Human-Robot Collaboration New System Connects Exoskeleton and Cobot

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Researchers at the Technical University of Munich, Germany connect an exoskeleton and a robotic arm for direct exchange. The new system significantly relieves skilled workers when lifting heavy components and simplifies workflows in the factory.

In industrial production halls, humans and robots usually work strictly separated. Safety regulations typically require that a robot completes its task before a skilled worker takes over the next step. Federico Masiero from the Chair of Intelligent Biorobotic Systems at the Technical University of Munich (TUM), Germany explains the challenge: "This can become exhausting, for example, during quality inspection of components that need to be repeatedly lifted and set down."

To improve these processes and reduce physical strain on users, a team led by Professor Lorenzo Masia at the Munich Institute of Robotics and Machine Intelligence (MIRMI) developed the Weara-Cob system. The name is a shorthand for the English terms "wearable" and "collaborative." The technology combines an exoskeleton for the upper body with a one-armed collaborative robot, known as a Cobot. This integration allows humans to lift heavy loads more easily while the machine actively and safely supports them.

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Sensors Transmit the Weight in Real Time

The exoskeleton is worn by employees similarly to a backpack on their back. An electric motor is located there, from which thin, tear-resistant wires run over the shoulders to special elbow pads at the front. As soon as the motor pulls on these wires, it takes a significant part of the workload off the biceps in the upper arm. In its default setting, the construction compensates precisely for the weight of the human arms.

The special feature of Weara-Cob lies in the direct communication between the robot and the exoskeleton. When the robotic arm hands an object to the human colleague, it weighs it at the same moment. The machine transmits the exact weight wirelessly to the exoskeleton. The electric motor on the back then precisely adjusts the tensile force of the wires to the mass of the object.

Significantly Less Muscle Force Required

Current studies by the university show that this combination reduces the muscle effort by up to 65 percent. The system not only takes into account the pure weight but also the shape of the objects. "To handle asymmetrical components as well, the robot also determines their center of gravity," says Masiero. The researcher highlights the specific benefit: "Advantage: It is possible to provide more support to one arm than the other, thereby balancing the loads."

Shoulder exoskeletons do function without a direct robot connection. So far, systems typically measure muscle activity in the upper arm via sensors to determine the required force. This method provides reliable results with deviations of only half a kilogram to one kilogram (approx. 1.1 to 2.2 lbs). However, users must painstakingly attach the sensors to their skin before each use. For everyday work in a factory, this approach often proves to be impractical.

Simple Programming Without Code

The robotic arm used features seven joints. This design provides the necessary mobility and safety in direct contact with humans. As soon as the Cobot approaches a person, it automatically reduces its speed. In addition to relieving the physical strain on skilled workers, Professor Lorenzo Masia highlights another aspect: "We were not only able to demonstrate that colleagues in the factory can be specifically relieved but also how easy it is to teach the Cobot something."

The machine is programmed by simply guiding the robotic arm by hand. Masia emphasizes: "Not a single line of code is needed. This is a huge advantage compared to many robots currently used in factories, separated from humans."