Person-specific evaluation method for occupational exoskeletons – Biomechanical body heat map

Human-centred and ergonomic work design is one of the most important drivers for increasing the competitiveness of the European Union. As a flexible, person-specific occupational measure, exoskeletons promise great potential for effectively reducing individual ergonomic stress. Digital human models can provide important insights and offer great potential for systematising the effect and targeted use of exoskeletons, supporting their effective implementation in practice. In this article, digital human models are applied on two levels. Firstly, a realistic industrial logistics scenario in which boxes had to be relocated is designed with the help of a digital human model for workplace and process planning and secondly, a new biomechanical evaluation methodology to analyse intended and unintended effects on internal stress on the human body is demonstrated by applying musculoskeletal exoskeleton human models of four test subjects. Finally, the modelled biomechanical support tendencies of one exoskeleton are preliminary validated using EMG measurement data of the back muscles collected from the four male workers. The preliminary analysis of two back-support exoskeletons to demonstrate the new methodological approach confirms the expected, intended effects in the lower back and reveals unintended effects, such as e.g. changes in knee kinetics when applying a soft or hard-frame exoskeleton. Furthermore, the exemplary results to demonstrate the methodological approach expose notable differences between the test subjects, which underlines the relevance of person-specific evaluation and consideration of exoskeleton support. The preliminary validation shows a correlation between the modelled and the EMG-measured biomechanical exoskeleton support of the considered back muscles. • Biomechanical modelling of a soft and rigid back support exoskeleton. • Novel approach for evaluation of intended and unintended effects of exoskeletons. • Threshold-based biomechanical evaluation of occupational exoskeletons. • Scientific basis for a new comprehensive tool for industrial ergonomic risk assessment. • Roadmap for multi-layer and individual ergonomic work design using DHMs.