Objective the study aimed to construct a multi-parameter coupled evaluation system to investigate the impact of manipulator operations on pilots’ physiological and psychological states, providing theoretical and practical insights for optimizing human-machine collaboration and ensuring operational safety. Methods The study designed manipulator tasks with varying difficulty levels and employed multiple physiological monitoring techniques to collect hemodynamic parameters, electrocardiographic indicators, and mental workload data from pilots. Operational performance was recorded simultaneously. Results Physiological indicators showed that stroke volume (SV) and total peripheral re-sistance (TPR), while decreasing heart rate variability (HRV), as indicated by reduced SDNN and a lower ratio of low-frequency to high-frequency normalized units (LFn/HFn). Subjective evaluations and performance metrics revealed increased mental workload and reduced operational efficiency. These effects were further exacerbated when task difficulty and complexity were increased. Conclusion Manipulator operations significantly affect pilots’ hemodynamic and electrocardiographic parameters, substantially increasing mental workload and leading to decreased operational performance.