Patent ID: 12239597

InFIG.1, numeral1indicates in its entirety an operator who conducts his/her working operations within a work station, referenced by numeral2. Thanks to the characteristics of the system which is here described, the work station2can be an open, fenceless space within a factory.

In the example illustrated inFIG.1, the operator1is intent on lifting a workpiece3, but it is understood that the operator1may be engaged in conducting any type of operation required within a work station2.

The work station2comprises a system for assisting the operator1in conducting the working operation, so as to minimize his/her fatigue level and to optimize his/her work performance.

In particular, this system comprises a plurality of sensors S associable to the body of the operator1for the detection of one or more parameters.

The sensors S are configured for detecting one or more physiological parameters, which are indicative of the fatigue level of the operator1, and/or one or more movement parameters, which are indicative of the position and of the orientation of the operator1in the work station2.

Examples of parameters which are detected by sensors S are the heart rate, the metabolic consumption, the skin conductivity, the surface electromyography, the pressure at the interface between an active exoskeleton worn by the operator1and the body of the operator1, the movement of the operator1and the relative orientation of the body districts of the operator1. It is understood that it is possible to carry out detections in which the above parameters are detected all together, individually or in groups.

It is understood that the number, the type and the shape of the sensors S which are associated to the body of the operator1may vary in different embodiments, based also on parameters which are intended to be detected. For instance, if you want to perform a surface electromyography for detecting the activation of the muscles of the operator1or a detection of the heart rate of the operator1, the sensors consist of electrodes usually used in the art for this type of detections.

In an embodiment, the sensors S are associated to a garment4intended to be worn by an operator1, so that when the operator1wears the garment, the sensors S are in contact with the body of the operator1.

In the example shown inFIG.2, such garment4is a shirt. However, it is understood that such example is non-limiting, since also embodiments wherein the sensors S are associated to garments4other than a shirt, for example a tracksuit as shown inFIG.5, fall under the scope defined by the present description.

In the example shown inFIG.2, the sensors S are of a substantially circular or elliptic shape, and are arranged at the areas of the shirt intended to be in contact with the chest and with the arms of the operator1wearing the shirt.

Nevertheless, such characteristics are non-limiting, since the sensors S may also be of shape and size other than the ones represented inFIG.2and may be arranged in areas of the shirt intended to be in contact with other body districts of the operator1, such as for instance the forearm, the abdomen, the back and, if the garment4to which the sensors S are associated is a tracksuit, the legs, as shown inFIG.5.

In an embodiment, the sensors S are associated directly to the body of the operator1, as represented by way of example inFIG.3.

In the example shown inFIG.3, the sensors S are arranged at the torso, the arms, the hands, the legs and the feet of the operator1. This characteristic is non-limiting, since it is possible that in other embodiments the sensors S are arranged also at body districts of the operator1different than shown inFIG.3, for instance at the abdomen, the forearm or the neck of the operator1.

In the embodiment shown inFIG.3, the sensors S are supported in pockets of support structures5, which are used to keep the sensors S stationary at the body district where the detection of the parameter or of the parameters of interest is intended to be conducted.

In the example shown inFIG.3, the support structures5are portions of fabric shaped so that they can be worn at the various body districts of the operator1. It is understood that the shape of the support structures5may also be different than the one shown inFIG.3, being suitable any type of shape capable of keeping the sensors S in the desired position and in contact with the body of the operator1.

Moreover, in embodiments not visible in the figures, the support structures5are absent, as the sensors S are capable of remaining autonomously at the suitable body district for detecting the parameters. For example, in the case a surface electromyography or the detection of the heart rate of the operator1is intended to be conducted, electrodes can be used that include an adhesive strip at the portion that comes into contact with the body of the operator1, capable of keeping the electrode attached to the skin, so that support structures5are not required.

It is evident from the above description that the preferred body districts of the operator1with which the sensors S are put in contact for conducting the detections of parameters are the arms, the legs and the torso. However, this characteristic is non-limiting, since the sensors S may be arranged at any other body district of the operator1in which the detection of one or more parameters is intended to be conducted.

The system for assisting the operator1in the work station2further comprises at least one active exoskeleton6, wherein “active exoskeleton” refers to an exoskeleton comprising one or more electrically operated actuators. The active exoskeleton6is wearable by the operator1for receiving assistance in the execution of one or more operations and, preferably, for receiving assistance in maintaining postures in which the muscles of the operator1are contracted for prolonged periods of time.

It is understood that both embodiments wherein the system comprises only one active exoskeleton6and embodiments wherein the system comprises more than one active exoskeleton6, each for providing a corresponding body district of the operator1who is wearing them with support, fall under the scope of the present description. In the embodiment wherein the system comprises more than one active exoskeleton6, each active exoskeleton6comprises one or more corresponding electrically operated actuators.

In a preferred embodiment, the active exoskeleton6is worn by the operator1for receiving assistance in forward reclining movements of the torso, and is particularly useful when the operator1has to remain for many hours in a row with the torso forward reclined or when the operator1has to perform tasks, such as lifting weights, in the reclined position, as exemplified inFIG.1.

However, this characteristic is non-limiting, since in embodiments not visible in the figures the active exoskeleton6provides the operator1with a different support, for example a support to movements of the muscles of the legs or to movements of the muscles of the arms.

A preferred example of active exoskeleton6suitable for being worn by an operator1has already been proposed by the same inventors in the European patent application EP 20162846, still secret at the date of filing of the present application, and is shown inFIG.4.

In this preferred example, the active exoskeleton6is worn by the operator1for receiving assistance in forward reclining movements of the torso, and comprises an upper structure7, for the engagement of the torso of the operator1, and a lower structure8, for the engagement of the legs of the operator1. The upper structure7and the lower structure8are pivotally connected with each other around an axis a.

As visible inFIG.4, the upper structure7comprises a pair of lateral uprights7A and7B joint at the top by a panel8, provided for the support of the torso of the operator1wearing the active exoskeleton6, while the lower structure8comprises two lower lateral semi-structures8A and8B, intended to be associated to each leg of the operator1respectively. In the embodiment shown, each of the two lower lateral semi-structures8A and8B carries a panel9of support for the leg of the operator1.

The active exoskeleton6further comprises at least one elastic device, not visible inFIG.4, preferably a spiral spring or an elastic joint, operatively interposed between the upper structure7and the lower structure8, and at least one electric motor10operatively arranged in series with the elastic device, between the upper structure7and the lower structure8.

The electric motor10comprises a motor shaft10B, capable of driving the rotation of a driven shaft11by means of a belt reducer transmission12. Being the driven shaft11linked to the elastic device, such elastic device is deformed by the rotation and consequently delivers a resisting torque which results in a supporting effect felt by the operator1in the forward reclining movement of the torso.

In an embodiment, the sensors S are associated to the structure of the active exoskeleton6so as to be in contact with the body of the operator1, with reference to the condition of the active exoskeleton6worn by the operator1. The association between the sensors S and the active exoskeleton6may be performed in any type know in the art, for example by means of the use of an adhesive material.

In the embodiment wherein the active exoskeleton6is the exoskeleton shown inFIG.4, the sensors S are preferably arranged at the panel8and/or the panels9.

In the embodiment wherein the operator1wears a garment4in which the sensors S are integrated, the active exoskeleton6is worn by the operator1over the garment4.

The system for assisting the operator1in conducting work operations further comprises at least one collaborative robot12, configured for conducting one or more operations adjacent to the operator1and in cooperation with the operator1, wherein “collaborative robot” refers to a robot operating in an open space not protected by a fence or other means of protection. In other words, the collaborative robot12operates in the same work station2where the operator1conducts his/her operations.

The collaborative robot12is configured for cooperating with the operator1in order to facilitate the conduction of his/her operations, for example by providing him/her with tools necessary for the work or by conducting actions complementary to the actions conducted by the operator1.FIG.1is exemplificative of a situation in which the collaborative robot12and the operator1conduct complementary operations on products P to be worked which are arranged on a worktop13within the work station2.

The collaborative robot12further comprises a robot electronic controller ERassociated to it. In particular, the electronic controller ERsends signals to the collaborative robot12so as to control the actions which are conducted by the collaborative robot12or the position of the collaborative robot12within the work station2.

It is understood that more than one collaborative robot12may be present in the work station2for cooperating with the operator1. In such a case, each collaborative robot12is associated to a corresponding robot electronic controller ER.

It is understood that the collaborative robot12may be any type of collaborative robot known in the art and suitable for being used in a work station2. Typical examples of collaborative robots are robots equipped with sensorized coatings or casings, which allow the robot to stop when an excessive proximity of parts of the robot with respect to an external body is detected.

The system for assisting the operator1further comprises at least one system electronic controller ESconfigured and programmed for receiving signals by the sensors S, which are elaborated by them based on the parameters detected from the operator1, and for sending signals to the one or more electrically operated actuators of the active exoskeleton6and to the robot electronic controller ERbased on the elaboration of signals detected by the sensors S.

In particular, the electrically operated actuators of the active exoskeleton6worn by the operator1are controlled by the system electronic controller ESbased on the physiological parameters detected by the sensors S which are indicative of the fatigue level of the operator1, such as the heart rate, the surface electromyography, the skin conductivity and the metabolic consumption.

Moreover, the robot electronic controller ERis controlled by the system electronic controller ESbased on the parameters indicative of the movement of the operator1and on the position and relative orientation of his/her body districts. In this way, the electronic controller ERmoves the collaborative robot12so that the operator1does not risk to collide with it and always operates safely.

In the preferred embodiment, the system electronic controller ESadvantageously comprises an artificial neural network configured for learning the movements and the physical and physiological features of the operator1and for consequently elaborating both signals to send to the robot electronic controller ERand command signals for the electrically operated actuators of the active exoskeleton6. It is understood that the definition “artificial neural network” as used herein refers to a circuit or a controller configured for performing an elaboration by means of a method of machine learning.

A scheme of the use of the embodiment shown in the figures is visible inFIG.5. The operator1who works within the work station2wears the garment4in which the sensors S are integrated which, in the worn condition, are in contact with the body of the operator1. Over the garment4, the operator1wears the active exoskeleton6(not visible on the operator1inFIG.5, for allowing the visualization of the garment4), in order to receive support in maintaining the postures in which the muscles are contracted for prolonged times. The collaborative robot12, which cooperates with the operator1in conducting his/her work operations, is also present in the work station2.

The sensors S detect physiological parameters of the operator1, namely heart rate, skin conductivity, surface electromyography, metabolic consumption, which are indicative of the fatigue level of the operator1, and parameters indicative of the movement and of the relative orientation of the body districts of the operator1.

Based on the detected parameters, the sensors S generate a plurality of signals, indicated as A1-A8inFIG.5, and send them to the system electronic controller ES. Based on the signals received by the sensors S, the system electronic controller ESsends one or more signals B to the robot electronic controller ER, associated to the collaborative robot12, and one or more signals C to the electrically operated actuators of the active exoskeleton6.

Based on the signals B received from the system electronic controller ES, the robot electronic controller ERcontrols the collaborative robot12so that it cooperates in an optimal way with the operator1. In particular, the robot electronic controller ERcommands movements of the collaborative robot12within the work station2so as to avoid that it collides with the operator1, thus ensuring safe work conditions and reducing the risk that the operator1is accidentally injured. Moreover, the robot electronic controller ERcontrols the collaborative robot12so that it conducts complementary operations to the operations conducted by the operator1. For example, the collaborative robot12may deliver work tools to the operator1, or conduct part of the workload of the operator1.

Moreover, based on signals C received by the system electronic controller ES, the electrically operated actuators of the active exoskeleton6are activated, deactivated or regulated so as to provide the operator1wearing the active exoskeleton6always with the optimal assistance, which is set based on the fatigue level detected with the elaboration of the parameters detected by the sensors S.

Thanks to the presence of the artificial neural network, the system electronic controller ESstores the physiological parameters and the movement parameters detected for every operator1who uses the assistance system, and elaborates these parameters by means of methods of machine learning. As a consequence, an optimal control of the collaborative robot12and of the active exoskeleton6is set for every operator1, so as to receive an assistance that is as adapted as possible to the physical and physiological features, to the postures and to the workload of the operator1, and as a function of the time and of the evolution of the physical state of the operator1during the working period.

For example, depending on the height of the operator1, the artificial neural network is capable of storing the optimal position for the delivery of working tools from the collaborative robot12to the operator1, so that every time that specific operator1uses the assistance system within the work station2, the collaborative robot12delivers the working tools to the operator1at the stored position.

It is evident form the above description that the assistance system subject of the present invention is characterized by a high level of active cooperation among the involved apparatus. In fact, the system allows not only to avoid that the operator collides with the collaborative robot, but also to foster an active cooperation between the collaborative robot and the active exoskeleton so as to maximize the assistance felt by the operator and to make the working environment comfortable and safe.

Moreover, unlike what has been described in the US patent application US 2019099877 A1 cited at the beginning of the present description, collisions between the collaborative robot and the operator are prevented not by moving the exoskeleton—and thus the muscles of the operators—against the control of the operator, but simply by moving, braking or blocking the collaborative robot within the work station based on the parameters of movement and of relative orientations of the body districts that are detected by the sensors. This involves an increase in the comfort felt by the operator.

Studies and tests carried out by the Applicant has further proved that the parameters listed above, including physiological parameters aimed at determining the fatigue level of the operator and movement parameters aimed at determining the position of the operator within the work station in relation to the collaborative robot, if detected simultaneously by sensors in contact with the body of the operator, have a synergistic effect in ensuring an optimal control of the collaborative robot and of the active exoskeleton for assisting the operator in conducting his/her operations.

Naturally, without prejudice to the principle of the invention, the details of construction and the embodiments may vary widely with respect to those described and illustrated purely by way of example, without departing from the scope of the present invention, as defined by the attached claims.