Active shoulder exoskeleton for assembly and overhead work

Physical strain during manual activities is still a key issue in many industrial sectors. Working overhead or in a raised arm position in particular leads to permanent strain on the shoulder muscles.

With an active shoulder exoskeleton, exoIQ is demonstrating an approach that addresses precisely this issue: mechanical support from a wearable system that recognises movements and provides targeted relief. In contrast to passive solutions, this system works with an integrated drive. A rechargeable battery powers the unit, allowing active force to be applied. The aim is not only to provide selective support, but also to noticeably reduce the strain in everyday working life.

exoIQ shoulder exoskeleton provides targeted support for overhead work

The basic principle is clearly defined: The exoskeleton relieves the shoulders by partially taking the weight of the arms. Activities in which arms are lifted for long periods of time in particular cause constant strain on the muscles and joints. This is where the system comes in and actively reduces this strain. The support is not static, but dynamic. Sensors detect movements and control the power supply accordingly. The result is not a rigid system, but a type of assistance that adapts to the user. Typical areas of application can be clearly identified:

• Welding work with longer seam guides
• Assembly processes in front of the body or overhead
• Maintenance and servicing of machines
• Fabrication with recurring motion sequences

Carrying system like a rucksack with stable weight distribution

The design of the system is based on a familiar principle: wearing a rucksack. The exoskeleton is positioned on the back and secured using shoulder, chest and lap straps. The decisive factor here is the shift in weight. The load is not placed on the shoulders, but is absorbed via the pelvis. This creates a stable seat that does not cause additional strain, even during prolonged use. The adjustment is customised so that different body sizes and working positions can be taken into account. The armrest is a central element. The upper arm is inserted into it and fixed in place. It is operated from the side and is designed to be intuitive to use. Excess straps can be stowed away, which is also relevant from a safety point of view.

Active support from compressor and sensors

The actual technical speciality lies in the drive system. After switching on, the appliance is initially in standby mode. The desired support is set via a control element. A compressor works inside, building up pressure and storing it temporarily. This means that the system does not run continuously, but only when required. The system is controlled by sensors that recognise the movement of the arm. As soon as a movement is registered, the support is activated automatically.

The effect is immediately noticeable: the system takes over some of the force that would normally have to be applied by the user. In practice, this means that even the weight of the arm itself can be supported. This makes overhead work much more relaxed. A pause function makes it possible to temporarily deactivate the support completely. This is important for secondary activities or changing positions. The power is switched on again at the touch of a button.

Adaptation to the user and familiarisation in everyday working life

The first contact with such a system is unfamiliar. This is less due to the weight than to the active support. The device reacts to movements and generates forces that the user initially has to categorise. However, the more you use it, the more you get used to it. Similar to new work shoes, the wearing comfort adapts and the system is increasingly perceived as support rather than a foreign body. Correct adjustment and a snug fit on the body are crucial. The total weight is distributed over the carrying system and therefore remains manageable in everyday working life. Even longer periods of use are possible without the device itself causing additional fatigue.

Economic classification and use in an industrial environment

With a price of around 3,500 euros including batteries, carrying unit and charger, the system is in a range that is relevant for industrial applications. The fact that it is manufactured in Germany emphasises the demand for quality and availability. The economic assessment depends heavily on the area of application. In industries with high physical strain, the investment can be amortised relatively quickly through reduced downtime, lower physical strain and more stable work performance. The exoIQ system thus demonstrates how traditional manual tasks are being transformed by technical assistance systems. Not as a replacement for people, but as a supplement that reduces stress and stabilises work processes in the long term.