Occupational exoskeletons and exosuits have been shown to reduce muscle demands and fatigue for physical tasks relevant to a variety of industries (e.g., logistics, construction, manufacturing, military, healthcare). However, adoption of these devices into the workforce has been slowed by practical factors related to comfort, form-factor, weight, and not interfering with movement or posture. We previously introduced a low-profile, dual-mode exosuit comprised of textile and elastic materials to address these adoption barriers. Here we build upon this prior work by introducing an extension mechanism that increases the moment arm of the exosuit while in engaged mode, then collapses in disengaged mode to retain key benefits related to being lightweight, low-profile, and unobstructive. Here we demonstrate both analytically and empirically how this extensible exosuit concept can (a) reduce device-to-body forces (which can improve comfort for some users and situations), or (b) increase the magnitude of torque assistance about the low back (which may be valuable for heavy-lifting jobs) without increasing shoulder or leg forces relative to the prior form-fitting exosuit. We also introduce a novel mode-switching mechanism, as well as a human-exosuit biomechanical model to elucidate how individual design parameters affect exosuit assistance torque and device-to-body forces. The proof-of-concept prototype, case study, and modeling work provide a foundation for understanding and implementing extensible exosuits for a broad range of applications. We envision promising opportunities to apply this new dual-mode extensible exosuit concept to assist heavy-lifting, to further enhance user comfort, and to address the unique needs of last-mile and other delivery workers.

Hemiparetic walking after stroke is typically slow, asymmetric, and inefficient, significantly impacting activities of daily living. Extensive research shows that functional, intensive, and task-specific gait training is instrumental for effective gait rehabilitation, characteristics that our group aims to encourage with soft robotic exosuits. However, standard clinical assessments may lack the precision and frequency to detect subtle changes in intervention efficacy during both conventional and exosuit-assisted gait training, potentially impeding targeted therapy regimes. In this paper, we use exosuit-integrated inertial sensors to reconstruct three clinically meaningful gait metrics related to circumduction, foot clearance, and stride length. Our method corrects sensor drift using instantaneous information from both sides of the body. This approach makes our method robust to irregular walking conditions poststroke as well as usable in real-time applications, such as real-time movement monitoring, exosuit assistance control, and biofeedback. We validate our algorithm in eight people poststroke in comparison to lab-based optical motion capture. Mean errors were below 0.2 cm (9.9%) for circumduction, −0.6 cm (−3.5%) for foot clearance, and 3.8 cm (3.6%) for stride length. A single-participant case study shows our technique’s promise in daily-living environments by detecting exosuit-induced changes in gait while walking in a busy outdoor plaza.

Despite the promise of powered lower limb prostheses, existing controllers do not assist many daily activities that require continuous control of prosthetic joints according to human states and environments. The objective of this case study was to investigate the feasibility of direct, continuous electromyographic (dEMG) control of a powered ankle prosthesis, combined with physical therapist-guided training, for improved standing postural control in an individual with transtibial amputation. Specifically, EMG signals of the residual antagonistic muscles (i.e. lateral gastrocnemius and tibialis anterior) were used to proportionally drive pneumatical artificial muscles to move a prosthetic ankle. Clinical-based activities were used in the training and evaluation protocol of the control paradigm. We quantified the EMG signals in the bilateral shank muscles as well as measures of postural control and stability. Compared to the participant’s daily passive prosthesis, the dEMG-controlled ankle, combined with the training, yielded improved clinical balance scores and reduced compensation from intact joints. Cross-correlation coefficient of bilateral center of pressure excursions, a metric for quantifying standing postural control, increased to .83(±.07) when using dEMG ankle control (passive device: .39(±.29)). We observed synchronized activation of homologous muscles, rapid improvement in performance on the first day of the training for load transfer tasks, and further improvement in performance across training days (p = .006). This case study showed the feasibility of this dEMG control paradigm of a powered prosthetic ankle to assist postural control. This study lays the foundation for future study to extend these results through the inclusion of more participants and activities.

This paper presents a soft, tendon-driven, robotic glove designed to augment grasp capability and provide rehabilitation assistance for postspinal cord injury patients. The basis of the design is an underactuation approach utilizing postural synergies of the hand to support a large variety of grasps with a single actuator. The glove is lightweight, easy to don, and generates sufficient hand closing force to assist with activities of daily living. Device efficiency was examined through a characterization of the power transmission elements, and output force production was observed to be linear in both cylindrical and pinch grasp configurations. We further show that, as a result of the synergy-inspired actuation strategy, the glove only slightly alters the distribution of forces across the fingers, compared to a natural, unassisted grasping pattern. Finally, a preliminary case study was conducted using a participant suffering from an incomplete spinal cord injury (C7). It was found that through the use of the glove, the participant was able to achieve a 50% performance improvement (from four to six blocks) in a standard Box and Block test.

Force feedback is often beneficial for robotic teleoperation, as it enhances the user’s remote perception. Over the years, many kinesthetic haptic displays (KHDs) have been proposed for this purpose, which have different types of interaction and feedback, depending on their kinematics and their interface with the operator, including, for example, grounded and wearable devices acting either at the joint or operational space (OS) level. Most KHDs in the literature are for the upper limb, with a majority acting at the shoulder/elbow level, and others focusing on hand movements. A minority exists which addresses wrist motions. In this paper, we present the Wearable Delta (W$ \Delta $), a proof-of-concept wearable wrist interface with hybrid parallel–serial kinematics acting in the OS, able to render a desired force directly to the hand involving just the forearm–hand subsystem. It has six degrees of freedom (DoFs), three of which are actuated, and is designed to reduce the obstruction of the range of the user’s wrist. Integrated with positions/inertial sensors at the elbow and upper arm, the W$ \Delta $ allows the remote control of a full articulated robotic arm. The paper covers the whole designing process, from the concept to the validation, as well as a multisubject experimental campaign that investigates its usability. Finally, it presents a section that, starting from the experimental results, aims to discuss and summarize the W$ \Delta $ advantages and limitations and look for possible future improvements and research directions.

Passive wearable exoskeletons are desirable as they can provide assistance during user movements while still maintaining a simple and low-profile design. These can be useful in industrial tasks where an ergonomic device could aid in load lifting without inconveniencing them and reducing fatigue and stress in the lower limbs. The SpringExo is a coil-spring design that aids in knee extension. In this paper, we describe the muscle activation of the knee flexors and extensors from seven healthy participants during repeated squats. The outcome measures are the timings of the key events during squat, flexion angle, muscle activation of rectus femoris and bicep femoris, and foot pressure characteristics of the participants. These outcome measures assess the possible effects of the device during lifting operations where reduced effort in the muscles is desired during ascent phase of the squat, without changing the knee and foot kinematics. The results show that the SpringExo significantly decreased rectus femoris activation during ascent (−2%) without significantly affecting either the bicep femoris or rectus femoris muscle activations in descent. This implies that the user could perform a descent without added effort and ascent with reduced effort. The exoskeleton showed other effects on the biomechanics of the user, increasing average squat time (+0.02 s) and maximum squat time (+0.1 s), and decreasing average knee flexion angle (−4°). The exoskeleton has no effect on foot loading or placement, that is, the user did not have to revise their stance while using the device.

Individuals with lower limb amputation experience reduced ankle push-off work in the absence of functional muscles spanning the joint, leading to decreased walking performance. Conventional energy storage and return (ESR) prostheses partially compensate by storing mechanical energy during midstance and returning this energy during the terminal stance phase of gait. These prostheses can provide approximately 30% of the push-off work performed by a healthy ankle–foot during walking. Novel prostheses that return more normative levels of mechanical energy may improve walking performance. In this work, we designed a Decoupled ESR (DESR) prosthesis which stores energy usually dissipated at heel-strike and loading response, and returns this energy during terminal stance, thus increasing the mechanical push-off work done by the prosthesis. This decoupling is achieved by switching between two different cam profiles that produce distinct, nonlinear torque–angle mechanics. The cams automatically interchange at key points in the gait cycle via a custom magnetic switching system. Benchtop characterization demonstrated the successful decoupling of energy storage and return. The DESR mechanism was able to capture energy at heel-strike and loading response, and return it later in the gait cycle, but this recycling was not sufficient to overcome mechanical losses. In addition to its potential for recycling energy, the DESR mechanism also enables unique mechanical customizability, such as dorsiflexion during swing phase for toe clearance, or increasing the rate of energy release at push-off.

The large-scale adoption of occupational exoskeletons (OEs) will only happen if clear evidence of effectiveness of the devices is available. Performing product-specific field validation studies would allow the stakeholders and decision-makers (e.g., employers, ergonomists, health, and safety departments) to assess OEs’ effectiveness in their specific work contexts and with experienced workers, who could further provide useful insights on practical issues related to exoskeleton daily use. This paper reviews present-day scientific methods for assessing the effectiveness of OEs in laboratory and field studies, and presents the vision of the authors on a roadmap that could lead to large-scale adoption of this technology. The analysis of the state-of-the-art shows methodological differences between laboratory and field studies. While the former are more extensively reported in scientific papers, they exhibit limited generalizability of the findings to real-world scenarios. On the contrary, field studies are limited in sample sizes and frequently focused only on subjective metrics. We propose a roadmap to promote large-scale knowledge-based adoption of OEs. It details that the analysis of the costs and benefits of this technology should be communicated to all stakeholders to facilitate informed decision making, so that each stakeholder can develop their specific role regarding this innovation. Large-scale field studies can help identify and monitor the possible side-effects related to exoskeleton use in real work situations, as well as provide a comprehensive scientific knowledge base to support the revision of ergonomics risk-assessment methods, safety standards and regulations, and the definition of guidelines and practices for the selection and use of OEs.

Assistive strategies for occupational back-support exoskeletons have focused, mostly, on lifting tasks. However, in occupational scenarios, it is important to account not only for lifting but also for other activities. This can be done exploiting human activity recognition algorithms that can identify which task the user is performing and trigger the appropriate assistive strategy. We refer to this ability as exoskeleton versatility. To evaluate versatility, we propose to focus both on the ability of the device to reduce muscle activation (efficacy) and on its interaction with the user (dynamic fit). To this end, we performed an experimental study involving $ 10 $ healthy subjects replicating the working activities of a manufacturing plant. To compare versatile and non-versatile exoskeletons, our device, XoTrunk, was controlled with two different strategies. Correspondingly, we collected muscle activity, kinematic variables and users’ subjective feedbacks. Also, we evaluated the task recognition performance of the device. The results show that XoTrunk is capable of reducing muscle activation by up to $ 40\% $ in lifting and $ 30\% $ in carrying. However, the non-versatile control strategy hindered the users’ natural gait (e.g., $ -24\% $ reduction of hip flexion), which could potentially lower the exoskeleton acceptance. Detecting carrying activities and adapting the control strategy, resulted in a more natural gait (e.g., $ +9\% $ increase of hip flexion). The classifier analyzed in this work, showed promising performance (online accuracy > 91%). Finally, we conducted 9 hours of field testing, involving four users. Initial subjective feedbacks on the exoskeleton versatility, are presented at the end of this work.

Although wearable robotic systems are designed to reduce the risk of low-back injury, it is unclear how effective assistance is, compared to improvements in lifting technique. We use a two-factor block study design to simulate how effective exoskeleton assistance and technical improvements are at reducing the risk of low-back injury when compared to a typical adult lifting a box. The effects of assistance are examined by simulating two different models: a model of just the human participant, and a model of the human participant wearing the SPEXOR exoskeleton. The effects of lifting technique are investigated by formulating two different types of optimal control problems: a least-squares problem which tracks the human participant’s lifting technique, and a minimization problem where the model is free to use a different movement. Different lifting techniques are considered using three different cost functions related to risk factors for low-back injury: cumulative low-back load (CLBL), peak low-back load (PLBL), and a combination of both CLBL and PLBL (HYB). The results of our simulations indicate that an exoskeleton alone can make modest reductions in both CLBL and PLBL. In contrast, technical improvements alone are effective at reducing CLBL, but not PLBL. The largest reductions in both CLBL and PLBL occur when both an exoskeleton and technical improvements are used. While all three of the lifting technique cost functions reduce both CLBL and PLBL, the HYB cost function offers the most balanced reduction in both CLBL and PLBL.

The science and technology of wearable robots are steadily advancing, and the use of such robots in our everyday life appears to be within reach. Nevertheless, widespread adoption of wearable robots should not be taken for granted, especially since many recent attempts to bring them to real-life applications resulted in mixed outcomes. The aim of this article is to address the current challenges that are limiting the application and wider adoption of wearable robots that are typically worn over the human body. We categorized the challenges into mechanical layout, actuation, sensing, body interface, control, human–robot interfacing and coadaptation, and benchmarking. For each category, we discuss specific challenges and the rationale for why solving them is important, followed by an overview of relevant recent works. We conclude with an opinion that summarizes possible solutions that could contribute to the wider adoption of wearable robots.

Exoskeletons that assist the hip, knee, and ankle joints have begun to improve human mobility, particularly by reducing the metabolic cost of walking. However, direct comparisons of optimal assistance of these joints, or their combinations, have not yet been possible. Assisting multiple joints may be more beneficial than the sum of individual effects, because muscles often span multiple joints, or less effective, because single-joint assistance can indirectly aid other joints. In this study, we used a hip–knee–ankle exoskeleton emulator paired with human-in-the-loop optimization to find single-joint, two-joint, and whole-leg assistance that maximally reduced the metabolic cost of walking. Hip-only and ankle-only assistance reduced the metabolic cost of walking by 26 and 30% relative to walking in the device unassisted, confirming that both joints are good targets for assistance (N = 3). Knee-only assistance reduced the metabolic cost of walking by 13%, demonstrating that effective knee assistance is possible (N = 3). Two-joint assistance reduced the metabolic cost of walking by between 33 and 42%, with the largest improvements coming from hip-ankle assistance (N = 3). Assisting all three joints reduced the metabolic cost of walking by 50%, showing that at least half of the metabolic energy expended during walking can be saved through exoskeleton assistance (N = 4). Changes in kinematics and muscle activity indicate that single-joint assistance indirectly assisted muscles at other joints, such that the improvement from whole-leg assistance was smaller than the sum of its single-joint parts. Exoskeletons can assist the entire limb for maximum effect, but a single well-chosen joint can be more efficient when considering additional factors such as weight and cost.

This article presents a novel smart sensor garment with integrated miniaturized inertial measurements units (IMUs) that can be used to monitor lower body kinematics during daily training activities, without the need of extensive technical assistance throughout the measurements. The smart sensor tights enclose five ultra-light sensor modules that measure linear accelerations, angular velocities, and the earth magnetic field in three directions. The modules are located at the pelvis, thighs, and shanks. The garment enables continuous measurement in the field at high sample rates (250 Hz) and the sensors have a large measurement range (32 g, 4,000°/s). They are read out by a central processing unit through an SPI bus, and connected to a centralized battery in the waistband. A fully functioning prototype was built to perform validation studies in a lab setting and in a field setting. In the lab validation study, the IMU data (converted to limb orientation data) were compared with the kinematic data of an optoelectronic measurement system and good validity (CMCs >0.8) was shown. In the field tests, participants experienced the tights as comfortable to wear and they did not feel restricted in their movements. These results show the potential of using the smart sensor tights on a regular base to derive lower limb kinematics in the field.