Mechanical and Control Design of an Industrial Exoskeleton for Advanced Human Empowering in Heavy Parts Manipulation Tasks

Exoskeleton robots are a rising technology in industrial contexts to assist humans in onerous applications. Mechanical and control design solutions are intensively investigated to achieve a high performance human-robot collaboration (e.g., transparency, ergonomics, safety, etc.). However, the most of the investigated solutions involve high-cost hardware, complex design solutions and standard actuation. In the presented work, an industrial exoskeleton for lifting and transportation of heavy parts is proposed. A low-cost mechanical design solution is proposed, exploiting compliant actuation at the shoulder joint to increase safety and transparency in human-robot cooperation. A hierarchic model-based controller is then proposed (including the modeling of the compliant actuator) to actively assist the human while executing the task. An inner optimal controller is proposed for trajectory tracking, while an outer fuzzy logic controller is proposed to online deform the task trajectory on the basis of the human’s intention of motion. A gain scheduler is also designed to calculate the optimal control gains on the basis of the performed trajectory. Simulations have been performed in order to validate the performance of the proposed device, showing promising results. The prototype is under realization.