User-Centered Back-Support Exoskeleton: Design and Prototyping

Exhausting manual labor is still predominant in the industrial context. It typically consists in manipulating heavy parts or working in non-ergonomic conditions. The resulting work-related musculoskeletal disorders are a major problem to tackle. The most-affected body section is the the lumbar spine. Recently, exoskeletons have been identified as a possible non-invasive solution to reduce the impact of low-back pain. State-of-the-art prototypes have been optimized to: follow unconstrained human kinematics, (partially) relieve the load on assisted joints, and allow anthropometric adaptation. Yet, this technology still has limited adoption. Manufacturing optimization may address the following limitations: bulky/heavy resulting designs, complex assembly and maintenance, high manufacturing costs, long procedures for adaptation and wearing, and psychological effects (e.g., cognitive load and usability). In this contribution, the aforementioned issues are tackled improving a previous low-back exoskeleton prototype. In particular, kinematic analysis, Finite-Element-Method, and topological optimization have been combined to obtain a lightweight prototype, testing different materials (Nylon, carbon-fiber reinforced PC/ABS, etc.). We applied both Design for Assembly and Design for Manufacturability. The resulting exoskeleton prototype is described in the paper, ready for end-user field tests

SPEXOR passive spinal exoskeleton decreases metabolic cost during symmetric repetitive lifting

PURPOSE: Besides mechanical loading of the back, physiological strain is an important risk factor for low-back pain. Recently a passive exoskeleton (SPEXOR) has been developed to reduce loading on the low back. We aimed to assess the effect of this device on metabolic cost of repetitive lifting. To explain potential effects, we assessed kinematics, mechanical joint work, and back muscle activity. METHODS: We recruited ten male employees, working in the luggage handling department of an airline company and having ample experience with lifting tasks at work. Metabolic cost, kinematics, mechanical joint work and muscle activity were measured during a 5-min repetitive lifting task. Participants had to lift and lower a box of 10 kg from ankle height with and without the exoskeleton. RESULTS: Metabolic cost was significantly reduced by 18% when wearing the exoskeleton. Kinematics did not change significantly, while muscle activity decreased by up to 16%. The exoskeleton took over 18-25% of joint work at the hip and L5S1 joints. However, due to large variation in individual responses, we did not find a significant reduction of joint work around the individual joints. CONCLUSION: Wearing the SPEXOR exoskeleton decreased metabolic cost and might, therefore, reduce fatigue development and contribute to prevention of low-back pain during repetitive lifting tasks. Reduced metabolic cost can be explained by the exoskeleton substituting part of muscle work at the hip and L5S1 joints and consequently decreasing required back muscle activity

Design methodology of an active back-support exoskeleton with adaptable backbone-based kinematics

Abstract Manual labor is still strongly present in many industrial contexts (such as aerospace industry). Such operations commonly involve onerous tasks requiring to work in non-ergonomic conditions and to manipulate heavy parts. As a result, work-related musculoskeletal disorders are a major problem to tackle in workplace. In particular, back is one of the most affected regions. To solve such issue, many efforts have been made in the design and control of exoskeleton devices, relieving the human from the task load. Besides upper limbs and lower limbs exoskeletons, back-support exoskeletons have been also investigated, proposing both passive and active solutions. While passive solutions cannot empower the human's capabilities, common active devices are rigid, without the possibility to track the human's spine kinematics while executing the task. The here proposed paper describes a methodology to design an active back-support exoskeleton with backbone-based kinematics. On the basis of the (easily implementable) scissor hinge mechanism, a one-degree of freedom device has been designed. In particular, the resulting device allows tracking the motion of a reference vertebra, i.e., the vertebrae in the correspondence of the connection between the scissor hinge mechanism and the back of the operator. Therefore, the proposed device is capable to adapt to the human posture, guaranteeing the support while relieving the person from the task load. In addition, the proposed mechanism can be easily optimized and realized for different subjects, involving a subject-based design procedure, making possible to adapt its kinematics to track the spine motion of the specific user. A prototype of the proposed device has been 3D-printed to show the achieved kinematics. Preliminary tests for discomfort evaluation show the potential of the proposed methodology, foreseeing extensive subjects-based optimization, realization and testing of the device

Back-Support Exoskeletons for Occupational Use: An Overview of Technological Advances and Trends

OCCUPATIONAL APPLICATIONSMany new occupational back-support exoskeletons have been developed in the past few years both as research prototypes and as commercial products. These devices are intended..