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Editorial Articles


Issue no 05, 04 - 10 May 2024

Exoskeletons: The Future of Work Safety and Productivity

Advitya Bahl

From our childhood days, we've all marvelled at characters like Iron Man, donning his legendary armour to become a technological spectacle. Now, instead of Tony Stark battling villains, picture a factory worker or a soldier equipped with similar power-enhancing technology. That's the essence of exoskeleton technology - transforming ordinary individuals into formidable heroes in their own domains.

In the realm of modern work environments, where efficiency and productivity are paramount, the expectation for workers to perform at superhero levels of strength and endurance has never been more prevalent. Moreover, with an increased focus on workers' rights, workplaces are actively seeking ways to enhance productivity while simultaneously safeguarding the health and safety of their workforce. In this context, exoskeletons emerge as indispensable tools in achieving this dual objective.

While exoskeletons may not grab headlines as frequently, these marvels of engineering are primed to make significant impacts across various sectors, with industrial applications leading the charge. By 2030, the global exoskeleton market is projected to exceed US$4.7 billion in revenue, signaling a profound shift in how we approach physically demanding tasks.

How do Exoskeletons Enhance Workplace Safety and Productivity?

At their core, exoskeletons represent a form of augmented technology aimed at enhancing human performance in physically taxing endeavours. These wearable devices provide support to crucial body parts like the hands, lower back, legs and upper body, thereby reducing the strain on workers during activities such as lifting, transporting heavy loads and handling industrial tools. By mitigating physical strain, exoskeletons play a pivotal role in curbing the frequency of Work-related Musculoskeletal Disorders (WMSD), a significant concern for industries worldwide.

WMSD have a staggering economic toll on businesses. According to Injury Facts, these injuries collectively cost companies a whopping US$163.9 billion annually. Breaking it down, we see a staggering sum:

·       US$44.8 billion for wage and human performance loss

·       US$34.9 billion in medical expenses

·       US$61 billion in administrative costs

The panacea to this problem is exoskeleton - a game-changer in the realm of workplace safety and productivity. By providing crucial support and protection to the human body, exoskeletons have the potential to deliver substantial savings to manufacturers, logistics firms and other enterprise users. Beyond merely reducing injury rates, they directly address the financial damage caused by productivity losses and medical expenses associated with WMSD.

The implications of widespread exoskeleton adoption extend far beyond the balance sheets of individual companies. By fostering safer, more efficient work environments, these devices empower workers to perform at their best while minimising the risk of debilitating injuries. Moreover, as technology continues to evolve, we can anticipate exoskeletons becoming increasingly sophisticated and tailored to specific industry needs, further amplifying their impact.

Exoskeletons represent a symbiotic fusion of human ingenuity and technological innovation, unlocking new realms of productivity and safety in the workplace. As we march towards the future, it's clear that these wearable wonders will play an integral role in shaping the workforce of tomorrow.

Types of Exoskeletons

Did you know that there are different types of exoskeletons, each with its own unique features and functions?

Passive Exoskeletons:  Imagine putting on a suit that doesn't require any electricity or batteries - that's a passive exoskeleton for you. These marvels of engineering use mechanical components like springs to increase your strength and provide stability. They're like a supportive armour that helps you tackle physically demanding tasks without breaking a sweat. Passive exoskeletons are popular because they're cost-effective and widely available. Many industries, from manufacturing to healthcare, have adopted these suits to assist workers in lifting heavy objects or maintaining proper posture.

Powered Exoskeletons: Unlike their passive counter-parts, these suits utilise energy sources such as pneumatic systems, hydraulic actuators, or batteries to power sensors and other tools. They're like the Iron Man suits of the real world - ambitious, transformative and incredibly cool.

Powered exoskeletons represent the cutting edge of wearable technology. They offer advanced features like real time data capture and analysis, providing valuable insights to leadership teams. However, these suits come at a cost - both financially and complexity. They often require rental or subscription models (known as Robotics as a Service or RaaS) and significant research expenditure, with long development time frames.

Futuristic Exoskeletons: As technology continues to evolve, the future of exoskeletons looks brighter than ever. Researchers are exploring ways to integrate these suits with the Internet of Things (IoT), allowing them to communicate with other devices and gather even more data. They aim to develop exoskeletons that not only enhances strength but also communicates with robotic arms, collaborative robots and mobile robots, seamlessly guiding you through tasks with advanced location technologies, haptics and gesture control.

Exoskeleton Technology for Indian Armed Forces 

The Indian armed forces are turning their attention towards the adoption of exoskeleton technology, mirroring global trends. Exoskeletons, also known as exosuits, represent a transformative advancement in military gear, offering soldiers a blend of enhanced capabilities and reduced physical burdens. Spear-headed by the Defence Research and Development Organisation (DRDO)'s Defence Bioengineering and Electro-medical Laboratory (DEBEL), efforts are underway to analyse musculoskeletal data for simulation and enhancement purposes. The defence ministry has allocated resources to upgrade wearable gear for soldiers, aligning with the dynamic challenges of modern combat environments. Collaborating with private sector firms, research and development initiatives are customising exosuit designs to meet the specific requirements of Indian soldiers. With the potential to augment a soldier's load carrying capacity by up to 100 kg for extended operational durations, exosuits offer a strategic advantage. Moreover, beyond the battlefield, these technologies hold promise in assisting disabled soldiers to lead a more functional life post-combat. As the Indian armed forces embrace the future of warfare, exoskeleton techno-logy emerges as a pivotal asset, promising enhanced effectiveness and adaptability in the face of evolving threats.

What Prompted the Demand for Exoskeletons?

One major factor is the ageing workforce. Even before the COVID-19 pandemic exacerbated labour shortages, the manufacturing sector was grappling with an ageing workforce, with younger generations showing little interest in warehouse jobs. To ensure the sustainability of operations, companies are turning to exoskeletons to increase the productivity of each worker while safeguarding those at high risk of injuries.

Furthermore, as warehouses and industrial environments embrace digitisation, there's a growing appetite for data driven insights to inform strategic decision making. Exoskeletons serve as a vital link between robotics and smart wearables, providing a holistic view of workspace performance. By capturing data points directly from the human body, these devices offer valuable insights into worker’s movements, ergonomics and overall efficiency.

While automation remains a key driver of the ongoing industrial revolution, the complementary role of exoskeletons cannot be overstated. Rather than replacing human workers, these devices empower them, creating safer, more efficient work environments. As industries continue to evolve, exoskeletons are poised to play an increasingly pivotal role in shaping the future of work.

Exoskeleton Market Overview

With a projected Compound Annual Growth Rate (CAGR) of 27.4% between 2022 and 2030, exoskeleton revenue is on an upward trajectory, signaling immense potential for growth and innovation in the coming years.

The United States, Germany, China, South Korea and Japan currently lead the charge in exoskeleton adoption, collectively accounting for 75% of global revenue in 2023, amounting to US$673 million. However, by 2030, this dominance is expected to decline slightly to 68% of global revenue, as other countries enter the market. Nevertheless, these regional leaders are projected to continue expanding their deployments, driving sustained growth in the industry.

When it comes to market segments, industrial exoskeletons are positioned as the frontrunners in revenue fore-casts. Industrial shipments are forecasted to reach a staggering 181 million units by 2030, with revenue expected to soar to US$2.2 billion by the end of the decade. This underscores the industrial sector's pivotal role as the primary adopter of wearable robotics, particularly in segments such as manufacturing, cons-truction, oil/gas energy/utilities, agriculture and mining.

While the sale of passive exoskeleton shipments out-number powered ones, it's the latter that generates a higher revenue across all verticals. For instance, in 2023, globally around 46,000 shipments of passive exoskeletons were made compared to 12,000 powered ones. Yet, revenue from powered exoskeletons surpassed passive exoskeletons by US$42 million. Looking ahead, by 2030, powered exoskeleton revenue is fore-expected to approach US$3 billion, nearly double that of passive exoskeletons. This highlights the significant financial commitment associated with purchasing fully active (powered) suits, despite their lower shipment numbers.

Challenges for Early Adopters

Implementation Complexity: Deploying exoskeletons en masse can be a daunting task, especially considering the added weight and technical intricacies involved. This complexity can lead to anxiety among workers and pose logistical challenges for companies.

Investment Considerations: The investment required in robotics and software technology for exoskeleton deployment can be significant. However, advancements in mechatronics - the intersection of mechanical and electrical engineering - tend to progress at a slower pace compared to software innovation. This disparity may hinder the maximum potential of exoskeleton deployment, posing a barrier for some organisations.

ROI Calculation: Determining the Return on Investment (ROI) for exoskeletons presents a unique challenge. How do you measure ROI in this context? Is it through reduced work-related injuries or increased productivity? If it's the latter, tangible results may take years to materialise, leading key stake-holders to adopt a skeptical stance.

Infrastructure Limitations for SMEs: For Small and Medium Enterprises (SMEs), infrastructure shortcomings pose a significant hurdle. These businesses may lack the necessary facilities to receive and store exoskeleton suits and components effectively. To address this challenge, vendors may need to explore partnerships with eco-system integrators or develop in house solutions tailored to the needs of SMEs.

In navigating these challenges, it's essential for organisations to adopt a strategic approach, considering factors such as workforce readiness, technology integration and long term sustainability. Despite the obstacles, the potential benefits of exoskeleton technology in enhancing work place safety and productivity make it a compelling investment for forward thinking enterprises.

 

 

 

 

Examples of Exoskeletons

As exoskeleton technology continues to gain momentum in industries worldwide, it's essential to understand how these innovative devices operate in practice. Let's take a closer look at some examples of exoskeletons, shedding light on their unique features and functionalities:

Arm Support Exoskeleton (Ekso EVO): This exoskeleton supports the weight of a worker's arms, alleviating strain on the shoulders and arms during overhead lifting tasks. With this vest, users can experience lift assistance ranging from 5 to 15 pounds per arm, enhancing comfort and reducing fatigue. The vest is designed for easy use, simply wrapping around the waist to allow for a full range of motion while standing.

Thumb Support Exoskeleton (Paexo Thumb):  This exoskeleton reduces thumb strain by redistributing forces across the hand, minimising thumb-related injuries and highlighting the importance of protecting fingertips from mechanical impacts like clipping and plugging.

 Back Support Exoskeletons (FLEX and V2.50): These exoskeletons provide superior performance, delivering in-creased support torque and energy return compared to other models. Designed for dynamic lifting and all day wear, these exoskeletons ensure comfort, flexibility and resistance to dust and water, accommodating users of all body shapes.

Vest Exoskeleton (VEX): This lightweight wearable suit is designed to provide load support and enhanced mobility for production line workers. Featuring a multilink lift assistant module, this suit mimics human shoulder joint movements, facilitating tasks such as overhead bolting and attaching exhausts. Easy to wear, the VEX suit seamlessly integrates into workers' daily routines.

As industries continue to embrace exoskeletons, the path to success lies in understanding their capabilities, integrating them seamlessly into workflows and prioritising user comfort and safety. With innovation driving the evolution of exoskeleton technology, the future holds boundless opportunities for enhancing human performance and reshaping the way we work.

First International Workshop on 'Emerging Technologies & Challenges for Exoskeleton'

The first international workshop on 'Emerging Technologies & Challenges for Exoskeleton' organised by the Defence Research and Development Organisation (DRDO) in Bengaluru was held  on April 16-17, 2024. The event discussed various issues, themes, and ideas related to exoskeleton technology. The workshop brought together over 300 participants from various sectors including the armed forces, industry, academia, and researchers, indicating a broad interest and engagement in the field of exoskeleton technology.

The workshop emphasised the transformative potential of exoskeleton technology in both military and civilian environments. There was a call for collaboration among diverse stakeholders including the R&D community, Armed Forces, industry, and academia to collectively address the challenges and define the future roadmap for exoskeleton technology. Exoskeleton technology was recognised as having dual-use capabilities with significant commercial potential beyond military applications. This aspect underscores the importance of exploring civilian applications such as rehabilitation, occupational therapy, and augmentation. In-depth technical talks by experts from renowned institutions like ETH Zurich and Northwestern University provided insights into the current state of exoskeleton technology, ongoing research efforts, and future prospects.

( The author is a correspondent of a leading daily newspaper. Feedback on this article can be sent to feedback.employmentnews@gmail.com)

Views expressed are personal.