Session: 02-06-01: eXtended Reality & Digital Design

Paper Number: 145262

145262 - Extended Reality and Motion Capture for Ergonomics in Industrial Contexts 

In recent years, there has been a growing emphasis on operator ergonomics, driven by increased regulations on work environments and worker’s safety. Work-related musculoskeletal disorders (MSDs) underscore the importance of improved ergonomics. Traditional methods rely on subjective observations and manual measurements, leading to inaccuracies and inefficiencies. As a result, there is a need for more accurate and efficient ergonomic analysis methods to redesign operator’s task. To address these challenges, technologies, such as virtual reality and motion capture, can help to improve ergonomics assessment. By automating data collection and providing objective measures, these technologies permit to enhance the efficiency and accuracy of ergonomic evaluation process.

Furthermore, there is an important distinction between whether the ergonomic approach is carried out in a reactive or proactive manner. Most of the traditional ergonomic assessment modalities are reactive, meaning that the evaluations concern existing workstations. Emerging practices are focusing mainly on a proactive approach relying on the virtual prototype, saving time and costs.  

The research aims at developing a comprehensive tool for the ergonomist by integrating virtual models, VR setups, motion capture systems, and automated data gathering processes. These tools can be used for real-time physical ergonomics evaluation in loco and in simulated environment. The innovative aspects of this research lie in the integration of cutting-edge technologies and methodologies to an accurate ergonomic assessment in manufacturing settings for both the reactive and proactive approach.

The working task evaluation is performed using Xsens, an inertial motion capture device. Data gathered by the tracking system is elaborated by a specific module for the calculation of standard ergonomic indices (e.g., REBA).  Regarding the proactive approach, a simulation of the task is required. An HTC Vive Pro device is used to immerse the user into the simulated environment and enable virtual interaction to perform the task. The digital twin of the working environment is modeled using a 3D CAD system and with Unreal Engine 5 enabling virtual interactions. In addition, a semi-immersive virtual environment is used to provide additional information at the ergonomist for a more detailed post-session evaluation. The use case chosen to validate the framework includes a smart production line composed of a series of automated workstations programmed for specific functions. The line is programmed to assemble a specific product previously requested. The operator has to check for any interruptions in the line process and finally store the product in its final position.

This research study seeks to integrate various systems to establish a comprehensive framework for ergonomic assessment in manufacturing, demonstrating its feasibility through the analysis of a specific production scenario. By leveraging technological advancements, this approach has the potential to enhance worker’s safety and productivity while reducing time associated with traditional ergonomic evaluations.

Presenting Author: Daniel Lanzoni University of Bergamo

Presenting Author Biography: He is a PhD student in 'advanced human robot collaboration and interaction'. The focus of his research is the evaluation of the working condition of the operator during the collaboration with a robot.

Authors:

Daniel Lanzoni University of Bergamo
Marco Nava University of Bergamo
Andrea Vitali University of Bergamo
Daniele Regazzoni University of Bergamo
Caterina Rizzi University of Bergamo