rehabilitation progress—whether improving or worsening—based on biomechanical features. An integrated electronic prototype enables seamless data flow to a cloud-based monitoring platform, supporting real-time feedback and adaptability. The classification algorithm demonstrates robust performance across different test conditions, while the electronic system confirms its applicability in rehabilitation settings. The novelty of this paper lies in the closed-loop integration of FEM-based simulation, AI-driven analysis, and embedded electronics into a unified monitoring architecture. This intelligent and non-invasive approach provides a scalable tool for tracking motor recovery and enhancing therapy effectiveness through adaptive, feedback-driven interventions.