Compensating the weight of human limbs is important in reducing muscle fatigue experienced by manual laborers. In this study, a compact and lightweight soft wearable weight support device was developed and evaluated. The device supports gravitational force on the shoulder at any arm posture, although there are some limitations in its assistive performance. The device actuator consists of a cam-rod structure, a tendon-driven mechanism, and a rubber band. The desired assistive torque is translated to the shoulder joint along a tendon routing structure. Device performance was evaluated by measuring muscle activation in with-assist and without-assist conditions. Muscle activation on the deltoid was measured by surface electromyography. An experimental protocol consisting of a series of exercises was executed with six healthy subjects. The subjects raised and lowered their arm from 0 to 100 degrees for 30 times under eight conditions, which were combined with-assist and without-assist conditions, and holding the horizontal angle of the arm at 0, 30, 60, or 90 degrees against the sagittal plane. Surface electromyography data were pre-processed and analyzed using a root mean square method. When muscle fatigue occurs, the root mean square of the surface electromyography increases nonlinearly. This was calculated using the standard deviation of the root mean square. Three of six subjects showed decreased variation of the root mean square between the exercises in the with-assist condition. One subject’s result was significantly reduced (by about 57.6%) in the with-assist condition. In contrast, two subjects did not show significant difference between measurements taken in the with-assist and without-assist conditions. One subject was dropped from the experiment because the device did not fit the subject’s body. In conclusion, the effectiveness of the soft wearable weight support device in supporting shoulder movements was verified through the decreased variation of muscle activation.

Shoulder-sideWINDER is an exoskeleton to assist the shoulder movement of workers performing manual tasks. It aims to minimize discomfort caused by a joint misalignment between the shoulder and an exoskeleton, which is a common problem with many closely coupled systems. Based on the shoulder’s musculoskeletal structure, we propose two novel misalignment correction mechanisms: center-of-rotation tracking mechanism and force-guiding mechanism. The center-of-rotation tracking mechanism compensates for the vertical misalignment that arises from the scapulohumeral rhythm. The force-guiding mechanism compensates for the horizontal misalignment due to changes in the plane of the arm elevation. The kinematic performance of reducing joint misalignment was evaluated using the angle ratio as the indicator under two conditions: with and without the center-of-rotation tracking mechanism. The muscle load caused by the kinematic disturbance was evaluated under three conditions: wearing the exoskeleton with and without the center-of-rotation tracking mechanism and not wearing the exoskeleton. The analysis used muscle load data measured by surface electromyography on five shoulder muscles. Five subjects executed 12 arm motions each, in 4 planes of elevation. Since the system was optimized for a pilot user, subjects with similar morphology presented positive results showing that the proposed mechanism reduced the misalignment in the dominant range of working motion. Apart from the anterior deltoid, the loads on muscles responsible for the dominant range of working motion also showed a significant reduction compared to the case without the mechanism. In conclusion, we verified that the Shoulder-sideWINDER provides comfortable support by reducing joint misalignment, and identified directions for design improvements that will further enhance usability.

Despite an increase in the use of exoskeletons, particularly for medical and occupational applications, few studies have focused on the wrist, even though it is the fourth most common site of musculoskeletal pain in the upper limb. The first part of this paper will present the key challenges to be addressed to implement wrist exoskeletons as wearable devices for novel rehabilitation practices and tools in the occupational/industrial sector. Since the wrist is one of the most complex joints in the body, an understanding of the bio-mechanics and musculo-skeletal disorders of the wrist is essential to extracting design requirements. Depending on the application, each wrist exoskeleton has certain specific design requirements. These requirements have been categorized into six sections: purpose, kinematics, dynamics, rigidity, ergonomics, and safety. These form the driving factors behind the choice of a design depending on the objectives. Different design architectures are explored, forming the basis for the various technical challenges that relate to: actuation type, power source, power transmission, sensing, and control architecture. This paper summarizes, in a systematic approach, all the current technologies adopted, analyzes their benefits and limitations, and finally proposes future perspectives.

Manual handling tasks, both in daily activities and at work, require high dexterity and the ability to move objects of different shapes and sizes. However, musculoskeletal disorders that can arise due to aging, disabilities, overloading, or strenuous work can impact the natural capabilities of the hand with serious repercussions both in working and daily activities. To address this, researchers have been developing and proving the benefits of wrist exoskeletons. This paper, which is Part II of a study on wrist exoskeletons, presents and summarizes wearable wrist exoskeleton devices intended for use in rehabilitation, assistance, and occupational fields. Exoskeletons considered within the study are those available either in a prototyping phase or on the market. These devices can support the human wrist by relieving pain or mitigating fatigue while allowing for at least one movement. Most of them have been designed to be active (80%) for higher force/torque transmission, and soft for better kinematic compliance, ergonomics, and safety (13 devices out of 24, more than 50%). Electric motors and cable transmission (respectively 11 and 9 devices, out of 24, i.e., almost 50% and 40%) are the most common due to their simplicity, controllability, safety, power-to-weight ratio, and the possibility of remote actuation. As sensing technologies, position and force sensors are widely used in all devices (almost 90%). The control strategy depends mainly on the application domain: for rehabilitation, CPM (control passive motion) is preferred (35% of devices), while for assistance and occupational purposes, AAN (assistance-as-needed) is more suitable (38% of the devices). What emerges from this analysis is that, while rehabilitation and training are fields in which exoskeletons have grown more easily and gained some user acceptance (almost 18 devices, of which 4 are available on the market), relatively few devices have been designed for occupational purposes (5, with only 2 available on the market) due to difficulties in meeting the acceptance and needs of users. In this perspective, as a result of the state-of-the-art analysis, the authors propose a conceptual idea for a portable soft wrist exoskeleton for occupational assistance.

Musculoskeletal Disorders associated with the elbow are one of the most common forms of work-related injuries. Exoskeletons have been proposed as an approach to reduce and ideally eliminate these injuries; however, exoskeletons introduce their own problems, especially discomfort due to joint misalignment. The Elbow-sideWINDER with its associated control strategy is a novel elbow exoskeleton to assist elbow flexion/extension during occupational tasks. This study describes the exoskeleton showing how this can minimize discomfort caused by joint misalignment, maximize assistive performance, and provide increased robustness and reliability in real worksites. The proposed medium-level control strategy can provide effective assistive torque using three control units as follows: an arm kinematics estimator, a load estimator, and a friction compensator. The combined hardware/software system of the Elbow-sideWINDER is tested in load-lifting tasks (2 and 7 kg). This experiment focuses on the reduction in the activation level of the biceps brachii and triceps brachii in both arms and the change in the range of motion of the elbow during the task. It is shown that using the Elbow-sideWINDER, the biceps brachii, responsible for the elbow flexion, was significantly less activated (up to 38.8% at 2 kg and 25.7% at 7 kg, on average for both arms). For the triceps brachii, the muscle activation was reduced by up to 37.0% at 2 kg and 35.1% at 7 kg, on average for both arms. When wearing the exoskeleton, the range of motion of the elbow was reduced by up to 13.0° during the task, but it was within a safe range and could be compensated for by other joints such as the waist or knees. There are extremely encouraging results that provide good indicators and important clues for future improvement of the Elbow-sideWINDER and its control strategy.

In industrial environments, the control of arm assistive exoskeletons presents significant challenges due to complex dynamic movements. We propose a high-level controller for the Shoulder-sideWINDER that assists dynamic arm movement during a variety of tasks, based on mechanical characteristics of a novel joint alignment mechanism. The high-level controller consists of control units related to four main considerations: (i) Shoulder-sideWINDER Force Model, (ii) Friction Compensator, which determines the structurally required torque, (iii) Arm Kinematics Estimator, which estimates the required torque according to arm postures using a simple IMU-based approach, (iv) Load Estimator, which estimates muscle load and the required torque caused by external weights and also determines the force engagement. To validate the controller, a right arm system emulated three different postures. One participant operated the Load Estimator by lifting and lowering a 5 $kg$ weight five times with a 3-second interval for each posture. Although, when reducing the torque, a force transmission delay and a residual force were caused by friction, the result shows that the controller estimated correctly and generated the target required torque with an error of less than 6.6%. Finally, we verified that the proposed control strategy is simple but effective in generating the required torque based on four main considerations, and identified the direction for further improvement of the friction compensator that enhances comfort as well as control performance.