Taguchi-ANOVA optimization of FEM rehabilitation systems

Finite element modelling (FEM) has become an important tool for analysing biomechanical behaviour in rehabilitation systems. However, the optimization of model parameters is often performed empirically, resulting in limited reproducibility and increased computational cost. This work proposes a statistical optimization framework for FEM-based rehabilitation systems using the Taguchi method combined with analysis of variance (ANOVA). An L9 orthogonal array was employed to investigate the influence of material, geometric, and loading parameters while reducing the number of simulations required compared with full factorial approaches. The biomechanical response of the system was analysed through three-dimensional FEM simulations implemented in COMSOL Multiphysics. Experimental measurements acquired using a deformation gauge-based electronic acquisition system were used for model validation. ANOVA enabled the identification of the most influential parameters affecting deformation behaviour and mechanical response stability. The optimized configuration showed reduced deformation variability and improved agreement between numerical and experimental results. In particular, the optimization procedure reduced the average modelling error from 12.4% to 4.1%, while improving response consistency under different loading conditions. The proposed methodology provides a computationally efficient and physically interpretable approach for the optimization of rehabilitation-oriented biomechanical systems.