Design Failure Mode Effect Analysis of Exo robot arm prototype model

As a part of the Exorobot arm prototype design process, a Design Failure Mode and Effects Analysis (DFMEA) was conducted to systematically identify and mitigate potential failure risks across three critical components: the robot base, motor holder flange, and exorobot arm. Each component was evaluated using a custom five-point severity, occurrence, and detection scale, with Risk Priority Numbers (RPN) calculated to prioritize corrective actions. The exorobot arm was identified as the highest-risk component with an initial RPN of 60 and a critical severity rating of 5 due to direct safety implications for the user. Following corrective actions including the addition of a mid-section load distribution bar and FEA validation, all RPN scores were reduced below the acceptable threshold of 20, with the exorobot arm achieving an 87% RPN reduction from 60 to 8. This study demonstrates a systematic, data-driven approach to design risk management in wearable robotic systems.

CAD schematics