The development of exoskeletons is currently a lengthy process full of challenges. We are proposing a framework to accelerate the process and make the resulting exoskeletons more user-centered. The needed accomplishments in science are described in an effort to lay the foundation for future research projects. Since the early 2000s, exoskeletons have been discussed as an emerging technology in industrial, medical, or military applications. Those systems are designed to support people during manual tasks. At first, those systems lacked broad acceptance. Many models found their niches in ongoing developments and more diverse systems entering the market. There are still applications that are in dire need of such assistance. Due to the lack of experience with body-worn robotics, the development of such systems has been shaped by trial and error. The lack of legacy products results in longer development times. In this paper, a process to generate a framework is presented to display the required research to enable future exoskeleton designers. Owing to their proximity to the user’s body, exoskeletons are highly complex systems that need sophisticated subsystems, such as kinematic, control, interaction design, or actuators, to be accepted by users. Due to the wide variety of fields and high user demands, a synchronized multidisciplinary effort is necessary. To achieve this, a process to develop a modular framework for exoskeleton design is proposed. It focuses on user- and use-case-centered solutions for matching kinematics, actuation, and control. To ensure the usefulness of the framework, an evaluation of the incorporated solutions is required.

Although passive occupational exoskeletons alleviate worker physical stresses in demanding postures (e.g., overhead work), they are unsuitable in many other applications because of their lack of flexibility. Active exoskeletons that are able to dynamically adjust the delivered support are required. However, the automatic control of support provided by the exoskeleton is still a largely unsolved challenge in many applications, especially for upper limb occupational exoskeletons, where no practical and reliable approach exists. For this type of exoskeletons, a novel support control approach for lifting and carrying activities is presented here. As an initial step towards a full-fledged automatic support control (ASC), the present article focusses on the functionality of estimating the onset of user’s demand for support. In this way, intuitive behavior should be made possible. The combination of movement and muscle activation signals of the upper limbs is expected to enable high reliability, cost efficiency, and compatibility for use in industrial applications. The functionality consists of two parts: a preprocessing—the motion interpretation—and the support detection itself. Both parts were trained with different subjects, who had to move objects. The functionality was validated both in the cases of (A) an unknown subject performing known tasks and (B) a known subject performing unknown tasks. The functionality showed sound results as it achieved a high accuracy ($$ 95\% $$) in training. In addition, the first validation results showed that this functionality is useful for integration in an appropriately adapted ASC and can then enable comfortable working.

Wearable devices, such as exoskeletons, are becoming increasingly common and are being used mainly for improving motility and daily life autonomy, rehabilitation purposes, and as industrial aids. There are many variables that must be optimized to create an efficient, smoothly operating device. The selection of a suitable actuator is one of these variables, and the actuators are usually sized after studying the kinematic and dynamic characteristics of the target task, combining information from motion tracking, inverse dynamics, and force plates. While this may be a good method for approximate sizing of actuators, a more detailed approach is necessary to fully understand actuator performance, control algorithms or sensing strategies, and their impact on weight, dynamic performance, energy consumption, complexity, and cost. This work describes a learning-based evaluation method to provide this more detailed analysis of an actuation system for our XoTrunk exoskeleton. The study includes: (a) a real-world experimental setup to gather kinematics and dynamics data; (b) simulation of the actuation system focusing on motor performance and control strategy; (c) experimental validation of the simulation; and (d) testing in real scenarios. This study creates a systematic framework to analyze actuator performance and control algorithms to improve operation in the real scenario by replicating the kinematics and dynamics of the human–robot interaction. Implementation of this approach shows substantial improvement in the task-related performance when applied on a back-support exoskeleton during a walking task.

This article presents a novel neuromechanical force-based control strategy called FMCA (force modulated compliant ankle), to control a powered prosthetic foot. FMCA modulates the torque, based on sensory feedback, similar to neuromuscular control approaches. Instead of using a muscle reflex-based approach, FMCA directly exploits the vertical ground reaction force as sensory feedback to modulate the ankle joint impedance. For evaluation, we first demonstrated how FMCA can predict human-like ankle torque for different walking speeds. Second, we implemented the FMCA in a neuromuscular transtibial amputee walking simulation model to validate if the approach can be used to achieve stable walking and to compare the performance to a neuromuscular reflex-based controller that is already used in a powered ankle. Compared to the neuromuscular model-based approach, the FMCA is a simple solution with a sufficient push-off that can provide stable walking. Third, to assess the ability of the FMCA to generate human-like ankle biomechanics during walking at the preferred speed, we implemented this strategy in a powered prosthetic foot and performed experiments with a non-amputee subject. The results confirm that, for this subject, FMCA can be used to mimic the non-amputee reference ankle torque and the reference ankle angle. The findings of this study support the applicability and advantages of a new bioinspired control approach for assisting amputees. Future experiments should investigate the applicability to other walking speeds and the applicability to the target population.

Exoskeletons are wearable devices intended to physically assist one or multiple human joints in executing certain activities. From a mechanical point of view, they are kinematic structures arranged in parallel to the biological joints. In order to allow the users to move while assisted, it is crucial to avoid mobility restrictions introduced by the exoskeleton’s kinematics. Passive degrees of freedom and other self-alignment mechanisms are a common option to avoid any restrictions. However, the literature lacks a systematic method to account for large inter- and intra-subject variability in designing and assessing kinematic chains. To this end, we introduce a model-based method to assess the kinematics of exoskeletons by representing restrictions in mobility as disturbances and undesired forces at the anchor points. The method makes use of robotic kinematic tools and generates useful insights to support the design process. Though an application on a back-support exoskeleton designed for lifting tasks is illustrated, the method can describe any type of rigid exoskeleton. A qualitative pilot trial is conducted to assess the kinematic model that proved to predict kinematic configurations associated to rising undesired forces recorded at the anchor points, that give rise to mobility restrictions and discomfort on the users.

To reduce the incidence of occupational musculoskeletal disorders, back-support exoskeletons are being introduced to assist manual material handling activities. Using a device of this type, this study investigates the effects of a new control strategy that uses the angular acceleration of the user’s trunk to assist during lifting tasks. To validate this new strategy, its effectiveness was experimentally evaluated relative to the condition without the exoskeleton as well as against existing strategies for comparison. Using the exoskeleton during lifting tasks reduced the peak compression force on the L5S1 disc by up to 16%, with all the control strategies. Substantial differences between the control strategies in the reductions of compression force, lumbar moment and back muscle activation were not observed. However, the new control strategy reduced the movement speed less with respect to the existing strategies. Thanks to improved timing in the assistance in relation to the typical dynamics of the target task, the hindrance to typical movements appeared reduced, thereby promoting intuitiveness and comfort.

Industrial exoskeletons have recently gained importance as ergonomic interventions for physically demanding work activities. The growing demand for exoskeletons is leading to a need for new knowledge on the effectiveness of these systems. The Exoworkathlon, as a prospective study approach, aims to assess exoskeletons in realistic use cases and to evaluate them neutrally in their entirety. For this purpose, a first set of four realistic Parcours was developed with experts from relevant industries, the German Social Accident Insurance, and the Federal Institute for Occupational Safety and Health. In addition, a set of ratings was defined to assess subjective user feedback, work quality, and objective physiological parameters. Exoworkathlon aims to bring together developers, researchers, and end-users, strengthen collaborative exchanges, and promote a platform for the prospective holistic data collection for exoskeleton evaluation. In this article, the focus is on the background and methodology of Exoworkathlon.

The purpose of this study was to assess an upper body exoskeleton during automotive assembly processes that involve elevated arm postures. Sixteen team members at Toyota Motor Manufacturing Canada were fitted with a Levitate Airframe, and each team member performed between one and three processes with and without the exoskeleton. A total of 16 assembly processes were studied. Electromyography (EMG) data were collected on the anterior deltoid, biceps brachii, upper trapezius, and erector spinae. Team members also completed a usability survey. The exoskeleton significantly reduced anterior deltoid mean active EMG amplitude (p = .01, Δ = −3.2 %MVC, d = 0.56 medium effect) and fatigue risk value (p < .01, Δ = −5.1 %MVC, d = 0.62 medium effect) across the assembly processes, with no significant changes for the other muscles tested. A subset of nine assembly processes with a greater amount of time spent in arm elevations at or above 90° (30 vs. 24%) and at or above 135° (18 vs. 9%) appeared to benefit more from exoskeleton usage. For these processes, the exoskeleton significantly reduced anterior deltoid mean active EMG amplitude (p < .01, Δ = −5.1 %MVC, d = 0.95 large effect) and fatigue risk value (p < .01, Δ = −7.4 %MVC, d = 0.96 large effect). Team members responded positively about comfort and fatigue benefits, although there were concerns about the exoskeleton hindering certain job duties. The results support quantitative testing to match exoskeleton usage with specific job tasks and surveying team members for perceived benefits/drawbacks.