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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
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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.
S = R1 · θarray,max (3)
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
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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.
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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
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