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Procedia CIRP 00 (2020) 000–000
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Procedia CIRP 00 (2020) 000–000
Procedia CIRP 00 (2017)
Procedia 000–000
CIRP 91 (2020) 243–248
www.elsevier.com/locate/procedia
30th CIRP Design 2020 (CIRP Design 2020)
30th CIRP Design 2020 (CIRP Design 2020)
Enhancement of human-centered workplace design and
Enhancement 28th CIRPofDesign
optimization human-centered
with Exoskeleton
Conference, Mayworkplace
2018,technology
Nantes, Francedesign and
optimization with Exoskeletona technology a, c
A new methodology
Daniele Ippolito to analyze *, Carmen theConstantinescu
functional ,and Claudiuphysical
Alin Rusu architecture of
a, b,

Daniele Ippolito
existing Graduate
products for an
a, b,
*, Carmen
assembly
Fraunhofer Constantinescu
12, Stuttgart 70569,,Germany
oriented
IAO, Nobelstraße
a a
Claudiufamily
product Alin Rusu a, c
identification
School of Excellence advanced Manufacturing Engineering, University of Stuttgart, Nobelstraße 12, Stuttgart
b
a
70569, Germany
Fraunhofer IAO, Nobelstraße 12, Stuttgart 70569, Germany
Technical
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
School ofUniversity
Excellenceofadvanced
Cluj-Napoca, Strada Memorandumului 28, Cluj-Napoca 400114, Romania12, Stuttgart
c
Graduate
b
Manufacturing Engineering, University of Stuttgart, Nobelstraße
70569, Germany
c
Technical University of Cluj-Napoca, Strada Memorandumului 28, Cluj-Napoca 400114, Romania
Écoleauthor.
* Corresponding Nationale
Tel.:Supérieure d’Arts et
+49711970-2289; Métiers,
E-mail Arts et
address: Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
daniele.ippolito@iao.fraunhofer.com

* Corresponding author. Tel.: +49711970-2289; E-mail address: daniele.ippolito@iao.fraunhofer.com


* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Abstract

Abstract
The employment of intelligent tools in production, such as the new area of wearable robotics, the Exoskeletons, represents valuable and promising
Abstract
technology to reduce the physical stress and increase innovation, productivity and workplace safety. The challenge of realizing these advanced
The employment
manufacturing of intelligentwith
environments toolsintegrated
in production, such as theisnew
Exoskeletons area of wearable
represented robotics,
by missing designtheand
Exoskeletons, representsrequired
planning methods valuabletoand promising
equip future
Intechnology
workplaces to
today’s business reduce
with this the physical
environment,
enabling stress
the trendand
technology. increase
towards
The innovation,
more
integration product productivity
variety
of Exoskeletons and workplace
andincustomization
logistics and is safety.
unbroken.
production Theactivities
challenge
Due to this ofdevelopment,
realizing
creates a new these theadvanced
hybrid need of
type of
manufacturing
workstation
agile thatenvironments
and reconfigurable with integrated
has to beproduction
designed according Exoskeletons
to
systems emerged a scientific
to cope is with
represented
approach. by
The article
various missing
presents
products anddesign andsteps
the first
product planning methods
in developing
families. To designan required
and to equip
innovative
optimize approachfuture
productionto
workplaces
planning
systems as and with
well asthis
optimizingenabling
to choose thetechnology.
intelligent working
optimal The integration
matches, of
environments
product withExoskeletons
product integrated in logistics
analysisadaptive
methods areand production
Exoskeletons.
needed. The activities
Indeed, topic ofcreates
mostharmonizes a three
the known newmethods
hybrid type
aim of
main areas to
workstation
research: a) that has
production to be designed
technologies according
and to
holistic a scientific
planning approach.
of production The article
processes; presents
b) the first
ergonomics, steps in
safety
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and developing
and security an
of innovative
workers inapproach
productionto
planning and and
environments optimizing intelligentbased
c) configuration working
on environments withthe integrated adaptive Exoskeletons. the The topic harmonizes three main areas of
nature of components. This fact impedes anthe components
efficient of
comparison new
and type
choiceof wearable robotics,
of appropriate product Exoskeletons.
family combinations for the production
research:
The a) production
validation technologies
of this approach and holistic
is provided through planning of production
the creation of digital processes; b) ergonomics,
human/Exoskeleton modelssafety and security
combining of workers inwith
digital Exoskeleton production
various
system. A new and
environments methodology is proposed to
c) configuration analyze existing ofproducts intype
viewofof their functional and physical architecture. The aim is to cluster
digital human models. The Digital based Twin on the human/Exoskeleton
of the components the newsystem wearable
is the heart ofrobotics, thedesign
a holistic Exoskeletons.
and optimization process that aims to
these
The products
validation inofnew
thisassembly
approach oriented product families for the of optimization of existing assembly lines and the creation of future reconfigurable
assess the appropriateness of theisselected
provided through
Exoskeleton theby
creation
simulating digital human/Exoskeleton
the tasks models
performed and adapting combining
the simulationdigital Exoskeleton
parameters. with various
assembly
digital
An systems.
human models.
exemplary Based
validation on
ThecaseDatum
Digital
in oneFlow
Twin Chain,
of of
thethe
most the physical
human/Exoskeleton structure
innovative and dynamic of the
system is products
the heart
sector, is analyzed. Functional
of a holistic design
the construction sector, and subassemblies
optimization
demonstrates are identified,
the process of and
that aims
applicability to
the
a model.
functional
assess the analysis is
appropriateness performed.
of the Moreover,
selected a
Exoskeletonhybrid byfunctional
simulating
A guideline for migrate the model in other industry sectors is provided, as well. and
the physical
tasks architecture
performed and graph
adapting (HyFPAG)
the simulationis the output
parameters. which depicts the
similarity
An exemplarybetween productcase
validation families
in onebyofproviding design support
the most innovative to both, sector,
and dynamic production system planners
the construction sector,and product designers.
demonstrates An illustrative
the applicability of the
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a first of the CIRP Design Conference 2020 approach.
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©2020 The Authors.
Authors. Published
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by Elsevier
Elsevier
outB.V.
B.
to give
V.
industrial evaluation of the proposed
©This
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is an open accessPublished
article underby Elsevier B.V.
thescientific
CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under responsibility of the committee of the CIRPCIRP Design Conference 2020 2018.
Peer-reviewunder underresponsibility
responsibilityofofthe thescientific
scientificcommittee
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CIRP Design Design Conference
Conference 2020
Keywords: Exoskeleton technology; Design and Planning Methodology
Keywords: Assembly; Design method; Family identification
Keywords: Exoskeleton technology; Design and Planning Methodology
1. Problem Statement many factories are integrating Exoskeletons into their assembly
and production lines and logistics processes with the aim of
1.1.Introduction
Problem Statement ofmany
reducingfactories
the product are integrating
range
physical and Exoskeletons
characteristics
stress and increasing into their
manufactured assembly
and/or
innovation,
According to the latest statistics of the European Survey on and production lines and logistics processes with the aim of
Working Conditions (ESWC), 43% of the European workers productivity
assembled in and
this safety.
system. The
In implementation
this context, the of
main Exoskeleton
challenge in
According
Due to theto the
fastlatest statistics
development of thein European
the Survey
domain on
of reducing physical
technology is expanding stressintoand the increasing construction,
industrial, innovation,
complain of back pain, followed by muscular pains in the neck modelling and analysis is now not only to cope with single
productivity
logistics and safety. fields,
The implementation of ofExoskeleton
Working
or upper Conditions
communication limbs and (42%), (ESWC),
an overall
ongoing 43% of the
trend
fatigue ofEuropean
(35%) digitizationworkers
and muscular and products, aand healthcare
limited product rangewith the purpose
or existing product providing
families,
complain of back pain, followed by muscular pains in the neck technology
adequate is expanding
equipment to into
prevent the
the industrial,
musculoskeletal construction,
disorders
digitalization, manufacturing enterprises are
disorders in the hip or lower limbs (29%) [1]. In recent years, facing important but also to be able to analyze and to compare products to define
or upper limbs (42%), overall fatigue (35%) and muscular logistics which
(MSDs) and healthcare
workers fields,
can be with the purpose
vulnerable and of ensure
to providing the
challenges in today’s market environments:
manufacturing companies, especially car manufactures, are a continuing new product families. It can be observed that classical existing
disorders in the hip or lower limbs (29%) [1]. In recent years, adequate equipment
flexibility required to prevent
by production the musculoskeletal
processes [6, 7,disorders
8]. The
tendency towards reduction of product development
investing in increasing the flexibility of the production times and product families are regrouped in function of clients or features.
(MSDs) Social
German which Accident
workers can be vulnerable and
Insurance to ensure the
manufacturing
shortened
processesproduct
and in companies,
preventingespecially
lifecycles. Inthe
addition, car
workers´ manufactures,
there [2, 3, are
is an increasing
health 4]. However, assembly oriented product (DGUV)
families arereported
hardlyinto2013
find.
investing ina complete
increasingautomation
the flexibility
that the required
investment by production
in improving processes
workingdiffer [6,
conditions 7, 8]. The
through
demand
Solutions of as
customization, beingflexibility
at of of time
theproduction
same theprocesses
production
in a global do On
German the product
Social family
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Insurance products
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with incompetitors
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of flexibility, especiallyhealth
the world. [2,lot3,
This
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sizes preventive
main measures(i)
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Solutions as a complete that the
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[9]. The
which
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markets,
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[5].due if the
Fortothese lot sizes
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Classical Exoskeleton
methodologies technology
considering inmainly
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singledesign and
products
are too small, production variability is too high and/or with a coefficient of 1,445 in manufacturing industries [9]. The
product
2212-8271
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production) [1].
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Peer-review under responsibility of the scientific committee of the CIRP Design Conference 2020
identify
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© 2020 The optimization
Authors. Publishedpotentials in the existing
by Elsevier B.V. causes difficulties regarding an efficient definition and
Peer-review under
production system,responsibility of the scientific
it is important to havecommittee of the
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knowledge comparison2020 of different product families. Addressing this

2212-8271 © 2020 The Authors. Published by Elsevier B.V.


This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th CIRP Design
Design Conference
Conference 2020
2018.
10.1016/j.procir.2020.02.173
D. Ippolito, C. Constantinescu, C. A. Rusu / Procedia CIRP 00 (2020) 000–000
244 Daniele Ippolito et al. / Procedia CIRP 91 (2020) 243–248
2

optimization should be preceded by improvements with standard for Ergonomics – ISO (International Standardization
classical Industrial Engineering solution. If the modification of Organization) 6385:2016 that introduces the fundamental
the existing workplace layout or the design of a new layout, principles of ergonomics as base guides for the work systems
based on a classical Industrial Engineering solution, will not design, where experts in ergonomics will cooperate with
enhance the ergonomics parameters of the workplace, an designers, engineers and technical staff to balance the
Exoskeleton technology integration must be taken into efficiency and ergonomic proprieties of the factory [10].
consideration. The Exoskeleton implementation establishes a
new workplace layout design and a new production planning. 1.2 Ethical, Legal and Social Aspects of the Exoskeleton
The challenge of implementing Exoskeletons in the working technology
environment is to employ suitable design and planning methods
needed to equip future workplaces with Exoskeleton enabling A possible barrier to the Exoskeleton technology
technology. implementation is the lack of clarity of rules and regulations
that protect the workers from being dehumanized and
overworked. Such complex issues of human Ethics and lack of
1.1. Challenge of design and optimization workplaces with
regularizations address the following aspects [11]: 1) Workers
Exoskeleton technology
Privacy: smart Exoskeletons can collect data from users, for
product feedback and/or health monitoring. Location
Workers are key factors for flexibility and productivity in
information, usage information, neural input information, vital
European industry. The industrial, construction, logistics and
data and other private information relating to the worker are
healthcare workplaces are often characterized by manual
collected as well; 2) Workers Compensation: Wearing the
material handing tasks (MMH), hazardous conditions,
Exoskeletons in working environments can lead to small or
uncomfortable postures and high vibration levels, and require significant injuries and it is not defined if the employer, the
a high level of flexibility that can only be achieved through the
Exoskeleton producer or the Insurance will compensate them;
use of workers. The tasks that characterize these workplaces,
3) Workers’ rights: Currently many workers have several
in addition to requiring high physical efforts, require increased
rights that limit their working hours. It is not regulated if
cognitive efforts to maintain sustained levels of vigilance that
Exoskeletons may change the work time and whether
lead to higher levels of mental fatigue. Such working
compensation may be different for workers that use the
conditions have a negative impact on workers and workplaces, technology than for those that do not use it.
and contribute to reduce the optimal health and the
At the same time some 4) Social concern must be monitored
productivity conditions. These difficulties can be overcome by
and continuously analyzed. In detail this aspects concern the
combining the flexibility, precision and intelligence of workers
Access to Exoskeleton technology: high costs of Exoskeleton
with the high resistance of Exoskeletons.
technology can represent an entry barrier for countries,
In manufacturing environments different types of
industries or companies with limited financial resources,
workstations, which range from fully manual to fully
creating the so-called “discrimination of access”.
automated can be defined. With the increasing implementation
of Exoskeleton technology in industry, a methodology must be
2. Requirements and hypothesis for holistic design and
developed in order to design hybrid workstation layouts. A
optimization of Exoskeleton - integrated workplaces
hybrid workplace is a new type of workplace in which the
workers are performing their tasks wearing an Exoskeleton.
The hybrid workplace will be characterized by the intelligence, For an efficient industrial Exoskeleton integration in the
precision and flexibility of the workers and the high strength workplace some specific aspects of the environment, motions
and resistance of the Exoskeleton. and actions, that the worker must realize, have to be studied.
The research group aims to design, implement and validate
an innovative approach for the design, planning and Exoskeleton technology suits the needs for workplaces
optimization of intelligent working environments with where the ergonomics cannot be improved through traditional
integrated Exoskeletons. The vision of this work is to support means, where the motions and tasks done by the operative
the design and planning of a workplace with a new affects specific body area that can be supported by the device
methodology that allows the integration of Exoskeletons as a (e.g. upper body, lower back). Analogously, where the
new production resource or work tool to overcome major automation of the process is inefficient or impossible due to the
ergonomic issues in the manipulation of heavy parts. A environment or the nature of the workplace (e.g. mobile units,
working environment design, which focuses on the worker and short lot manufacturing) an Exoskeleton technology integration
his ergonomics´ needs, has to ensure the absence of alienation should take place. Design of workplaces characterized by
by the workers. One aspect that should not be underestimated manual material and parts handing tasks and which integrate
is the attitude that the worker takes towards this working tool. Exoskeletons should consider the following aspects: a)
A correct implementation of the Exoskeleton in the working workplace ergonomics; b) worker motivation and
environment must ensure that the worker accepts positively its concentration capacity; c) process quality; d) ethical, social and
integration and perceives autonomously the benefits that the legal aspects; e) working environment characteristics.
Exoskeleton introduces. This last aspect is fundamental in order to identify which
As the augmentation devices are becoming a common type of Exoskeleton can be used in a particular working
concept in the industries certain standards of quality and environment and which operations and precautions the worker
security of the workplace must be conceived and implemented must have in order to take the best care of the device.
in the fields that are affected by the new wave of technology. It is necessary to check whether the workplace is in an
A good representation of such standards is the International
D. Ippolito, C. Constantinescu, C. A. Rusu / Procedia CIRP 00 (2020) 000–000
Daniele Ippolito et al. / Procedia CIRP 91 (2020) 243–248 245
3

Fig.1: © Exo4Ergo enhancement: Holistic planning methodology overview

enclosed or external environment, which kind of chemical 3.1 Exo4Ergo phase’s description
agents and materials are used or present in the environment.
For example, active Exoskeletons, that are equipped with 1) The classification of the manufacturing operations and
electronic boards, electric motors and batteries, can risk serious logistic tasks, such as lifting, lowering, manipulating, carrying,
failures if introduced in outdoor environments. In the assembling, connecting screwing, drilling etc., and the
construction and agriculture industry, dirt and dust can remain identification of the product and the working tools features,
on the device and compromise the optimal functioning of it. such as volume, weight, material, ergonomicity of the grip etc.
Some of these aspects can be solved during the design phase or is done in the first phase. These information are collected and
by training workers to take care of their Exoskeleton. implemented in existing databases, called ExoData, developed
At the same time it is necessary that the workplace has a by a part of our research group, in order to detect any
specific layout in order to consider the storage location for similarities or novelties in the already analysed work
docking the Exoskeleton when it has to be wear/un-wear by the environments [13]. If there are significant differences between
worker. Each workstation must be equipped with a suit rack the new workstation and those already saved in the database,
capable to hold the Exoskeleton. If the Exoskeleton is active, the database will be updated with the new information.
the workplace have to be equipped with power sockets or with 2) The second phase of the methodology consists in
alternative solutions for recharging the batteries. The mapping the production processes, the work flow and the
integration of Exoskeletons in working activities induce ergonomics aspects. In the first case the processes times, such
additionally time that has to be recognized and taken in as the setup time, the cycle time, the frequency of the performed
consideration during the production planning. These times tasks, the recovery time between tasks and other timings are
consist in: a) wearing/un-wearing the Exoskeleton at the classified. For the ergonomics aspects, the layout of the
beginning and at the end of the shift, for breaks or for workplace will be measured and the body postures and the
physiological needs; b) setting initial Exoskeleton technical workflow will be identified.
parameters, such as reactivity, sensibility and support grade. 3) Based on the results of the previous phases, it is necessary
All these required times should be scientifically planned aiming to develop rapid ergonomic pre-analyses. These ergonomic
to optimize according to all other manual assembly or logistics analyses, such as the NIOSH, RULA and OWAS methods, etc.,
operation times, by increasing the ergonomics of the identify the body segments exposed to the most stress. This
workplace. phase is necessary to identify in the preliminary analysis
whether it is possible to improve the ergonomic conditions
3. Methodology for designing human-centered workplaces through classical Industrial Engineering solutions.
with integrated Exoskeletons 4) Once the most stressed body segment(s) has (have) been
determined, the focus is shifted to the evaluation of the
The methodology, shown in Figure 1, improves and working environment indicated in Paragraph 2. It is essential
enhances the approach named Exo4Ergo [12] developed in to analyze these characteristics in order to select an Exoskeleton
2018 and continued and financed by the Ministry of Research adaptable to the working conditions examined. If this equipment
and Education from Germany, under the project is not provided with adequate protection for certain working
Exo4LogiProd. Exo4Ergo studies in detail the worker environments, it cannot be selected in the next phases of the
ergonomic conditions during the execution of the tasks and the methodology.
working environment. The methodology consists of few 5) The information gathered during the previous phases, the
phases, presented in the next sub-paragraph. digital modeling and simulation of the “As it is” state can start.
D. Ippolito, C. Constantinescu, C. A. Rusu / Procedia CIRP 00 (2020) 000–000
246 Daniele Ippolito et al. / Procedia CIRP 91 (2020) 243–248
4

This fundamental phase involves the use of a Digital Twin The constraints that the device applies on the worker must be
to reproduce exactly and precisely the tasks performed in real correctly examined and the supports in terms of forces
workplaces. Through a careful modeling of the working efficiently evaluated.
environment, the simulation of the tasks carried out by the
workers is executed by the Digital Twin. The Digital Twin tool, To successfully perform this aspect the simulation phase
compared to the methods generally used in industry [14], will start and the motions and postures of the worker must be
enables us to monitor with precision each movement made by analyzed (stage b). In order to have an exact idea of how the
a worker. It is possible so to examine the impact that each worker interacts with this device, it is necessary to perform
movement has on a possible appearance of MSD. The software reliable experiments in the laboratory. These experiments,
used express results of the ergonomic state of the workstation conducted using Electromyography sensors EMG applied in the
and in particular the most stressed segments of the human body proximity of the most solicitous segments of the body and
can be identified. The difference between phase 5 and phase 2 identified previously, offer clear indications on the stress to
consists in the involvement of the Digital Twin, which provides which the musculoskeletal system is subjected. The sensors
the possibility to investigate in detail, in a digital environment capture the electric signal that the muscle release under the load.
which joint, muscles or skeletal parts are more stressed during The stage c of the process consists in the ergonomics analysis
the execution of the working task. The modelling and evaluation that highlight the effects of the technology on the
simulation phase in the digital environment is performed using workplace. This part is critical in the understanding of the
the following software: Classic Jack 9.0 – ©Siemens PLM deeper effects of the device on the human anatomy for short and
Software. Siemens Jack 9.0 is an independent product provided long term. Step d concerns the optimization of the
by Siemens PLM Software for Human Ergonomic Analysis humanoid/exoskeleton model. This step involves a verification
[15, 16]. and validation of the interactions between the worker and the
6) The selection of the Exoskeleton is then made by device.
inserting some filters and information obtained in the previous 8) The eighth phase of the methodology is to redefine or
phases, which allow to reduce the number of Exoskeletons modify the layout of the workstation, the additional time
selectable. The team uses a database developed in previous required, reported in Paragraph 2, and the instructions that
years that is called ExoMatch [13]. This system is equipped workers or companies must follow for the best use and care of
with equations that allow to give a score, based on different the device. Adequate instruction to the workers on the
parameters, to the Exoskeletons available, thus facilitating the Exoskeleton control, the setting of the setup parameters, the
choice of the team. care of the hygiene of the parts in contact with the worker's
7) In this phase the Digital Twin again fulfils a fundamental sweat and the cleaning of the mechanical parts of the device are
role. The digital models of the Exoskeletons can be coupled to provided in this phase.
the human model and act as in reality [17]. The digitization of 9) The final phase consists in the final integration of the
the "As it should be" condition allows to evaluate how the device into the workstation.
working space that the worker needs changes, what kind of
constraints and collisions occur when the worker wears the 3.2 Applicability of the method to a real workplace
device and the amount of physical support that the device offers
to the wearer. This phase of the methodology offers us a digital An exemplary validation case in the construction sector
validation of the Exoskeleton integration before the final demonstrates the applicability of the described method. The
introduction as a tool in the workplace. In practice, the Digital worker tasks consist in stabilizing the floor of a silos for the
Twin, wearing the selected Exoskeleton, is required to production of biogas in a waste-water treatment plant.
reproduce the simulated tasks, previously simulated in the “As Heavy stones with a weight of 20 kg and the following
it is” state. The new ergonomics analyses will be processed and dimensions (30 cm x 24 cm x 23 cm) have to be positioned on
compared with the previous ones. If this comparison shows that the floor (314𝑚𝑚2 ) as shown in Figure 2 (a) and (b). The process
the integrated Exoskeleton does not bring sufficient times for each individual operation last between 20 and 30
improvements, a new device, if available, will be selected from seconds, followed by 20/30 seconds of rest.
the database and new simulations will be performed in order to
determine the suitable Exoskeleton for the studied case.
Otherwise, if this comparison shows that the integrated
Exoskeleton provides satisfactory improvements of the
workers´ ergonomic conditions, the method moves on the final
recommendations phase, which expresses information on the
changes of the layout of the working environment, of the
production schedule, etc.
In case a new model of Exoskeleton goes out on the market Fig.2: © Exo4LogiProd: (a) Final assembly disposition;
or has to be integrated in the ExoMatch database, it is the (b) Working task.
research team´s task to identify all its features and update the
used database. To do this, an approach has been developed and These operations are repeated hundreds of times for the 8
shown in the center of Figure 1. The team started with the working hours. In the analysis step, based on the impossibility
concept of coupling the Exoskeleton to the humanoid, of establishing the precise number of repetition performed in a
generated in Human Jack, and to visualize the technology in day, the research team predicted that this task would be
the work environment (stage a) [17]. Once the coupling has repeated 400 times in a day considering 5 minute breaks for
been properly performed, it is essential to identify the each working hour and 30 minutes of lunch break. The digital
combined performance of the worker with the Exoskeleton. ergonomics analysis, obtained after the development of the "As
D. Ippolito, C. Constantinescu, C. A. Rusu / Procedia CIRP 00 (2020) 000–000
Daniele Ippolito et al. / Procedia CIRP 91 (2020) 243–248 247
5

it is" digital state, reveals that the most stressed human body regulations, have been identified, as shown in Figure 5. The
segments were the L4/L5 vertebrae, as shown in Figure 4. results presented in Figure 5 have been validated by
Based on these results a commercial active Exoskeleton experiments performed by the research group. The used tool
model has been selected and coupled on the Human Manikin and shown in Figures 4 (“As it is” state) and 5 (“As it should
as shown in Figure 3(a) and 3(b). be “state) is named Lower back analysis and gives the
possibility of evaluating spinal forces acting on the lower back
(skeletal part) and on the erector spinae muscles by using a
complex biomechanical low back model based on the NIOSH
methods [5]. Applying Electromyographic sensors (EMG) on
the body part that previously was identified as most stressed
and, wearing the commercial Exoskeleton selected in our
database, the working task was executed similarly in
laboratory.
To capture the stimuli of the erector spine muscles (muscles
near the lumbar vertebrae) the EMG sensors were applied as
shown in Figure 6(a). The activity of the muscle (measured in
microvolts) was directly related to the amount of muscle
contraction as well as the number of contracted muscles. When
the muscle contraction was stronger and implied a higher
number of activated muscles, the voltage amplitude raised.
Figure 7 shows a first difference between lifting and
Fig.3: Digital Twin of the hybrid human-Exoskeleton Worker (a) Back part; lowering the manipulated product. In addition, there is a
(b) Front part. © Fraunhofer IAO
difference between the stresses involved in performing the
operation without the Exoskeleton and with the commercial
The choice of this Exoskeleton is strongly based on the
Exoskeleton by configuring three different setup options.
analysis of the following parameters:
 the redesign of the workplace and the use of traditional
industrial engineering solutions, such as industrial
manipulators or Human-robot collaboration, was not
possible. The design of the silo is centred on the use of
it and cannot be redefined. The industrial manipulators
and the Human-robot collaboration cannot be installed
due to the complexity of the working environment;
 the body segments exposed to the greatest stress are
the lumbar vertebrae L4/L5. It is necessary to select an
Exoskeleton that supports this area of the body;
 the weight of the manipulated parts is 20kg. It is
necessary to select an active Exoskeleton since a
Fig.5: © Exo4LogiProd: Digitalization of the “As it should be” situation.
passive Exoskeleton, even if lighter, is not able to
provide enough support to bring the physical stress
The lifting task, executed with the selected Exoskeleton,
revealed through the Lower Back analysis instrument
compared to lifting task without it, leads to a 58% reduction in
within the safety regulation from MSD;
muscle activity. For the average values, a 27% reduction in
 the supplier of such Exoskeletons is located in the muscle activity is shown. The resulting data were centralized
vicinity of the user company. This aspect facilitates the and analyzed by comparing the usual transport, lifting and
contact and the opportunity of counselling by the two flexion effort to the reduced stress of the device, and the setting
actors; used for the Exoskeleton controller as the physical capacity of
 the supplier of such an Exoskeleton has solid the subject was taken into account. The results from the lab
experience in this field. were also detected in the ergonomic analysis performed on the
software.

Fig.4: © Exo4LogiProd: Digitalization of the “As it is” situation.

The simulation of the “As it should be” status was


Fig.6: © Exo4LogiProd: EMG sensors placement on the erector
performed and the results, which comply with safety spine muscle of the tester.
D. Ippolito, C. Constantinescu, C. A. Rusu / Procedia CIRP 00 (2020) 000–000
248 Daniele Ippolito et al. / Procedia CIRP 91 (2020) 243–248
6

The integration of the Exoskeleton ended with Wirtschaft; Verantwortung; Nachhaltigkeit; (2015).
recommendations for the protection of the device against dirt [3] Pexa R., Mit klassischen gesundheitsfördernden Maßnahmen
and dust and instructions for treating the hygiene of parts in und neuesten Technologien ist das BMW Group Werk Steyr für
contact with the worker's body. A storage rack was provided den demografischen Wandel gerüstet, Sichere Arbeit:
as well outside the silos to avoid obstructing the work space. Internationales Fachmagazin für Prävention in der Arbeitswelt,
(2017).
[4] Kirchgeßner S.; Roboter-Kraftanzug am STR - Flugblatt-
Magazin – Stories, (2020).
[5] Constantinescu C., Todorovic O., Ippolito D., Comprehensive
modelling and simulation towards the identification of critical
parameters for evaluation of exoskeleton-centred workplaces,
12th CIRP Conference on Intelligent Computation in
Manufacturing Engineering, 18-20 July 2018, Gulf of Naples,
Italy, Volume 79, 2019, Pages 176-179; (2018).
[6] https://www.germanbionic.com/en/press/bmw-branch-in-
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[7] Tomberlin M.; Alabama Newscenter, Workers at Hyundai’s
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Fig.7: © Exo4LogiProd: Task of unloading – With and without on Prevention" für Unternehmen - Kosten und Nutzen von
Exoskeleton Investitionen in den betrieblichen Arbeits- und
Gesundheitsschutz. DGUV Report 2013; 1:34–38. (2013).
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The developed method provides a clearer perspective on [11] Greenbaum D.; Ethical, legal and social concerns relating to
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exoskeletons; ACM SIGCAS Computers and Society
Digital Twin is fundamental for the existence of the described
45(3):234-239; January 2016 (2016).
method since it allows to collect accurate results that with
[12] Ippolito D., Constantinescu C., Holistic planning and
traditional methods would not be possible to obtain in a short
optimization of human-centred workplaces with integrated
time. The fundamental aspect is the observation of the
Exoskeleton technology, In: 13th CIRP ICME `19, (2019).
performance of the humanoid/Exoskeleton in the digital world,
[13] Dahmen C., Wöllecke F., Constantinescu C., Challenges and
allowing a digital validation of a possible integration of an
Exoskeleton in the workplace. The ethical, legal and social possible solutions for enhancing the workplaces of the future
cannot be faced at the moment in our methodology due to the by integrating smart and adaptive exoskeletons, 11th CIRP
fact that technical definitions and certifications, or rather a Conference on Intelligent Computation in Manufacturing
declaration of conformity, are still non-final and not clearly Engineering - CIRP ICME '17, (2017).
solved challenges for most world markets [18, 19]. [14] Spada, S., Ghibaudo, L., Gilotta, S., Gastaldi, L., &
New experiments with complex software such as Cavatorta, M. P. (2017). Analysis of Exoskeleton Introduction
©Anybody are planned in order to verify and validate the in Industrial Reality: Main Issues and EAWS Risk Assessment.
results obtained with the ©Siemens Classic Jack software. Advances in Physical Ergonomics and Human Factors,
New couplings between digital Human Model and other 2017(1), 236–244; (2017).
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the recommendation of hybrid work models, with and without Tinca V. T., Methodology of realizing the digital twin of
Exoskeleton in specific time intervals of the shift, day and exoskeleton-centred workplaces, 2018 International
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