Mechatronic Bio-Design and Development of an Exoskeleton to Improve Egonomics and Reduce Occupational Risks in Operators

In 2020, the International Labor Organization reported that more than 2.78 million fatalities occur annually due to occupational accidents or work-related diseases, highlighting a critical global issue. To address this concern, an innovative study was conducted in 2024 under the auspices of the Professional School of Mechatronic Engineering at Ricardo Palma University, the objective of this research was to develop a bio-inspired exoskeleton designed to augment the strength capabilities of workers performing tasks at shoulder height, including lifting, holding, and manipulating objects. The mechanical design phase defined a safe elbow range of motion from 0° to 90°, and subsequent simulation analyses were carried out using Autodesk Fusion 360. For the prototyping stage, Enhanced Polylactic Acid (EPLA) and Polylactic Acid Plus (PLA+) were employed, with 3D models fabricated on a Creality Ender3 V3 SE printer. Finite Element Analysis (FEA) revealed a maximum deformation of 0.489 mm in the forearm exoskeleton and a maximum Von Mises stress of 3.243 MPa. Furthermore, Electromyography (EMG) testing demonstrated a reduction in biceps muscle activity exceeding 75% when the exoskeleton was utilized. Without the exoskeleton, the steady-state response reached approximately 200 bits while holding an object; in contrast, with the exoskeleton, this response decreased to less than 50 bits, indicating a significant reduction in muscle effort. For future works, it is recommended to integrate torque sensors and implement artificial intelligence algorithms to enhance the system’s capability to accurately interpret operator intent, thereby improving both task efficiency and adaptability.