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Related Experiment Video

Updated: Aug 18, 2025

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Model-Based Biomechanical Exoskeleton Concept Optimization for a Representative Lifting Task in Logistics.

Jonas Schiebl1, Mark Tröster1, Wiem Idoudi1

  • 1Fraunhofer Institute for Manufacturing Engineering and Automation IPA, 70569 Stuttgart, Germany.

International Journal of Environmental Research and Public Health
|December 11, 2022
PubMed
Summary

This study optimized occupational exoskeletons for heavy lifting, reducing joint forces and muscle activities during strenuous tasks. An effective design was identified to prevent work-related musculoskeletal disorders.

Keywords:
AnyBody Modeling Systemactivities above shoulder heightassistive systemsergonomicsexoskeletonheavy liftinglogisticsmanual workmultibody simulationmusculoskeletal modeling

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Area of Science:

  • Biomechanics
  • Ergonomics
  • Robotics

Background:

  • Work-related musculoskeletal disorders (WMSDs) are a significant concern in occupational settings.
  • Existing occupational exoskeletons lack systems for effective heavy lifting to shoulder height.
  • Model-based analysis and simulation are crucial for optimizing exoskeleton design.

Purpose of the Study:

  • To analyze heavy lifting activities using multibody simulations.
  • To optimize occupational exoskeleton concepts for supporting heavy lifting.
  • To identify exoskeleton designs that reduce joint forces and muscle activities.

Main Methods:

  • Captured motion sequences of three subjects performing lifting tasks.
  • Analyzed muscle activities (MAs) and joint forces (JFs) using multibody simulations.
  • Simulated 32 exoskeleton concept variants on a human model for comparative analysis.

Main Results:

  • Symmetric lifting of a 21 kg box to shoulder height was identified as the most strenuous motion.
  • Six exoskeleton concepts significantly reduced mean JFs (spine: >70%, glenohumeral: >69%) and MAs (back: >63%, shoulder: >59%).
  • Identified an optimal exoskeleton design balancing musculoskeletal relief and low parasitic loads.

Conclusions:

  • Occupational exoskeletons can be effectively optimized to support heavy lifting tasks.
  • The developed workflow aids in designing exoskeletons that mitigate WMSDs.
  • Further research can refine exoskeleton designs for enhanced worker safety and performance.