Working in logistics often involves repeated carrying and lifting. Such strenuous activities can lead to musculoskeletal problems, particularly back and joint pain. Exoskeletons promise to provide relief by reducing the strain on people performing such activities. We take a look at how different exoskeletons work and demonstrate the areas in which they can support people in logistics.
What Is an Exoskeleton?
The ancient Greek word “exo” (ἔξω) means “external”. Thus, an exoskeleton is an external device designed to support the internal skeletal system, our “endoskeleton”, if you will. Simply put, an exoskeleton is a mechanical support structure worn outside the body. It relieves strain on certain areas of the body and assists with specific workplace tasks. For instance, it can cushion movements and distribute the weight of lifted loads more evenly.
In concrete terms, an exoskeleton should not be imagined as a futuristic robot suit. Rather, it is best envisioned as an orthotic-like support structure that is often fastened with straps. Exoskeletons are typically worn on the back, hips, shoulders, knees, and legs. They are also used in medical rehabilitation. Here, they can support certain parts of the body during regeneration or maintain impaired bodily functions, for example.
Passive and Active Exoskeletons
There are basically two types of exoskeletons:
- Passive exoskeletons are purely mechanical. They usually feature springs or special rubber bands that absorb energy during certain movements, releasing it back to the wearer when the direction of movement is reversed. Passive exoskeletons are lighter than active systems and therefore easier to wear.
- Active exoskeletons have their own energy source. They use sensors to detect the user’s movements and translate them into control signals for electric or pneumatic motors. Then, motor power supports movements and lifting operations.
Exoskeletons: a Trend with High Priority
For the DHL Logistics Trend Radar Echo, the DHL Innovation and Trend Research Team surveyed logistics experts from our corporate clients about current and future trends. The Trend Radar Echo focuses on logistics trends that influence companies’ operational business, their strategy, and future prospects. Within the bionic improvements trend cluster, logistics experts rate the development and logistical application of exoskeletons as a high-priority trend.
This human-centered bionic solution has the potential to optimize work processes by making them easier. This increases effectiveness, albeit less than automation and standardization. On the other hand, it directly reduces the physical strain on employees. Occupational safety and employee health are valuable in their own right, but there is also an economic factor because health and safety benefits improve a company’s attractiveness as employers.
The Exoskeleton Is Not a Future Concept, But a Current Reality
Unlike in the fields of autonomous driving and last-mile delivery by drone, where regulatory issues are also a stumbling block, marketable exoskeletons for various applications already exist. However, not all exoskeletons are equally well-suited for logistics – and here, we are primarily concerned with warehouse logistics.
Large-scale deployments are still to come. This is mainly because current systems typically only support specific movements, limiting them to niche applications.
Main Functions of Marketable Exoskeletons
Manufacturers of exoskeletons have identified three areas of application that are particularly important in industrial workplaces.
Exoskeletons for Overhead Work
Some passive exoskeletons are designed specifically for prolonged overhead work, such as workshop repairs to the underside of delivery vehicles or repeatedly lifting loads above shoulder height. These exoskeletons serve as support structures for the upper arms, thereby reducing strain on the neck and shoulders.
Exoskeletons for Workspaces without Seating
Many industrial facilities do not have seating at workstations due to space or safety constraints. Exoskeletons, designed specifically to address this issue, serve as an alternative to chairs. Attached to employees’ legs, they fold out to provide chair-like support when workers squat, retracting again when they stand up.
Exoskeletons for Tasks with Frequent Lifting and Bending
Manual lifting is one of the main risk factors for back pain. Employees who frequently lift heavy loads can benefit from specially developed exoskeletons that support the lower back. The effectiveness of this technology depends on how well the exoskeleton supports bending and lifting movements. A wide range of active and passive exoskeletons are already available on the market for this purpose.
Logistical Applications for Exoskeletons
Despite growing automation, exoskeletons are a very relevant technology for supporting humans in warehouse logistics. Fully automated warehouses that do not require human labour cannot be realised for all applications.
The wide variety of shapes and sizes of goods shipped, as well as small quantities, make automatic warehouse management difficult. Since picking and loading often involves strenuous postures and movements, exoskeletons are an ideal solution for promoting employee health.
The three main types of exoskeletons have different levels of relevance for everyday operational logistics.
- Exoskeletons for overhead work have only limited applications in logistics due to their very specific function, as there are hardly any job profiles that exclusively involve overhead work.
- Exoskeletons designed for sitting, on the other hand, can reduce strain for warehouse workers by enabling them to rest while performing tasks such as operating machines or reviewing documents.
- Active and passive lifting assistance systems are undoubtedly the most relevant for logistics. Features such as cushioning repetitive movements, distributing weight more evenly and improving force transmission, as well as active lifting assistance, are particularly interesting. Such exoskeletons have great potential to improve the health and safety of employees.
Advantages and Disadvantages of Exoskeletons
The potential advantages of exoskeleton technology have already been discussed in detail here. Primarily, they lie in the systems’ ability to assist with lifting and repetitive movements. However, there is a gap between their potential and everyday operations. The (possible) disadvantages of the systems arise from the remaining uncertainties.
Marketable exoskeletons do not have a long history. Even if the operating principles of individual models appear plausible, there are still no long-term studies of their use in industry. This means that evidence-based proof of their economic efficiency and health-promoting effectiveness is still pending. This lack of evidence fuels scepticism and poses a barrier to market entry, as many companies are reluctant to take on a pioneering role.
Two aspects are particularly affected by the lack of research:
- Cost efficiency: A lack of data means it is not yet clear whether the exoskeleton can reduce logistics costs by increasing productivity and reducing sick days. Quantifiable data is essential for substantiating the business case and dispelling doubts about the exoskeleton’s medical effectiveness.
- Health risks: These include, for example, possible muscle loss and increased strain on the cardiovascular system when using active exoskeletons for overhead work. The biomechanical effects of load distribution by exoskeletons when lifting heavy weights are also still unknown. Consequently, exoskeletons cannot be adequately evaluated from an ergonomic perspective.
Employee acceptance and comfort can also cause problems. Most available exoskeletons are not completely effortless to wear and some add considerable extra weight. This creates a conflict between the benefits for certain movements and the possible restrictions for others.
Conclusion: Exoskeletons Show Promise – Questions Remain
Whether in logistics, manufacturing, agriculture, handicrafts or care, all these sectors involve tasks that require repetitive movements and/or lifting heavy loads. These tasks cannot be fully automated. This makes exoskeletons a promising technology. While primarily focusing on occupational safety and employee health, exoskeletons also aim to increase efficiency and reduce costs.
The near future will reveal whether exoskeletons can be used on a large scale, or if they will remain confined to niche applications. As with green logistics, we at DHL Freight do not just want to observe developments in this area; we want to actively shape them. When innovative technology and employee protection are aligned, we are eager to play a leading role.
