Design, Validation, and Metrological Limits of Biofidelic Instrumentation in PFL Collaborative Robotics: A Systematic Review of Longitudinal Trends and Future Paradigms

The integration of collaborative robots into industrial environments requires rigorous safety validation under the Power and Force Limiting (PFL) regime. This review article systematically maps the technological and normative development of certified Pressure and Force Measurement Devices (PFMDs) and experimental biofidelic instruments for Physical Human–Robot Interaction (pHRI) between the years 2011 and 2026. A quantitative screening of 68 studies revealed a publication peak in impact metrology in 2021. This peak occurred with a five-year latency after the release of the ISO/TS 15066 technical specification. Although global interest in collaborative robotics steadily grows, the publication trend indicates a gradual shift in scientific focus from reactive testing toward proactive prevention. A methodological deconstruction of four Research Questions (RQs) identifies persistent limitations in safety evaluation. The findings demonstrate that the internal structure of conventional sensors induces nonlinear shock filtering and parasitic oscillations (RQ1). Furthermore, the rigid fixation of test stands generates unrealistic pressure spikes. This physical limitation forces a transition to flexible and pendulum-based configurations (RQ2). Commercial flat films physically fail due to sensor saturation and introduced stiffness. Such failures accelerate the development of conformable electronic skins (e-skins) and multimodal test manikins (RQ3). To ensure interlaboratory reproducibility within the current ISO 10218-2:2025 standard, the text defines imperative metrological parameters. These parameters strictly include frequency response, calibration protocols, and volumetric mapping of inertial masses (RQ4). Furthermore, the analysed publications were systematically stratified into distinct technological categories, strictly reflecting their primary engineering domains, ranging from empirical metrological evaluation and sensor hardware design to advanced numerical modeling. Finally, the vision for future research anticipates a definitive shift toward proactive anti-collision technologies, encompassing Artificial Intelligence (AI), machine vision, and Augmented Reality/Virtual Reality/Mixed reality (AR/VR/MR). Future methodologies must also consider demographic anisotropies and the cognitive fatigue of the human operator.