Collaborative Robot and Exoskeleton Coordination for Operator Safety
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Solution Overview
Problem
Existing systems for assisting operators in workstations are not comfortable for the operator and do not allow for active cooperation between assistance apparatus, such as collaborative robots and exoskeletons, to alleviate operator effort, ensure safety, and enhance efficiency.
Innovation Solution
A system comprising a collaborative robot, an active exoskeleton with electrically operated actuators, and sensors detecting physiological and movement parameters, with a system electronic controller dynamically controlling the apparatus to prevent collisions, adapt assistance to operator fatigue, and optimize task division between the operator and the robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electronic control unit controls the exoskeleton by detecting robot position to prevent collisions, then collision prevention is achieved, but the system becomes uncomfortable for the operator and limits the exoskeleton to passive collision avoidance only
Solution Approach 1:
The system uses sensors to detect operator physiological parameters (heart rate, electromyography, metabolic consumption) and provides feedback to the control unit, which dynamically adjusts exoskeleton assistance. This closed-loop feedback mechanism enables the exoskeleton to adapt to operator needs in real-time, improving comfort while maintaining collision prevention through active cooperation with the robot.
Solution Approach 2:
The exoskeleton monitors the operator's physiological state and autonomously adjusts its assistance level without requiring explicit operator commands. The system serves itself by using sensor data to determine when and how much assistance to provide, enabling active cooperation with the robot while maintaining operator comfort through adaptive, needs-based support.
2Reliability
If the exoskeleton is controlled passively to prevent collisions, then safety is maintained, but active cooperation between the robot and exoskeleton to alleviate operator effort is not achieved
Solution Approach 1:
The system merges the collision prevention function with the operator assistance function into a single integrated control system. The control unit simultaneously manages robot-exoskeleton coordination for safety and exoskeleton actuation for productivity enhancement. This unified approach enables both safety and active cooperation, allowing the exoskeleton to share tasks with the robot while maintaining protective functions.
Solution Approach 2:
The exoskeleton transitions from passive collision avoidance to active, dynamic cooperation with the robot. The system continuously adapts its assistance level based on real-time sensor data about operator physiological state and task requirements. This dynamic behavior enables the exoskeleton to actively share workload with the robot, improving productivity while maintaining safety through continuous monitoring and adaptive response.
3Device complexity
If the system provides fixed assistance regardless of operator state, then simple control is maintained, but the system cannot adapt to the operator's physical and physiological features under different working conditions
Solution Approach 1:
The system changes multiple parameters simultaneously - physiological parameters (heart rate, electromyography, metabolic consumption) and mechanical parameters (exoskeleton actuation force, robot positioning) - to adapt to operator needs. The control unit processes sensor data and dynamically adjusts these parameters in real-time, enabling the system to adapt to different operator states and working conditions while maintaining a unified control architecture that manages this complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides comfortable and safe working conditions by actively cooperating with the operator, reducing fatigue, and enhancing productivity through effective task division and adaptive assistance tailored to the operator's physical and physiological features.
Implementation Method 1
a plurality of sensors associable to the body of the operator and configured for detecting at least one parameter selected from heart rate, metabolic consumption, skin conductivity, surface electromyography
Implementation Method 2
at least one active exoskeleton including one or more electrically operated actuators
Data Source
AI summary
A system for assisting an operator in a work station includes a collaborative robot, with a robot electronic controller, configured for conducting an operation in an open, non-protected space, adjacent and in cooperation with the operator, an exoskeleton including one or more actuators, wearable by the operator for receiving assistance in conducting one or more operations, a plurality of sensors associable to the body of the operator and configured for detecting at least one parameter. An electronic controller is configured for receiving signals by the sensors and for sending signals to the one or more actuators of the exoskeleton and to the robot controller based on an elaboration of signals received by the sensors, wherein the system controller is configured and programmed for dynamically controlling the exoskeleton and the robot so as to avoid collisions or injuries between the robot and the operator or conditions of lack of safety for the operator, and to enable the robot to cooperate with the operator by assuming positions suitable to the physical and physiological features, to the workload and to the postures of the operator.