Nowadays, the use of Rehabilitation Robots for stroke patients has been growing rapidly. However, there was a limited scope of using such Rehabilitation Robots for patients suffer from an accidental physical fracture. Since the pain condition of such accidents needs a critical treatment, precise control of such robotic manipulators is mandatory. This paper presents the design and control of the Elbow-Forearm Rehabilitation Robot by considering the pain level of the patient. This design consists of the mechatronic design processes including mechanical design, controller design, and Virtual prototyping using ADAMS-MATLAB Co-simulation. The pain level is estimated using three parameters i.e the patient general condition, the muscle strain, and the duration of exercise from the beginning of rehabilitation. Based on these three input parameters, the manipulator's desired range of motion has been determined using the Fuzzy Logic System. The output of this fuzzy logic system would be an input to the main control system. ADAMS-MATLAB Co-simulation is carried out based on three reference inputs i.e Step, sinusoidal and the proposed fuzzy reference input. Using step input, we have discussed the step response characteristics of the developed system. The Co-simulation of the ADAMS dynamic model is realized with a 30 degree oscillating motion by providing a sinusoidal input. Finally, using the developed fuzzy reference input, we have done a Co-simulation of ADAMS plant. The simulation result demonstrates that the proposed PID controller with gains Kp=0.001 and Ki=0.01 yields 99.6% of accuracy in the tracking of the reference input as compared to the simulation without introducing controller which has an accuracy of 94.9%. The simulation also shows that derivative gain (Kd) of the PID controller has no effect on the system so that it is over damping system. From the above three simulation schemes, we can conclude that the Elbow-Forearm rehabilitation robot could be controlled as per the desired signal. Since this desired signal is developed from the pain level of the patient, we can say that the system is controlled as per the pain level of the patient.