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A Novel Soft Elbow Exosuit to Supplement Bicep Lifting Capacity

Conference Paper · October 2018


DOI: 10.1109/IROS.2018.8594403

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2018 IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS)
Madrid, Spain, October 1-5, 2018

A Novel Soft Elbow Exosuit to Supplement Bicep Lifting Capacity


Carly M. Thalman, Student Member, IEEE, Quoc P. Lam, Pham H. Nguyen, Student Member, IEEE,
Saivimal Sridar, Student Member, IEEE, and Panagiotis Polygerinos∗ , Member, IEEE

Abstract— This paper investigates the design of a soft elbow


exosuit capable of providing supplemental lifting assistance
by reducing muscle activity of the bicep muscle. The aim
is to improve the efficiency and endurance of workers who
are tasked with repetitive lifting. The design consists of an
array of pneumatically pressurized soft actuators, which are
encased in nylon fabric that allows for a high force-to-weight
ratio of 211.5N/g. An analytical model governing the bending
behavior of two consecutive actuators and torque generated by
the exosuit is developed, with test results showing less than
10% error from the theoretical model. An elbow joint torque
value of 27.6N·m is achieved at 300kPa, which is comparable
to the 30N·m maximum set by OSHA requirements in the
USA. Further testing with a healthy participant is performed
using surface electromyography (sEMG) sensors and a motion
capture system to assess the capabilities of the exosuit to provide
active assistance to the bicep during isometric and concentric
contractions. Measurable assistance to lifting is observed with
minimal obstruction to the user’s range of motion for all
experiments.

I. INTRODUCTION
Freight, stock, and warehouse workers are required to Fig. 1. Illustrated concept of the soft robotic elbow exosuit in a warehouse
perform strenuous and repetitive tasks such as packing, environment. The physical prototype of the soft elbow exosuit is depicted
in the expanded view. Key design elements include: (1) Actuator array for
shelving, loading, and unloading goods on a daily basis. flexion motion of elbow (2) Straps to tighten and loosen the elbow exosuit,
These repetitive motions can lead to muscle fatigue, as well (3) Elastic elbow sleeve to attach elbow exosuit to users arm.
as lower-back and upper-limb injuries that reduce productiv-
ity. Injuries in this line of work can cause musculoskeletal the amount of physical exertion the user is required to
disorders (MSDs) as a result of improper lifting postures, sustain. Examples of human augmentation via exoskeletons
repetitive high strain activities, and age-related factors [1]. have been seen for multi-purpose use in healthcare, rehabil-
According to the US Department of Labor in 2015, there itation, and industrial settings [5]. There have been a variety
were 376,190 cases (33% of all injury cases) of MSDs caused of lower-limb exoskeletons [6] and upper-limb devices [7].
by overexertion in lifting [2]. Of all the occupations, laborers These devices seek to increase the load bearing capability of
and freight, stock, and material movers were part of the the user. However, some of the primary concerns of using
highest number of injury cases [2]. The cost of workplace exoskeletons is: rigidity, high development cost, portability,
injury in the USA alone is amounted to approximately $190 alignment complications with the biological joint they are
billion and has resulted in over 1.1 million lost days of work trying to assist, and comfort over long periods of use.
[3]. There has also been a consistent increase in the age of The recent introduction and advancement of soft robotics
the labor force since the beginning of the century and the has led to promising designs of wearable devices that are
category of workers 45 years old and over has grown from compliant, safe for human-robot interaction, lightweight,
34% to 44% of the total labor force [4]. low-cost to fabricate, allow even distribution of force on
Potential solutions for approaching this problem have been the user’s joints, and are less affected by alignment issues
seen in the field of wearable robotics. These robotic devices [8]. These intrinsically soft wearable devices have been
are designed to help augment load carriage capacity and categorized based on their novel form of actuation, including
normal muscle function in healthy individuals while reducing cable-driven actuators [7], [9]–[11], pneumatic artificial mus-
cles [12]–[14], fluidic elastomeric actuators[15]–[17], and
∗ Corresponding Author
Carly M. Thalman, Quoc P. Lam, Pham H. Nguyen, Saivimal
pneumatically inflatable bladder-based actuators [16], [18]–
Sridar, and Panagiotis Polygerinos are with the Polytechnic School, [20].
Ira A. Fulton Schools of Engineering, Arizona State University, Mesa, In this paper the design and validation of a soft elbow
AZ 85212, USA. cmthalma@asu.edu, qlam1@asu.edu,
nhpham2@asu.edu, ssridar@asu.edu, exosuit utilizing a novel actuator array for bicep assistance
polygerinos@asu.edu during lifting is presented. Figure 1 illustrates the context

978-1-5386-8094-0/18/$31.00 ©2018 IEEE 6965


Fig. 3. Final Design of the soft robotic elbow sleeve (left) and the governing
free body diagram (FBD) of the actuator array against the elbow (right)
Fig. 2. (a) Deflated soft actuator with labeled dimensions for width, w
and height, h. (b) Inflated soft actuator. (c) Deflated soft actuator array. (d) where, T is the torque produced about the joint, F is the
Inflated soft actuator array. generated force by pressurization of the soft actuator array
and applied at a height of LF from the user’s arm where
the ends of the array contact the edge of the retainer as
in which the exosuit is intended to be utilized. Section II shown in Fig. 3(a) and (b). The force F is determined by
introduces the novel design of an inflatable actuator array the contact area between the soft actuator and retainer, h·w
as well its fabrication process. An analytical model detailing and the internal pressure.
the bending angle and torque generation of the exosuit is Keeping the safe maximum Occupational Safety and
introduced in Section III. Benchmarking and validation of the Health Administration (OSHA) requirements as noted in
analytical models are presented in Section IV, while Section [23], the exosuit is designed to provide 30N·m of torque
V evaluates the efficacy of the exosuit in participant testing. about the elbow joint to assist the bicep. A lightweight,
fabric-based design [19] is implemented through the use of
II. DESIGN OF THE SOFT ELBOW EXOSUIT compliant and soft materials. The base of each soft actuator
is designed to fit the curvature of arm as shown in Fig 2(b),
The design of the soft elbow exosuit is based on a
which ensures the forces are applied over a distributed area.
network of small, soft cylindrical actuators (Fig. 2(a) and
Adjustable hook and loop straps secure the fabric sleeve to
(b)) arranged in an array and constrained along the base with
the arm without covering the elbow crease. By adjusting the
an inextensible fabric. When inflated, the individual actuators
straps, the actuator array is secured against the curvature of
interact with one another other, to produce a bending motion
the elbow joint so that it does not dislodge from the joint
as depicted in Fig. 2(c) and (d).
when inflated.
This methodology has been successfully proven to achieve
predictable bending patterns using individual actuators cre- A. Fabrication
ated by hermetically sealing the borders of two sheets of The TPU (DT-2001, American Polyfilm, Branford, CT)
thermoplastic polyurethane (TPU) material [8], [16], [21]. is sealed using a custom CNC router with a modified
However, by encasing these actuators in an inextensible, soldering iron tip set at 320◦C to trace and seal the complex
weaved nylon material of the same net shape, the actuators contours of the soft actuators. A laser cutter (Glowforge
can sustain higher pressures as they are no longer limited Pro, Glowforge, Seattle, WA) is used to cut the outer nylon
by the low tensile strength of the TPU during inflation. material pouches into the desired shape. It is then sewn into
This allows the soft actuators to obtain a higher force-to- its final shape with the use of a sewing machine (SE-400
weight ratio than previously possible. Previous work has Brother, Bridgewater, NJ). The minimum distance between
implemented similar ”bellow” actuator designs to assist the soft actuators is limited to 5mm due to manufacturing
human joints [22], however these solutions still rely on an constraints of the sewing machine, which does not accurately
entirely rigid frame. enable a placement closer than this tolerance for the given
The bending of the soft actuator array is assumed to be configuration of the array. The height of each soft actuator
constrained to the back of the elbow by a nylon fabric sleeve, is also restricted to a maximum of 50mm in order to have a
which houses the components of the exosuit, as shown in Fig compact, low-profile exosuit.
3(a). The soft actuators at the end of the array are required
to remain perpendicular to the arm in order to achieve III. T HEORETICAL M ODELING
the maximum torque output. To achieve this, a triangular A. Modeling Free Space Bending Angle
retainer is placed on either side of the array (Fig 3(a)). When To model the bending curvature of the actuator array, the
pressurized, the actuators produces a bending moment given cross-section of two adjacent individual actuators is simpli-
by: fied to two dimensions as seen in Fig. 4. When deflated, the
T = F·LF (1) actuators have no interaction with adjacent actuators in the

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Fig. 4. (a) Model of two adjacent soft actuators in a deflated state, where
no contact occurs. (b) Two-dimensional geometric model of two adjacent
soft actuators are fully pressurized.

array, as shown in Fig. 4(a). The interaction between two


actuators is modeled using the following assumptions: i) the
individual actuators inflate to create a circular cross section, Fig. 6. (a) Simple bladder arrangement demonstrating interactions in the
ii) the deformation when fully pressurized is negligible, iii) array. (b) Spherical elbow joint representation of constant radius. S. The
a point contact will form with adjacent actuators; and iv) the length of the actuator array is defined with this model. (c) Section view of an
individual actuator depicting dimensions used in calculating the interacting
actuators are fixed at a point to the inextensible layer (Fig. area.
4(b)). The bending behavior of adjacent actuators is defined
as:
d
θactuator = sin−1 (1 − ) (2) values whereas Fig. 5(b) shows the the same with constant
2R values of d. It is observed that θactuator increases with both
where, θactuator is the bending caused by the interaction the decrease in d and increase in R. Feasible regions for
of adjacent soft actuators, d is the spacing between them, both R and d are identified by imposing the aforementioned
and R is the radius of a single inflated actuator. A boundary manufacturing constraints depicted by the unshaded regions
condition of 2R > d is implemented to ensure that the in Fig. 5. Possible angles between two actuators have been
interaction between two adjacent actuators causes bending limited to 90◦ as the bending angle becomes asymptotic as d
for every considered value of θactuator . becomes infinitely small. The angle θactuator , represents the
To determine the optimal parameters to achieve maximized angle between the center of an actuator and its edge. It is
bending angles, the R and d values are plotted separately by equivalent to θarray /2n, where θarray is the elbow angle and
setting one of the parameters as a constant each time. Figure n, the number of soft actuators in the array.
5(a) shows the variation in bending angles with constant R
B. Modeling Torque Output
Modeling the torque output of the soft actuator array
follows the same geometric principles outlined in Section
IIIA. However, line contact across two actuators is replaced
with the interacting area to account for shape deformation.
Additionally, the array is no longer considered in free space
bending, but constrained to the elbow joint. The resultant
shape of the inflated soft actuators is shown in Fig 6(a).
The total length of the actuator array is represented by:

S = R1 · θarray,max (3)

where, S is the arc length, R1 is the radius of the presumed


spherical elbow joint, and θarray,max is the maximum bending
angle of the elbow (Fig. 6(b)). As torque is dependent on the
moment arm LF , as seen in (1), any additional length and/or
number of actuators past the retainer has no effect on the
torque output.
As a result of the actuator array bending with the elbow,
Fig. 5. All information presented in graphs has been normalized from 0o S bends as well with its radius of curvature defined as:
to 90o , for d and R. (a) shows the relationship between θactuator and d for
incremental values of R. (b) shows the relationship between θactuator and a
varying d given a fixed R. The shaded areas are unfeasible regions due to θarray,max
the previously mentioned manufacturing constraints of the sewing machine.
Rx (θarray ) = R1 (4)
θarray
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where Rx , is the radius of curvature at the current angle,
θarray . Equation (4) demonstrates that Rx can range from R1
to ∞, which is portrayed in Fig. 4(a).
Upon closer inspection of the individual soft actuator, it
can be observed that the shape resembles that of a right
triangle with a quarter circle attached to the end (Fig. 6(c)).
Using this shape as the foundation for the following torque
model, we define the required dimensions needed to calculate
the reaction force of the actuators of Eq. 1. Using the tangent
relationship, the minor radius, r1 is determined to be:

d
r1 (θactuator ) = . (5)
2cos(θactuator )
While the major radius, r2 , also utilizes the tangent, the Fig. 7. Various actuator heights (h) and quantities (n) plotted to assess
potential solutions to finding the optimum parameters that would yield
solution is expressed as 30N·m of torque. The shaded regions indicated infeasible regions attributed
r to the aforementioned manufacturing constraints.
b2 − 4ac
r2 (θactuator ) = −b + , (6)
2a
where a, b, and c are defined by

1 π
a = 1+ q + ( )2 , (7)
(πR + (Rx + r1 )2 + r12 )2 2

π 2 r1
q
b = π 2R + π (Rx + r1 )2 + r12 − , (8)
2
q
c = (πR + (Rx + r1 )2 + r12 )2 − (πR + λ )2 ...
Fig. 8. Testing of an individual actuator to determine stiffness when fully
(9) pressurized (a) Displacement of the actuator and the corresponding force
required to cause displacement.(b) Actuator in the UTM before compression,
q
πR 2
+ π 2 Rr1 − ( ) + (Rx + rq )2 + r12 πr1 . (c) and actuator in the UTM after compression
2
To obtain the length of interaction, L, the perimeter length where, P is the pressure input parameter and LF remains
of a semi-circle is used to define the relationship between L as defined in Eq. 1.
and the minor and major radius, r1 and r2 , respectively, as The torque output of the actuator array is plotted against
shown: the number of individual actuators for fixed h as shown in
π Fig 7. An increasing soft actuator radii, R results in improved
L(θactuator ) = (r1 + r2 ) − πR (10)
2 torque with diminishing returns from increasing the number
assuming a constant width, w, as discussed in Section II. of actuators, n. Using the set 30N·m as the minimum
However, this does not provide a sufficient representation of desired threshold and limiting the maximum pressure to
the final inflated soft actuator. The actuators do not retain 300kPa for safety consideration. Fig. 7 suggests multiple
the same longitudinal cross-section dimensions when pres- design parameters that can be selected to generate a balance
surized, witnessed in previous work and studies conducted between manufacturability and ergonomics. As a result, we
on inflatable actuators [21]. Therefore, an adjusted effective select a spacing, d=8mm, number of actuators, n=12, and
width is required to better represent the behavior of the soft deflated actuator height, h=44mm. The width of the actuator
actuators: is constrained to w=75mm to fit the diameter of an average
adult arm.
h1 (θactuator ) − 2R IV. EXPERIMENTAL METHODS AND RESULTS
w1 (θactuator ) = w0 − 2R(1 − ) (11)
h − 2R A. Soft Actuator Stiffness
where, w1 represents the adjusted effective width of the A single soft actuator is placed between compression
actuator and h1 represents the variable height. Utilizing (10) platens of a universal tensile strength machine (UTM) (In-
and (11) to measure the effective area of interaction, a stron 5944, Instron Corp., High Wycombe, United Kingdom)
bending angle of 90◦ degrees is used as the variable input to determine its stiffness. The soft actuator is inflated up
into the equation below to calculate the theoretical torque to a pressure of 300kPa (as per the design parameters)
(T ) generated by the exosuit: and compressed to a total displacement of 19.5 mm, to
the spacing between two adjacent actuators. The pressure
T (θactuator ) = PLLF w1 (12) is held constant for the entirety of the test. A high force to

6968
distance from elbow to center of palm: 0.32m). Surface elec-
tromyography measurement (sEMG) (Delsys Trigno, Delsys,
Natick, MA) and motion capture (T40s, VICON Inc., Los
Angeles, CA) are utilized for recording muscle activity of
the bicep and bending angle of the elbow, respectively. Two
experiments are performed with and without assistance from
the exosuit. A total of three trials for each experiment are
performed with two minute resting intervals between trials.
An sEMG sensor is placed at the bicep of the participant,
shown in Fig. 11(a), to measure muscle activity during the
trials. The maximum voluntary contraction (MVC) and the
muscle activity during relaxation is collected as per standard
Fig. 9. Setup of torque test, showing the soft exosuit strapped to the analog
joint while fixed in the UTM. International Society of Electrophysiology and Kinesiology
(ISEK) protocols [24]. The MVC limit is measured with the
participant exerting maximum force against the load cell of
the UTM with their elbow at a 90◦ bend, and their upper arm
lying on the coronal plane (Fig. 11(b)). Three individual tests
are recorded, which result in an average maximum load of
73.6±9N (7.5±0.9kg) of force exerted by the participant.
This value is considered the maximum load the participant
can support at 90o . The current control method of exosuit
actuation is built on a single-input-single-output (SISO) open
loop system. Pressure is manually defined and monitored by
an adjustable analog pneumatic regulator.

A. Assisted Lift Test


The lifting assistance provided by the exosuit is verified
by repeating the procedure of flexing the arm from full
extension to a fixed elbow joint angle position at 90o and
Fig. 10. Results of five trials for the torque test, displaying a linear holding the arm there for five seconds before relaxing back
relationship between the predicted torque values and the measured torque
output of the exosuit. to full extension. The isometric contractions (i.e. muscle
contractions while the arm does not move) of the bicep are
weight ratio of 211.5N/g is obtained, given a single actuator monitored. Initially, a baseline for the isometric contraction
weight of 2.6g and a force output of 550N for a single soft of the participant’s bicep is established by recording the
actuator (excluding tubing, connectors and power source). A sEMG activity while performing the procedure without load,
calculated stiffness of 28.2 kN/m is found as a result of the with and without assistance from the exosuit (Fig. 11(c)). The
maximum displacement and force obtained. same procedure is then repeated for varying load of 1.5kg
and 2.5kg, first without then with assistance as shown in Fig.
B. Torque Verification 11(d) and (e).
The sEMG data is normalized with respect to the MVC
To verify the torque output compared to the theoretical and shows the unassisted isometric contractions for the 1.5kg
model shown in (12), the exosuit is secured to an analog load to be 19.2% of the participant’s MVC, and 31.2% of
elbow joint and placed in a UTM, with the joint angle fixed the MVC for the 2.5kg load. It is observed that the averaged
at 90o (Fig. 9). The actuator array is inflated in increments exosuit assistance provides 43% and 63% reduction in the
of 20kPa up to a maximum of 300kPa for five trials. A linear activity of the bicep during the static test, as shown in Fig 11
trend is observed for the relationship between pressure and (d) and (e). The sEMG data in Fig. 11 (d) and (e) indicate that
torque (r-squared of 0.99) as seen in Fig. 10. The linear there is residual muscle activity present even when assistance
regression model is compared to the theoretical model, and is provided by the exosuit possibly due to the effects of the
an average error of approximately 6.6% is observed. Overall, participant straining to prevent unwanted wrist extension.
a maximum experimental torque of 27.1±0.67 N ·m at a fixed
90◦ angle and 300kPa is obtained in contrast to the estimated B. Range of Motion (ROM) Study
30 N·m, validating the accuracy of the model. A test is performed to quantify whether the participant’s
ROM may be affected by the exosuit. The sEMG sensor
V. PARTICIPANT TESTING
is used to monitor the concentric contractions (i.e. muscle
In order to quantify the performance of the soft elbow ex- contraction during arm motion) of the bicep from full ex-
osuit, participant testing is performed with a healthy female tension to full flexion for signs of assistance through muscle
participant (age: 23 years old, height: 1.67 m, weight: 52 kg, activity reduction. Passive reflective markers are placed at

6969
Fig. 11. (a) Surface electromyography sensor and motion capture markers placement. (b) The measured positions of the arm for participant testing. (c)
Baseline isometric muscle activity with no load. (d) Measured isometric muscle activity of bicep with a 1.5kg load (e) measured muscle activity of bicep
with a 2.5kg load.

VI. CONCLUSIONS
In this paper, the design, characterization, and evaluation
of a lightweight, soft elbow exosuit aimed to assist in elbow
flexion of warehouse workers was presented. Such a design
has the potential to be utilized by warehouse workers to
reduce muscle strain and injuries. The exosuit is composed of
an array of overlapping TPU based actuators enclosed in an
inelastic fabric pouch in order to withstand higher pressures,
and therefore produced more force. The individual actuators
were designed with a curved base to match the curvature of
the arm.
The actuators were tested and characterized for stiffness,
and the final actuator array was tested for torque generation
at the elbow joint. It was observed that a single actuator can
Fig. 12. Range of Motion of the participant with and without wearing achieve high stiffness (28.2kN/m), with a force-to-weight
the device from 0o (full extension) to 115o (full flextion) is shown on the ratio of 211.5N/g. The array of actuators was able to perform
vertical axis on the left. sEMG data during motion is shown on the right. the primary task of providing 27.6N·m of torque about about
the elbow at 90o . Retainers were placed on either ends of
the top of the shoulder (acromion), center of upper arm the array to transmit forces to the body and to maintain
(humerus), elbows axis of rotation (medial epicondyle), and the actuators perpendicular to the surface of the arm. It was
wrist (styloid process) (Fig. 11(b)) to allow the motion observed that slight slippage of the straps at higher pressures
capture system to track the motion during a single bicep curl. had a tendency to cause loss in overall torque output.
The participant performs a single curl with no assistance A participant was recruited to assess the efficacy of the
from the exosuit, then repeats the motion relying on only exosuit, with and without assistance while carrying different
the exosuit to achieve full flexion. Three trials are recorded loads (1.5kg and 2.5kg). It was demonstrated that the exo-
with the upper arm remaining parallel to the coronal plane suit was successful in providing assistance during isometric
throughout the experiment. The observed angle at the elbow contractions of the bicep through the duration of a static test
joint and corresponding bicep activity is shown in Fig. 12. where the elbow was held at 90o . The results of the processed
The total elbow angle prior to wearing the exosuit spans sEMG data showed a 43% reduction in muscle activity for
115o ± 4o from full extension to full flexion. The range of the 1.5kg weight and 63% reduction for the 2.5kg weight
motion while wearing the device is found to be 107o ± 8o . when the device was active. The exosuit also demonstrated
This verifies that the exosuit does not obstruct 93% of the the ability to maintain 93% of the original ROM during
the ROM. Additionally, a reduction of 47% in the muscle full extension to flexion of the elbow. It was also shown
activity of the bicep is observed throughout the entire motion to provide assistance through the entire ROM with no load
when the exouit is assisting. This validates that the exosuit and an average of 47% muscle activity reduction with the
is capable of providing active assistance to the bicep through exosuit active.
the entire motion. Future work will include incorporation of soft inflatable

6970
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