Industrial exoskeletons are globally developed, explored, and increasingly implemented in industrial workplaces. Multiple technical, physical, and psychological aspects should be assessed prior to their daily application in various occupational environments. The methodology for evaluating these aspects is not standardised and differs in terms of focussed research objectives, used types of analyses, applied testing procedures, and use cases. The aim of this paper is to provide a matrix comparing the prevalence of different types of analyses combined with their respective research objective(s). A systematic review in the database ‘Web of Science’ identified 74 studies, mainly in laboratory settings, with a focus on short-term effects as well as with male-dominated samples being low representative for industrial workforces. The conducted evaluation methodologies are further discussed and compared in terms of testing procedure, sample, and research objectives. Finally, relevant aspects for prospectively evaluating industrial exoskeletons in a more harmonised and comprehensive way are suggested. Practitioner summary: Industrial exoskeletons are still inconsistently and insufficiently evaluated in scientific studies, which might hamper the comparability of systems, threaten the human health, and block an iterative system optimisation. Thus, a comprehensive evaluation methodology is needed with harmonised and multicriteria types of analyses.

In recent years, the trend for implementing exoskeletons in industrial workplaces has significantly increased. A variety of systems have been developed to support different tasks, body parts, and movements. As no standardized procedure for evaluating industrial exoskeletons is currently available, conducted laboratory and field tests with different setups and methodologies aim to provide evidence of, e.g., the support for selected isolated activities. Accordingly, a comparison between exoskeletons and their workplace applicability proves to be challenging. In order to address this issue, this paper presents a generic method and modular test course for evaluating industrial exoskeletons: First, the seven-phase model proposes steps for the comprehensive evaluation of exoskeletons. Second, the test course comprises a quick check of the system’s operational requirements as well as workstations for an application-related evaluation of exoskeletons’ (short-term) effects. Due to the vastness and heterogeneity of possible application scenarios, the test course offers a pool of modular configurable stations or tasks, and thus enables a guided self-evaluation for different protagonists. Finally, several exemplary exoskeletons supporting varying body regions passed the test course to evaluate and reflect its representativity and suitability as well as to derive discernible trends regarding the applicability and effectiveness of exoskeleton types.

Repetitive overhead work with a heavy load increases the risk for work-related shoulder disorders. Occupational exoskeletons supporting arm elevation are potential solutions to reduce that risk by lowering the physical strains on the shoulder. Many studies have reported a reduction in shoulder stress in various overhead tasks by using such exoskeletons. However, the support demand can vary in each phase of motion as well as in each individual task. This paper presents a laboratory study with five participants to evaluate the influence of the support level of an active shoulder exoskeleton in different motion phases (e.g., arm lifting, screw-in, and arm lowering of two overhead tasks) to identify the potential optimization of support at each phase. Results show that the support level of the exoskeleton should be adapted to the motion phase of the two chosen tasks. A higher support force is desired for the screw phase compared to the arm lifting and lowering phases, and the support level needs to be reduced immediately for arm lowering after the screw phase. The time for switching the support levels can be recognized by the electric current of the screwdriver.

Working at and above head height with a power tool represents a common activity in craft and assembly applications. To assist and protect the user from overload and injuries in these situations, the development and use of application-specific support systems, such as exoskeletons and power tools, have greatly increased in recent years. Thus, the integration of aspects of the user-centered product development of support systems in the early phases of product development process has high potentials. A common approach to integrate the user early in the product development process is the use of musculoskeletal human models, which allow the evaluation of effects on the human body. This could also be applicable in the mentioned use case to enable the evaluation of the interactions for the user. Therefore, a co-simulation model for virtual modelling and simulating human–machine interactions is presented. The co-simulation model is made up of a musculoskeletal human model and the models of the technical systems (exoskeleton and power tool). By applying the co-simulation model, the impact of technical systems on the human body can be taken into account to derive design alternatives for the technical system due to the requirements of the user. The paper describes the design of the co-simulation model and particularly, the interaction of the submodels. The evaluation of the co-simulation model is carried out with the help of a subject study for the selected use case working at and above head height. The results show plausible results for the muscle loads considering the support by an exoskeleton. Furthermore, the comparison of simulated results to measured muscle activations via surface electromyography shows a good agreement. Thus, the co-simulation model passes the test for functionality and seems to be applicable for the derivation of design alternatives of technical systems regarding the user needs. In future, the co-simulation model will be further validated with a higher number of subjects and to implement design alterations in the technical systems.