Search Results (22)

Background/Objectives: Industry 5.0 emphasizes the protection and empowerment of human workers. Passive wearables reduce physical strain, but the evaluation of their efficacy remains incomplete when based solely on kinematics or electromyographic (EMG) envelope amplitude, failing to capture the underlying neural “cost” or the compensatory strategies. This paper proposes a computational framework centered on muscle synergy analysis to bridge the gap between laboratory-grade neural assessment and real-world industrial applications. The goal is to move beyond simple biomechanical metrics toward a deeper understanding of neural coordination during device interaction. Methods: Given the practical limitations of high-density EMG in industrial settings, we propose a “streamlining” approach: laboratory-derived synergy models guide the understanding of neural processes and the selection of a minimal set of sensors capable of detecting maladaptive motor compensations and early signs of fatigue. Results: This approach allows for long-term monitoring without compromising natural movement. By decoupling neural strategies from kinematic output, “silent” risk situations can be identified even when movement appears correct but the neural coordination is altered by the passive device. This supports personalized ergonomic indices and predictive prevention protocols, transforming wearables from simple mechanical aids into intelligent, human-centric systems. Conclusions: This framework provides a roadmap for translating complex motor control theories into practical tools for the next generation of safe and sustainable manufacturing. Full article

Lower limb exoskeletons significantly enhance human functionality. However, simultaneously improving the load capacity of these devices while reducing metabolic costs presents a major challenge in the industry. This paper presents a lower limb exoskeleton that integrates both rigid and flexible structures to facilitate active assistance and passive load transfer at the hip joint. The load transfer experiments were conducted with weights of 10 kg and 15 kg. During static standing, the load transfer rates were recorded at 90.48% and 69.70%, respectively. In dynamic walking, these rates decreased to 62.07% and 43.69%. Furthermore, in metabolic experiments involving a load of 15 kg, metabolic costs in the exoskeleton assistance modes OFF (Assist OFF) and exoskeleton assistance ON (Assist ON) were reduced by 8.3% and 21.61%, respectively, compared to the exoskeleton-free condition (NE). Furthermore, the Assist ON mode further decreased metabolic costs by 13.22% compared to the Assist OFF mode. These findings demonstrate that the rigid-soft coupled lower limb exoskeleton exhibits exceptional load transfer capabilities and effective assistance, highlighting its potential to enhance human performance in weight-bearing activities. Full article

The half-sitting posture is essential for many functional tasks performed by industrial workers. Thus, passive lower-limb exoskeletons, known as wearable chairs, are increasingly used to relieve lower-limb loading in such scenarios. However, although these devices lighten muscle effort during half-sitting tasks, they can disrupt walking mechanics and balance. Moreover, rigorous biomechanical data on joint moments and contact forces during walking with such a device remain scarce. Therefore, this study conducted a biomechanical evaluation of level walking with a wearable chair to quantify its effects on gait and joint loading. Participants performed walking experiments with and without the wearable chair. An optical motion capture system and force plates collected kinematic and ground reaction data. Six-axis force sensors measured contact forces and moments. These measurements were fed into a Newton–Euler inverse dynamics model to estimate lower-limb joint moments and assess joint loading. The contact measurements showed that nearly all rotational load was absorbed at the thigh attachment, while the ankle attachment served mainly as a positional guide with minimal moment transfer. The inverse dynamics analysis revealed that the wearable chair introduced unintended rotational stresses at lower-limb joints, potentially elevating musculoskeletal risk. This detailed biomechanical evidence underpins targeted design refinements to redistribute loads and better protect lower-limb joints. Full article

This review provides a comprehensive analysis of recent advancements in lower limb exoskeleton systems, focusing on applications, control strategies, hardware architecture, sensing modalities, human-robot interaction, evaluation methods, and technical innovations. The study spans systems developed for gait rehabilitation, mobility assistance, terrain adaptation, pediatric use, and industrial support. Applications range from sit-to-stand transitions and post-stroke therapy to balance support and real-world navigation. Control approaches vary from traditional impedance and fuzzy logic models to advanced data-driven frameworks, including reinforcement learning, recurrent neural networks, and digital twin-based optimization. These controllers support personalized and adaptive interaction, enabling real-time intent recognition, torque modulation, and gait phase synchronization across different users and tasks. Hardware platforms include powered multi-degree-of-freedom exoskeletons, passive assistive devices, compliant joint systems, and pediatric-specific configurations. Innovations in actuator design, modular architecture, and lightweight materials support increased usability and energy efficiency. Sensor systems integrate EMG, EEG, IMU, vision, and force feedback, supporting multimodal perception for motion prediction, terrain classification, and user monitoring. Human–robot interaction strategies emphasize safe, intuitive, and cooperative engagement. Controllers are increasingly user-specific, leveraging biosignals and gait metrics to tailor assistance. Evaluation methodologies include simulation, phantom testing, and human–subject trials across clinical and real-world environments, with performance measured through joint tracking accuracy, stability indices, and functional mobility scores. Overall, the review highlights the field’s evolution toward intelligent, adaptable, and user-centered systems, offering promising solutions for rehabilitation, mobility enhancement, and assistive autonomy in diverse populations. Following a detailed review of current developments, strategic recommendations are made to enhance and evolve existing exoskeleton technologies. Full article

Long-term manual material handling (MMH) work leads to the trend of the younger onset of work-related musculoskeletal disorders (WMSDs), with low back pain (LBP) being the most common, which causes great trouble for both society and patients. To effectively prevent LBP and provide support for workers engaged in MMH work, wearable lumbar assistive exoskeletons have played a key role in industrial scenarios. This paper divides wearable lumbar assistive exoskeletons into powered, unpowered, and quasi-passive types, systematically reviews the research status of each type of exoskeleton, and compares and discusses the key factors such as driving mode, mechanical structure, control strategy, performance evaluation, and human–machine interaction. It is found that many studies focus on the assistive performance, human–machine coupling coordination, and adaptability of wearable lumbar assistive exoskeletons. At the same time, the analysis results show that there are many types of performance evaluation indicators, but a unified and standardized evaluation method and system are still lacking. This paper analyzes current research findings, identifies existing issues, and provides recommendations for future research. This study provides a theoretical basis and design ideas for the development of wearable lumbar assistive exoskeleton systems. Full article

Manual material handling, a common practice in various industries, often involves moving or lifting heavy objects, placing significant physical strain on workers, especially in the lower back. A prime example is manhole cover removal, which typically requires handling heavy weights, potentially leading to lower back muscle strain. This study investigates the effectiveness of a passive exoskeleton in reducing ergonomic risks during manhole cover removal. Twenty able-bodied workers participated, performing the task with and without extractor tools in the field. Techniques such as surface electromyography and inertial measurement units were employed to measure muscle activity and body posture using the Rapid Entire Body Assessment (REBA). This study compared muscle activities and REBA scores under different conditions: manually lifting covers, using an in-house lever tool, and using a sledgehammer and a pick bar tool named Jake, both with and without an exoskeleton. Results revealed that the in-house Lever tool was the safest and most efficient method, resulting in the lowest muscle activities and REBA scores, regardless of exoskeleton use. Interestingly, the exoskeleton significantly reduced muscle strain when using the Jake tool. These findings indicate that while the Lever tool is optimal for this task, passive exoskeletons can effectively lower ergonomic risks associated with more physically demanding tools. Full article

Recent advancements in exoskeleton technology, both passive and active, are driven by the need to enhance human capabilities across various industries as well as the need to provide increased safety for the human worker. This review paper examines the sensors, actuators, mechanisms, design, and applications of passive and active exoskeletons, providing an in-depth analysis of various exoskeleton technologies. The main scope of this paper is to examine the recent developments in the exoskeleton developments and their applications in different fields and identify research opportunities in this field. The paper examines the exoskeletons used in various industries as well as research-level prototypes of both active and passive types. Further, it examines the commonly used sensors and actuators with their advantages and disadvantages applicable to different types of exoskeletons. Communication protocols used in different exoskeletons are also discussed with the challenges faced. Full article

(1) Exoskeletons offer potential benefits for overhead working tasks, but gender effects or differences are unclear. This study aimed to compare the performance as well as subjective body strain and comfort of men and women using an upper-body exoskeleton. (2) n = 20 female and n = 16 male participants performed an overhead drilling task with and without a passive upper-body exoskeleton in a randomized cross-over study. The task performance of different movement phases, perceived exertion, and ease of use were measured to compare gender differences. One- and two-way analyses were used to compare genders in the different conditions. The body mass index (BMI) was included as a covariate. (3) Gender differences in task performance were found for error integrals (p < 0.001) with higher values in male participants. Moreover, there was a significant interaction effect for gender x exoskeleton use. While females showed performance decrements in aiming with exoskeleton use, the males’ performance increased (p = 0.025). No other gender differences were observed. (4) Gender differences in task performance using an upper-body industrial exoskeleton were less detectable than expected, indicating that body composition and anthropometrics might be valuable indicators for performance including assisting devices. Moreover, future studies should also integrate the examination of muscle activity to gain more insights into potential gender movement control patterns. Full article

This field study explores construction workers’ perceptions of using a passive shoulder exoskeleton to better understand how to improve its adoption in construction. We provided forty-one construction workers with an exoskeleton to perform their regular work activities for two days. Workers’ feedback of the tool was collected at the end of each day. Two-thirds indicated they would likely or very likely use an exoskeleton if their employer provided it. Participants felt exoskeletons were helpful for specific overhead tasks, such as installing upper tracks, framing and drywalling bulkheads, taping and mudding ceilings, and installing light fixtures. To improve their adoption within the construction industry, exoskeletons should be designed to be compatible with harnesses and toolbelts, be close-fitting to allow working in tight spaces, be easily adjustable (for fit and level of support), be rugged and easy to clean, and should not encumber workers in performing their tasks. Full article

This paper proposes a modular protocol for the designing of experimental studies to analyze exoskeletons used in industrial settings to support manual material handling (MMH). Despite exoskeleton technologies starting to be highly commercialized and present in workplaces, research still lacks a standardized procedure for analyzing the impact of these devices on workers. The protocol presented in this paper outlines a step-by-step procedure, including the parameters to be collected and analyzed in a research study. Moreover, the approach could be easily adapted to meet the specificity of a wide range of exoskeletons. The main novelty of the protocol is thus to support the experimental design and analysis of studies assessing the overall impact of exoskeletons on workers. To implement the protocol, the selected case study concerned a palletizing task involving the MMH of 12 cardboard boxes, weighing 10 kg. The results from physiological signals and pressure insoles show that the protocol is comprehensive and can be utilized by researchers evaluating different occupational exoskeletons for assistance during MMH (both active and passive), with modifications to specific parts based on the type of exoskeleton being assessed or the variables of interest. Full article

Work-related musculoskeletal disorders (WMSDs) are a common occupational health problem in industries, and they can lead to decreased productivity and a reduced quality of life for workers. Exoskeletons, as an emerging technology, have the potential to solve this challenge by assisting arm movements and reducing muscle effort during load lifting tasks. In this paper, a passive exoskeleton based on a variable stiffness mechanism (VSM) torque generator is proposed and evaluated. This exoskeleton can provide adjustable torque curves and accommodate three degrees of freedom (DOFs) while remaining compact and lightweight. The workspace analysis shows that the workspace of this exoskeleton is sufficient for most industrial manual handling tasks. The experimental results demonstrate that the exoskeleton effectively reduces muscle effort during overhead reaching and load-lifting tasks, highlighting its effectiveness for repetitive tasks in industrial settings. Full article

Industrial wool textile production exposes workers mainly to the biomechanical loading of the shoulder joint. In this work context, which is characterized by poor machine ergonomics, exposure to biomechanical risk factors, and variable work organization, exoskeletons could facilitate work processes or could be a valuable means to protect workers from overuse injuries. Field evaluation is essential to verify the suitability of specific devices and their acceptance by users. As part of a pilot study, we examined the short-term subjective effects of a passive Arm-Support Exoskeleton (ASE) on workers performing repetitive overhead tasks. In a textile factory, eight workers participated in the study, answering questionnaires after carrying out a work session with (ASE) and without an exoskeleton (FREE). Participants had been using the Paexo exoskeleton for $4.2\pm 5.8$ months (min 0–max 12). Subjective evaluations were collected regarding the workload (NASA-TLX) and relief (Borg’s CR10 scale) obtained from the use of the exoskeleton, satisfaction (Quebec User Evaluation of Satisfaction with Assistive Technology (QUEST)), usability (System Usability Scale (SUS)), and opinions on the ergonomics of the device (Ergonomics questionnaire). Workers reported a high workload (NASA $7.2\pm 1.0$) and assessed a 46% reduction in effort on the CR10 in ASE conditions compared to FREE. They expressed high satisfaction with most characteristics of the ASE (100% satisfied with durability and effectiveness), high level of usability (62% of scores above 80, out of a maximum score of 100), and ergonomics of the device ($88\pm 12$, out of a maximum score of 110). In addition to the objective effects (electromyography (EMG) reduction) already demonstrated in a previous publication, these qualitative results demonstrate a positive perception by textile workers regarding the effectiveness, usability, and suitability of the exoskeleton. The adoption of ASE in the textile industry appears beneficial in the short term, but the impact associated with individual variables and long-term effects remains to be explored. Full article

Manual material handling (MMH) significantly impacts worker health and productivity, often leading to musculoskeletal disorders (MSDs) primarily in the lower back. As a novel assistive technology, exoskeletons may serve as ergonomic tools to mitigate these work-related MSDs. It is essential to examine exoskeletons from the users’ perspectives before their widespread implementation in occupational settings. This study investigates the effectiveness of a passive back-support exoskeleton (BExo) in reducing perceived physical exertion and improving ergonomic safety in a manufacturing context. Twenty-two college students were recruited to perform MMH tasks in a controlled lab environment, both with and without the BExo, followed by completing a survey questionnaire on various aspects of the BExo. Using ANOVA, the study analyzed biomechanical exertion across various body parts and tasks. The findings indicate that the BExo substantially alleviated discomfort and physical exertion in the low back, shoulders and knees, thereby enhancing an ergonomic posture and reducing fatigue. These results underscore the potential of passive exoskeletons to boost workers’ safety and efficiency, providing valuable insights for future ergonomic strategies in industrial settings. Full article

Upper-limb exoskeletons for industrial applications can enhance the comfort and productivity of workers by reducing muscle activity and intra-articular forces during overhead work. Current devices typically employ a spring-based mechanism to balance the gravitational torque acting on the shoulder. As an alternative, this paper presents the design of a passive upper-limb exoskeleton based on McKibben artificial muscles. The interaction forces between the exoskeleton and the user, as well as the mechanical resistance of the exoskeleton structure, were investigated to finalize the design of the device prior to its prototyping. Details are provided about the solutions adopted to assemble, wear, and regulate the exoskeleton’s structure. The first version of the device weighing about 5.5 kg was manufactured and tested by two users in a motion analysis laboratory. The results of this study highlight that the exoskeleton can effectively reduce the activation level of shoulder muscles without affecting the lumbar strain. Full article

The back support exoskeletons have garnered significant attention to alleviate musculoskeletal injuries, prevalent in industrial settings. In this paper, we propose AeBS, a quasi-passive back-support exoskeleton developed to provide variable assistive torque across the entire range of hip joint motion, for tasks with frequent load changes. AeBS can adjust the assistive torque levels while minimizing energy for the torque variation without constraining the range of motion of the hip joint. To match the requisite assistance levels for back support, a compact variable gravity compensation module with reinforced elastic elements is applied to AeBS. Additionally, we devised a bio-inspired hip joint mechanism that mimics the configuration of the human hip axis to ensure the free body motion of the wearer, significantly affecting assistive torque transmission and wearing comfort. Benchtop testing showed that AeBS has a variable assistive torque range of 5.81 Nm (ranging from 1.23 to 7.04 Nm) across a targeted hip flexion range of 135°. Furthermore, a questionnaire survey revealed that the bio-inspired hip joint mechanism effectively facilitates the transmission of the intended assistive torque while enhancing wearer comfort. Full article