Use Case 1

COBOT-Worker cooperative assembly

(a) In-line use of upper body exoskeleton, (b) in-line use of COBOTs,(c) workers in proximity working inside a car chassis

In vehicle assembly operations, the process involves workers and several tasks characterized by largely different postures, workloads, and complexity often requiring exoskeletons to reduce the biomechanical load. Additionally, it can be improved by COBOTs that either support heavy parts such as the roof or pick components and tools for the workers.

In this context, the concomitant use of exoskeletons that oversize the workers’ body, represents a possible cause of collision and damage with the other worker and possibly with the COBOT inside the cockpit. This limits the movements of the workers and slows down the process. Moreover, the assistance in keeping the position of the roof and the motions for the pick-n-delivery of components of the COBOTS, create a complex dynamical changing environment where COBOTs and workers, need to cooperate safely and efficiently.

Use Case 1 includes innovative artificial intelligence for control strategies, and the adequate sensorization COBOTs.

Description of SestoSenso Use-Case 1, developed at University of Genoa.

This video describes the Sestosenso Use Case 1 testing, where we explore how collaborative technologies can improve real work conditions. You’ll see an operator assembling the internal roof, handling flexible and bulky parts like handles and courtesy lights. Supporting the task are a collaborative robot and a passive upper-arm exoskeleton, designed to reduce strain and enhance comfort. The lab trials include two interaction scenarios: the cobot positioned behind or beside the operator. The goal is to understand ergonomic impact and interaction quality, combining real data with user feedback. The results are clear: the solutions work, and all KPIs were achieved, ensuring efficiency, safety, and operator well-being.