Load Estimation Apparatus Using Body-Mounted Sensors

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Solution Overview

Problem

Existing load estimation methods for workers in manufacturing and distribution sites fail to accurately reflect the worker's actual load due to neglecting the worker's motion and individual differences in motion patterns, leading to deviations between estimated and actual loads.

Innovation Solution

A load estimation apparatus that uses multiple sensors attached to various body parts of a worker to acquire sensor data, which is then processed to calculate posture loads based on posture angles and displayed in a time-series graph, allowing for clustering and feature extraction to provide comprehensive load information.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a work table-based load estimation method is used, then the estimation process is simple, but the estimated load deviates from the actual load because worker motion is not reflected

Engineering Contradiction:

Improveestimation process complexityVSAvoidload estimation accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical/work table-based estimation system with a sensor-based measurement system. Motion sensors are attached to the worker's body to directly measure posture angles and motion patterns, substituting the indirect work table methodology with direct physical measurement, thereby improving accuracy while maintaining manageable complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces posture angle data and motion pattern analysis as intermediary elements between the worker and the load estimation. These intermediaries capture the actual motion characteristics and translate them into load metrics, bridging the gap between simple measurement and accurate estimation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If a motion sensor-based load estimation method is used, then the load can be estimated from sensor data, but it is difficult to grasp in which work state the warning is issued and individual motion differences cannot be considered

Engineering Contradiction:

Improveload estimation accuracyVSAvoidwork state context information

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent segments the load estimation into multiple components: posture load (based on posture angles), motion pattern analysis, and work state classification. By dividing the estimation process into these segments, the system can provide detailed context about which work state triggered a warning while maintaining overall load accuracy

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent adds temporal and contextual dimensions to the load estimation by analyzing motion patterns over time and classifying work states. This multi-dimensional approach preserves rich information about when and why warnings are issued, rather than providing only a scalar load value

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12277763B2Load estimation apparatus and method

Publication Date: 2025.04.15 KK TOSHIBA

AI summary

According to one embodiment, a load estimation apparatus includes processing circuitry. The processing circuitry acquires sensor data from a measurement target, calculates one or more posture loads relating to one or more body parts of the measurement target based on the sensor data, and displays display data including a posture load graph in which the one or more posture loads are illustrated in time series.