Industry 5.0 - Subscriber Content: Exoskeletons: Creating Human Robots?

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Industry 5.0 represents the next step in the evolution of the smart factory. 

Today’s factory floor has become increasingly automated, with every component of the production line connected to the network and data driving factory management. Automation initially reduced the number of human workers on factory floors; however, Industry 5.0 places human workers at the center of the manufacturing process once again. 

Mouser Electronics spoke with Volker Bartenbach, chief executive officer of Swiss company Auxivo AG, who is developing exoskeleton solutions that help improve worker safety and efficiency on the factory floor. Read on to see some of Bartenbach’s vision for the smart factory of Industry 5.0.

Expanding From Robots to Industry 5.0

Automation enables remarkable advances in efficiency. Immune to the fatigue with which human workers must contend, machines work with great precision for unlimited periods. Despite these advantages, traditional machines have limited flexibility. They perform a specific task such as spot welding or spray painting. This suits a mass production environment, where every item must be identical to the next, but a factory equipped with these machines reacts slowly to new requirements.

Computers and practical artificial intelligence (AI) changed decision-making processes, resulting in the smart factory. Sensors around the factory gather data, which are used to create a virtual representation of the manufacturing process. This digital twin provides an understanding of how the factory could be reconfigured quickly, delivering greater flexibility and the ability to react to change.

However, even with improved flexibility, the smart factory is unable to cope with unstructured environments. Bartenbach provided an example of such an environment: “We were approached by a client who was developing a robotic system to handle nonstandard loads. [The client] had invested heavily in AI-powered vision systems for recognition and had customized grippers for [its] robots. Despite this, the system simply did not work.” 

To explain why this system did not work, Bartenbach said, “The robots simply could not replicate the flexibility of the human operator. Changes in lighting fooled the vision systems—they worked great when it was sunny, but darker conditions confused them.” 

Placing Humans Back on the Factory Floor

Instead of trying to equip its systems with the ability to replace people, the client turned to solutions that will enhance human workers. With this specific challenge in mind, the client asked Auxivo for a way to place the human worker back into the production process. 

To overcome this challenge, Auxivo created exoskeleton solutions for the client. An exoskeleton is a mechanical device worn around the body that matches the movements of its user and, in the process, provides structural support. Exoskeletons have been a feature of science fiction for many years, providing their users with superhuman powers. While reality does not yet mirror fiction, exoskeletons play a unique and important role in Industry 5.0.

Bartenbach explained the exoskeleton’s task: “We design exoskeletons to work against gravity. Think about how a chair supports a human working at a desk. The chair acts against gravity, providing a comfortable seating position that reduces fatigue. Think of an exoskeleton as a dynamic chair that can support you anywhere during a large variety of activities.”

Bartenbach then described how exoskeletons work: “The exoskeleton functions as an ergonomic device. Its structure stabilizes the worker’s body and captures energy as the user moves. We employ a network of springs and straps that work with the user’s motion. These systems can reduce workload and fatigue, allowing [users] to work more safely and efficiently.”

Enhancing the Flexibility of Human Workers

The exoskeleton enhances human capabilities, allowing workers to become part of the production process. At the same time, workers’ cognitive abilities and flexibility of movement allow them to react to unexpected situations instinctively. In contrast, a robot faced with a similar situation might be unable to respond accordingly, halting production and creating costly delays.

Bartenbach discussed possible applications for exoskeleton technology. The most interesting quality of the exoskeleton solution is its versatility. Bartenbach noted, “As you can imagine, workers can use these systems in many ways on the traditional factory floor. Anyone working at a height where reaching above the head is required will appreciate the support these systems can give. Similarly, anyone who must reach forward and down can benefit. What surprised us most was how many potential uses exist for this technology.”

Bartenbach provided a few examples of this versatility: “Outside the factory, we found that agriculture is embracing this equipment. Workers who harvest crops spend much of their day bent forward at the waist. An exoskeleton supports their upper body and reduces their fatigue. But it’s not just limited to fields. We have oyster farmers using these devices and farriers who must bend to lift horses’ hooves during their work. The uses for this technology are almost endless.”

Furthermore, technology can be integrated into the exoskeleton. “One of the greatest advantages of these devices is their simplicity. Once they are fitted to the worker, wearing them becomes second nature. But we see opportunities for advanced technology. These devices can be fitted with sensors to monitor movement and measure the energy stored within them,” Bartenbach elaborated. “Combining these data with interfaces such as augmented reality displays will provide the user with a range of information. This includes monitoring fatigue levels, advising on the most efficient movement for a given task, or warning of potential dangers. In this way, humans become part of the smart factory.”

Yet, exoskeletons will face challenges during adoption. “These devices are still seen as science fiction, and so many of the challenges we face are emotional—some workers will be skeptical of this new technology. But we believe that they will become a common piece of safety equipment, equivalent to a hard helmet or safety footwear,” Bartenbach explained.

Conclusion

Industry 5.0 integrates humans into the automation environment, using advanced technology to improve processes. The most interesting aspect is the variety of ways in which the human can play a role. While one approach uses human cognition to understand unstructured situations and train machines to recognize them, the exoskeleton does not employ machine intelligence. Instead, it provides humans with additional capabilities to make them more effective and enhance their safety.

Each solution provides different strengths, but Industry 5.0 has room for both concepts. Human workers, with their intuition, cognitive skills, and flexibility, will still have a place on the factory floor of the future.

Volker Bartenbach is the CEO and Co-Founder of Auxivo AG, a Swiss exoskeleton company. With over 12 years of experience in developing, researching, and commercializing exoskeletons, Volker leads a talented and dedicated team to advance the field and positively impact many lives.

Volker holds a PhD in exoskeleton robotics from ETH Zürich and has been awarded an ETH Pioneer Fellowship and an SNSF/Innosuisse BRIDGE Fellowship.