An Occupational Shoulder Exoskeleton Reduces Muscle Activity and Fatigue During Overhead Work

Design and evaluation of AE4W: An active and flexible shaft-driven shoulder exoskeleton for workers

The wide adoption of occupational shoulder exoskeletons in industrial settings remains limited. Passive exoskeletons were proved effective in a limited amount of application scenarios, such as (quasi-)static overhead handling tasks. Quasi-active devices, albeit representing an improved version of their passive predecessors, do not allow full modulation of the amount of assistance delivered to the user, lacking versatility and adaptability in assisting various dynamic tasks. Active occupational shoulder exoskeletons could overcome these limitations by controlling the shape of the delivered torque profile according to the task they aim to assist. However, most existing active devices lack compactness and wearability. This prevents their implementation in working environments. In this work, we present a new active shoulder exoskeleton, named Active Exo4Work (AE4W). It features a new flexible shaft-driven remote actuation unit that allows the positioning of the motors close to the wearer's center of mass while it maintains a kinematic structure that is compatible with the biological motion of the shoulder joint. in vitro and in vivo experiments have been conducted to investigate the performance of AE4W. Experimental results show that the exoskeleton is kinematically compatible with the user's workspace since it does not constrain the natural range of motion of the shoulder joint. Moreover, this device can effectively provide different types of assistance while the user executes various dynamic tasks, without altering perceived comfort.

A Novel Passive Occupational Shoulder Exoskeleton With Adjustable Peak Assistive Torque Angle for Overhead Tasks

OBJECTIVE

Overhead tasks are a primary inducement to work-related musculoskeletal disorders. Aiming to reduce shoulder physical loads, passive shoulder exoskeletons are increasingly prevalent in the industry due to their lightweight, affordability, and effectiveness. However, they can only handle specific tasks and struggle to balance compactness with a sufficient range of motion effectively.

METHOD

We proposed a novel passive occupational shoulder exoskeleton designed to handle various overhead tasks at different arm elevation angles, ensuring sufficient ROM while maintaining compactness. By formulating kinematic models and simulations, an ergonomic shoulder structure was developed. Then, we presented a torque generator equipped with an adjustable peak assistive torque angle to switch between low and high assistance phases through a passive clutch mechanism. Ten healthy participants were recruited to validate its functionality by performing the screwing task.

RESULTS

Measured range of motion results demonstrated that the exoskeleton can ensure a sufficient ROM in both sagittal (164) and horizontal (158) flexion/extension movements. The experimental results of the screwing task showed that the exoskeleton could reduce muscle activation (up to 49.6), perceived effort and frustration, and provide an improved user experience (scored 79.7 out of 100).

CONCLUSION

These results indicate that the proposed exoskeleton can guarantee natural movements and provide efficient assistance during overhead work, and thus have the potential to reduce the risk of musculoskeletal disorders.

SIGNIFICANCE

The proposed exoskeleton provides insights into multi-task adaptability and efficient assistance, highlighting the potential for expanding the application of exoskeletons.

Evaluating Exoskeletons for WMSD Prevention: A Systematic Review of Applications and Ergonomic Approach in Occupational Settings

This review provides a comprehensive analysis of studies investigating the impact of occupational exoskeletons on work-related musculoskeletal disorder (WMSD) risk factors. The primary objective is to examine the methodologies used to assess the effectiveness of these devices across various occupational tasks. A systematic review was conducted following the PRISMA guidelines, covering studies published between 2014 and 2024. A total of 49 studies were included, identified through searches conducted in Scopus and Web of Science databases, with the search string launched in August 2024. The review identifies a growing body of research on passive and active exoskeletons, with a notable focus on laboratory-based evaluations. The results indicate that direct measurement and self-report methods are the preferred approaches in these domains. Ergonomic limitations and user discomfort remain concerns in some cases. The findings of this review may influence stakeholders by providing insights into the potential benefits of adopting exoskeletons and improving workplace ergonomics to reduce WMSD risks. Additionally, the identification of WMSD assessment methods will be valuable for validating the use of these technologies in the workplace. The review concludes with recommendations for future research, emphasizing the need for more real-world assessments and improved exoskeleton designs to enhance user comfort and efficacy.

The Use of Wearable Systems for Assessing Work-Related Risks Related to the Musculoskeletal System-A Systematic Review

Work-related musculoskeletal disorders (WRMSDs) are a leading cause of chronic conditions among working-age adults. Preventing these disorders is crucial to reducing their impact, and quantitative analysis through sensors can help identify their causes and guide ergonomic solutions. This systematic review aims to compile research from 2000 to 2023 published in English and sourced from Web of Science, Scopus, or PubMed that examines workers' movements during tasks using wearable sensor systems that are applicable in workplace settings. The goal is to identify the job sectors that have been studied and highlight tasks lacking ergonomic risk research. A total of 111 papers were selected through a screening process across three databases, assessed using the McMaster risk of bias tool. The studies span various job sectors and report on the use of different technologies for data collection and study population sizes. The review identifies existing research on WRMSD risks utilizing wearable systems in different job sectors, drawing attention to under-researched areas that warrant further study. It serves as a foundation for future research aimed at understanding the causes of WRMSDs and developing solutions supported by wearable technologies to mitigate these risks.

Changes in Neck and Shoulder Muscles Fatigue Threshold When Using a Passive Head/Neck Supporting Exoskeleton During Repetitive Overhead Tasks

OBJECTIVE

This study aimed to investigate the effects of a head/neck supporting exoskeleton (HNSE) on the electromyographic fatigue threshold (EMGFT) of the neck and shoulder muscles during a simulated overhead work task.

BACKGROUND

Overhead work is a well-known risk factor for neck and shoulder musculoskeletal disorders due to the excessive strain imposed on the muscles and joints in these regions.

METHOD

Fourteen healthy males performed a repetitive overhead nut fastening/unfastening task to exhaustion while wearing and not wearing the HNSE at two neck extension angles (40% and 80% of neck maximum range of motion). Electromyographic signals were continuously recorded from the right and left sternocleidomastoid (SCMR, SCML), splenius capitis (SCR, SCL), upper trapezius (UTR, UTL), and anterior deltoid (ADR, ADL) muscles. The normalized electromyographic amplitude (nEMG) data was time normalized, and a bisegmental linear regression was applied to determine the muscle fatigue break point.

RESULTS

The results showed a significant increase in fatigue threshold time in the SCMR (p < .001), SCML (p = .002), and UTR (p = .037) muscles when the HNSE was used. However, the EMGFT times for the right and left deltoid and left trapezius muscles showed a nonsignificant reduction due to the head/neck support exoskeleton use. In addition, the neck extension angle did not reveal a significant effect on muscles' EMGFT time.

CONCLUSION

Overall, the findings confirmed a significant delay in fatigue onset in sternocleidomastoid muscles, as measured by the electromyographic fatigue threshold. This finding suggests that the HNSE can be an effective ergonomic intervention for reducing the risk of musculoskeletal disorders in overhead workers. However, further studies are needed to investigate the effect of the HNSE at other neck extension angles and more realistic tasks to ensure the generalizability of our results.

APPLICATION

The present findings emphasize the application of the fatigue onset time to evaluate the effectiveness of ergonomic interventions, including exoskeletons, which can subsequently be utilized to alleviate postural demands and reduce the risk of musculoskeletal disorders.

A comparative study of biomechanical assessments in laboratory and field settings for manual material handling tasks using extractor tools and exoskeletons

To enhance physical capabilities of workers who regularly perform physically demanding tasks involving heavy lifting and awkward postures, various tools and occupational exoskeletons can be used. Most of the studies aiming to explore the efficiency of these tools and exoskeletons have been performed in confined and controlled laboratory spaces, which do not represent the real-world work environment. This study aimed to compare the outcome of biomechanical assessment of using a back support exoskeleton and assistive tools (Lever and Jake) in the procedure of a high demanding manual material handling task versus the results found by performing the same task in a laboratory. Ten able-bodied participants and ten able-bodied utility workers performed the same manhole removal task in-lab and in-field, respectively, with the aid of an exoskeleton and Lever and Jake tools. Muscle activity and Rapid Entire Body Assessment (REBA) scores were recorded using surface electromyography and inertial measurement units, respectively and compared between in-lab and in-field trials. The field experiments indicated significant differences (p < 0.05) in normalized muscle activity across most muscles when compared to laboratory data. These results revealed how muscle activity is affected by the controlled lab setting compared to real-world field conditions. However, REBA scores indicate similar ergonomic implications regardless of the utilization of exoskeletons or tools. These findings underscore that real-world field assessments are crucial for evaluating ergonomic risks and effects of occupational exoskeletons and tools to account for environmental factors and workers' skills in ergonomic evaluations of this nature.

A Novel Passive Shoulder Exoskeleton Using Link Chains and Magnetic Spring Joints

Work-related musculoskeletal disorders represent a major occupational disability issue, and 53.4% of these disorders occur in the back or shoulders. Various types of passive shoulder exoskeletons have been introduced to support the weight of the upper arm and work tools during overhead work, thereby preventing injuries and improving the work environment. The general passive shoulder exoskeleton is constructed with rigid links and joints to implement shoulder rotation, but there exists a challenge to align with the flexible joint movements of the human shoulder. Also, a force-generating part using mechanical springs require additional mechanical components to generate torque similar to the shoulder joint, resulting in increased overall volume and inertia to the upper arm. In this study, we propose a new type of passive shoulder exoskeleton that uses magnetic spring joint and link chain. The redundant degrees of freedom in the link chains enables to follow the shoulder joint movement in the horizontal direction, and the magnetic spring joint generates torque without additional parts in a compact form. Conventional exoskeletons experience a loss in the assisting torque when the center of shoulder rotation changed during arm elevation. Our exoskeleton minimizes the torque loss by customizing the installation height and initial angle of the magnetic spring joint. The performances of the proposed exoskeleton were verified by an electromyographic evaluation of shoulder-related muscles in overhead work and box lifting task.

Influence of an upper limb exoskeleton on muscle activity during various construction and manufacturing tasks

Musculoskeletal disorders (MSDs) significantly impact workers in the manufacturing and construction sectors. One solution that has gained interest to reduce MSDs incidence is the use of exoskeletons. In this study, the influence of an upper limb exoskeleton on muscle activity was investigated experimentally for three commonly performed tasks in the manufacturing and construction sectors. The tasks tested were overhead assembly, bricklaying, and box moving tasks. Eighteen males participated in the tests. The results showed a reduction in shoulder flexor muscle activation during all three tasks (up to -45.46 ± 4.52% for the anterior deltoid), but increased extensor activation (up to 15.47 ± 8.01% for the latissimus dorsi) was observed when the task was not primarily performed above shoulder level. The results revealed the dependence of the upper-body exoskeleton on tasks and arm posture, which should be considered for both in-field applications and designing new exoskeletons for performance enhancement.

Design of a Novel Exoskeleton with Passive Magnetic Spring Self-locking and Spine Lateral Balancing

This paper proposes a new upper-limb exoskeleton to reduce worker physical strain. The proposed design is based on a novel PRRRP (P-Prismatic; R-Revolute) kinematic chain with 5 passive Degrees of Freedom (DoF). Utilizing a magnetic spring, the proposed mechanism includes a specially designed locking mechanism that maintains any desired task posture. The proposed exoskeleton incorporates a balancing mechanism to alleviate discomfort and spinal torsional effects also helping in limb weight relief. This paper reports specific models and simulations to demonstrate the feasibility and effectiveness of the proposed design. An experimental characterization is performed to validate the performance of the mechanism in terms of forces and physical strain during a specific application consisting of ceiling-surface drilling tasks. The obtained results preliminarily validate the engineering feasibility and effectiveness of the proposed exoskeleton in the intended operation task thereby requiring the user to exert significantly less force than when not wearing it.

Simulation of passive exotendon assistive device for agricultural harvesting task

This study proposes and investigates the feasibility of the passive assistive device to assist agricultural harvesting task and reduce the Musculoskeletal Disorder (MSD) risk of harvesters using computational musculoskeletal modelling and simulations. Several passive assistive devices comprised of elastic exotendon, which acts in parallel with different back muscles (rectus abdominis, longissimus, and iliocostalis), were designed and modelled. These passive assistive devices were integrated individually into the musculoskeletal model to provide passive support for the harvesting task. The muscle activation, muscle force, and joint moment were computed with biomechanical simulations for unassisted and assisted motions. The simulation results demonstrated that passive assistive devices reduced muscle activation, muscle force, and joint moment, particularly when the devices were attached to the iliocostalis and rectus abdominis. It was also discovered that assisting the longissimus muscle can alleviate the workload by distributing a portion of it to the rectus abdominis. The findings in this study support the feasibility of adopting passive assistive devices to reduce the MSD risk of the harvesters during agricultural harvesting. These findings can provide valuable insights to the engineers and designers of physical assistive devices on which muscle(s) to assist during agricultural harvesting.

Exoskeletons: Contribution to Occupational Health and Safety

This review aims to characterize the current landscape of exoskeletons designed to promote medical care and occupational safety in industrial settings. Extensive exploration of scientific databases spanning industries, health, and medicine informs the classification of exoskeletons according to their distinctive attributes and specific footholds on the human physique. Within the scope of this review, a comprehensive analysis is presented, contextualizing the integration of exoskeletons based on different work activities. The reviewers extracted the most relevant articles published between 2008 and 2023 from IEEE, Proquest, PubMed, Science Direct, Scopus, Web of Science, and other databases. In this review, the PRISMA-ScR checklist was used, and a Cohen's kappa coefficient of 0.642 was applied, implying moderate agreement among the reviewers; 75 primary studies were extracted from a total of 344. The future of exoskeletons in contributing to occupational health and safety will depend on continued collaboration between researchers, designers, healthcare professionals, and industries. With the continued development of technologies and an increasing understanding of how these devices interact with the human body, exoskeletons will likely remain valuable for improving working conditions and safety in various work environments.

Integrating Exosuit Capabilities into Clothing to Make Back Relief Accessible to Workers Unserved by Existing Exoskeletons: Design and Preliminary Evaluation

OCCUPATIONAL APPLICATIONSWe developed a method for integrating back-assist exosuit capabilities into regular clothing to make musculoskeletal relief accessible to more workers. We demonstrated proof-of-concept that this uniform-integrated exosuit can be effective and usable. Existing occupational exosuits are standalone accessories worn on top of a user's clothing and are not suitable for all workers. Our newly developed sub-class of exosuit could be beneficial to workers who alternate between bending, lifting, and sitting tasks, or to those in customer- or patient-facing jobs where it is important for wearable technology to be discreet.

Quality, productivity, and economic implications of exoskeletons for occupational use: A systematic review

The objective of this systematic review was to synthesize the current state of knowledge on the quality and productivity of workers and their work while wearing exoskeletons, as well as the economic implications of exoskeletons for occupational use. Following the PRISMA guidelines, six databases were systematically searched for relevant journal articles, written in English, and published since January 2000. Articles meeting the inclusion criteria had their quality assessed using JBI's Checklist for Quasi-Experimental Studies (Non-Randomized Experimental Studies). A total of 6,722 articles were identified and 15 articles focusing on the impact of exoskeletons on quality and productivity of exoskeleton users while performing occupational tasks were included in this study. None of the included articles evaluated the economic implications of exoskeletons for occupational use. This study revealed several quality and productivity measures (e.g., endurance time, task completion time, number of errors, number of task cycles completed) used to evaluate the impact of exoskeletons. The current state of the literature suggests that quality and productivity impacts of exoskeleton use are dependent on task characteristics that should be considered when adopting exoskeletons. Future studies should evaluate the impact of exoskeleton use in the field and on a diverse pool of workers, as well as its economic implications to better support decision-making in the adoption of exoskeletons within organizations.

Biomechanical Assessments of the Upper Limb for Determining Fatigue, Strain and Effort from the Laboratory to the Industrial Working Place: A Systematic Review

Recent human-centered developments in the industrial field (Industry 5.0) lead companies and stakeholders to ensure the wellbeing of their workers with assessments of upper limb performance in the workplace, with the aim of reducing work-related diseases and improving awareness of the physical status of workers, by assessing motor performance, fatigue, strain and effort. Such approaches are usually developed in laboratories and only at times they are translated to on-field applications; few studies summarized common practices for the assessments. Therefore, our aim is to review the current state-of-the-art approaches used for the assessment of fatigue, strain and effort in working scenarios and to analyze in detail the differences between studies that take place in the laboratory and in the workplace, in order to give insights on future trends and directions. A systematic review of the studies aimed at evaluating the motor performance, fatigue, strain and effort of the upper limb targeting working scenarios is presented. A total of 1375 articles were found in scientific databases and 288 were analyzed. About half of the scientific articles are focused on laboratory pilot studies investigating effort and fatigue in laboratories, while the other half are set in working places. Our results showed that assessing upper limb biomechanics is quite common in the field, but it is mostly performed with instrumental assessments in laboratory studies, while questionnaires and scales are preferred in working places. Future directions may be oriented towards multi-domain approaches able to exploit the potential of combined analyses, exploitation of instrumental approaches in workplace, targeting a wider range of people and implementing more structured trials to translate pilot studies to real practice.

Development and Experimental Validation of a Passive Exoskeletal Vest

Passive upper limb exoskeletons are often designed to relieve muscle fatigue of manufacturing workers. Existing exoskeletons often provide partial assistance, and their assistive torque is only affected by elastic elements and mechanisms, which, however, are not sufficient because of the changing load of the shoulder joint due to the motion of the elbow and the weight of various tools. To improve the assistive effect without affecting the free movement of the arm, a passive exoskeletal vest has been designed. This exoskeleton has two operating states which can be switched using a unique ratchet bar mechanism. The upper arm can be locked at any vertical position when engaged. The assistive torque is determined by the load. The arm also can move freely without any resistance when separated. Seven subjects participated in the evaluation experiment, who performed static tasks, precision tasks, and dynamic tasks. The experimental data demonstrate that (1) the exoskeleton can effectively reduce the activation level of related muscles at a variety of tasks. (2) The accuracy and stability of the arm during heavy work are not affected. (3) The exoskeleton has a minimal restriction on the range of motion of the arm. (4) the comfort and portability achieved a high score of 8 (1-10) from subjective measures. The experimental results further revealed that the designed exoskeletal vest could effectively relieve the shoulder burden, where it does not impede or restrain the arms movements.