According to SAFE, the Stroke Alliance for Europe, over 13.7 million new strokes happen each year, and statistics have also shown that up to 80% of stroke survivors face upper limb impairment. However, a number of patients can overcome this condition around six months after the incident, even achieving full motor recovery, through neuro-rehabilitation and the brain’s ability to adapt to new incoming information and undertake a form of self-healing called neuroplasticity.

Yet, existing advanced neuro-rehabilitation techniques are faced with a variety of limitations. In order to address this and further support the chances of patient recovery, NeuRestore aims to become a cost-effective (£98k licensed unit/year) and non-invasive brain-computer interface (BCI), specifically tailored for motor rehabilitation of upper limb weakness in stroke survivors without the continuous intervention of specialist physiotherapists.

The NeuRestore consortium were able to commence the project as a result of winning Innovate UK funding in 2019. Each partner is responsible for delivering different parts of the BCI with Generic Robots focusing on constructing a robotic exoskeleton that covers the whole hand and arm, Castalia Innovation developing the virtual reality (VR) component of the project, and the Essex Innovation Centre working on the algorithmic model and the integration with the robotic exoskeleton.

NeuRestore uses relatively inexpensive EEG (electroencephalogram) devices to monitor and record the brain’s electrical patterns while simultaneously receiving trigger feedback or an action output. To achieve a comprehensive picture of cerebral activity, motor imagery (imagining a movement) is employed. With the repetition of mental images of movements, an algorithmic model is calibrated to identify and classify when the patient shows true intention of movement. The trained model is then paired with a robotic hand exoskeleton so that action outputs are generated from classifying the brain signals, and the movement of the robotic fingers is synchronised with them.

The whole process becomes even more immersive when the patient enters a virtual 3D environment where they can see their hand move, providing a more realistic visual output of their imagined movement. This VR dimension can greatly help with building a stronger link between brain signals and subsequent real-life physical movements.

Panos Chatzakos, director of the Essex Innovation Centre, said: “This project is enabled by the complementary expertise and experience of the consortium partners who, together, are combining their knowledge of advanced medical technologies development and application to deliver a brand new support system for stroke patients, that is both affordable and proven effective at making a real difference to people’s recovery.”

Among the advanced automation, digitalisation and electrification solutions on display, the company will feature its dedicated machining centres and interconnected digital technologies able to transmit, elaborate and analyse machine and process data. These include in.Grid, the IIot data analysis platform enables real-time monitoring of equipment and systems; MI.RA/Thermography, an innovative, in-line testing and quality control system that uses thermal imaging and artificial intelligence; and the highly-specialised Comau Laser Lab which offers advanced operational solutions in electrification. Comau will also present its e.DOTM Experience platform, which uses robotics as an engaging learning tool thanks to the interactive and open-source e.DO robot.

Of particular interest is the new RACER-5-0.80 (Racer-5 COBOT), a 6-axis articulated cobot with a 5 kg payload and 809 mm reach that can automatically switch from industrial robot speed to collaborative speed in complete safety. For ergonomic support during strenuous or repetitive tasks, Comau’s MATE-XT exoskeleton is the only commercially-available exoskeleton with EAWS certification, attesting to its proven ability to reduce biomechanical loads. Finally, Comau’s Smart Drive machining solutions deliver fast, precise and flexible machining processes, while its Urane 25 horizontal machining centre, featuring linear motors and electric spindles, ensures high-speed performance and stable, long-term accuracy.

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The scientific study will analyse the biomechanics of using MATE-XT for new applications, under new conditions and within new industries and outdoor environments, while verifying users’ learning and motor adaptation speeds. The results achieved can be applied in similar conditions within other contexts all over the world.

The joint collaboration is fuelled by the strong synergies in bio-engineering and advanced robotics that each partner brings to the table. Comau was introduced to Heidelberg University by IUVO, a spin-off company of Scuola Superiore Sant’Anna (Pisa, Italy). The majority share of IUVO is held by a joint venture between Comau and Össur, a market leader in the field of non-invasive orthopedics that improve human mobility, in which Comau is the majority holder. Comau has also co-developed both the original MATE and new MATE-XT exoskeletons together with IUVO.

The vast wealth of experience and scientific evidence collected by Comau and IUVO is the starting point of the new study. Heidelberg University will now research biomechanical and productivity results, among other factors, with the ultimate goal of collecting more data regarding MATE-XT’s effectiveness for novel and highly-demanding applications.

“The collaboration with Heidelberg University underscores our commitment to evolve the use of adaptive wearable technologies through the combination of empirically-backed research, advanced robotics and biomedical expertise,” said Giuseppe Colombina, Comau HUMANufacturing Innovation Hub leader and CEO of IUVO.

“The collaboration with Comau and IUVO is extremely strategic for my research group at Heidelberg University. We have the chance to test a certified device from a leading automation company, and one that is also complementary to the robotic technology we have been designing here,” emphasised Lorenzo Masia, PhD and tenured professor in medical technology and biorobotics at Heidelberg University.

“The proliferation of wearable robotic devices represents a long-term, sustainable answer to ensure wellbeing in the workplace,” explained Nicola Vitiello, PhD, associate professor at Scuola Superiore Sant’Anna and founding partner of IUVO. “Our research with Heidelberg University, studying the use of MATE-XT within the German industrial context, will amplify our knowledge about the platform and potential development areas.”

The validation of breakthrough technologies in the field of biomedical devices and wearable robotics is an important step toward improving the quality of life for workers tasked with heavy, repetitive or highly manual operations. According to Comau estimates, the global market for exoskeletons alone will reach a five-year CAGR of up to 40%, with the industrial sector representing close to half of this.

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To stay ahead of competitors, manufacturers must get their products from components at the factory to complete ready-to-sell pieces without hold-up. Automation has been widely adopted to increase manufacturing efficiency, but there are several tasks where the human ability to critically assess and respond to live situations cannot be replaced.

In areas where automating manufacturing processes is not the best option, human efficiency can still be increased. Providing human workers with occupational exoskeletons can help facility managers increase production rate, while also benefiting employee health.

Superior stamina

Occupational exoskeletons are worn by the worker to help them perform certain actions with a higher degree of strength and repeatability, or with less physical strain. An external mechanical frame is attached to various parts of the body such as the arms for repetitive assembly tasks, the legs for lifting heavy loads and the back for osteo and muscular support. The exoskeleton can provide a proportion of the effort required to carry out a task, therefore lowering the amount of exertion needed from the wearer.

With each movement requiring less energy, human workers can perform for longer, displaying increased endurance. This decreased physical fatigue offered by the skeletal support also gives the wearer heightened concentration, as they aren’t distracted by aches and tiredness. This boosts the speed and quality of production, as well as providing better working conditions for employees.

A real life example of occupational exoskeletons increasing worker stamina is the Noone Chairless Chair, which can be fastened to the back of a worker’s legs. Once attached, the shock absorber element behind the lower leg locks in stages when the user wishes to sit down, and releases when the user stands up.

With all weight being led directly to the ground, the user’s legs and back can be rested. The exoskeleton is useful for workers who work stationary for a long period of time, such as those attaching parts to a vehicle.

Powerful performance

As well as increasing endurance, the assistance of an occupational exoskeleton can give the user added strength. With more power provided by the exoskeleton, the user doesn’t have to put in as much physical effort, therefore reducing the chance of injury and strain.

Decreasing the possibility of injury inherently benefits the employee’s wellbeing, but also benefits the company’s production rate, as the employee will require fewer sick days and will be able to provide their best performance.

Repeated gripping and rotating actions, such as those used when welding together aircraft structure parts in aerospace manufacturing, carry a high risk of hand and wrist injury. It’s in these tasks that technology such as the Bioservo Technologies Ironhand can protect workers from injury. The Ironhand uses pressure-sensitive sensors to detect when the user performs a gripping action, then calculates and delivers the necessary extra gripping force.

By aiding the user’s grip, Ironhand can reduce strain, as well as helping the worker hold onto workpieces or tools that are difficult to grasp, such as those that are vibrating or are in cold environments. This makes sure processes can be carried out without wasted time and damage from dropping tools.

Motorised movements

Exoskeletons require motors with fine speed control to deliver the correct amount of power to assist each movement. This is especially true for exoskeletons such as the Ironhand, which require precise hand movements and coordinated movements of the fingers, as well as varying responses to different tasks.

High torque is required in motors for exoskeletons to be able to move parts of the user’s body. Torque is also advantageous for handling large weights when performing lifting tasks such as box shifting. In the Chairless Chair, this is beneficial for quick locking of the seat so the user is supported before they lower too far to the floor.

For all occupational exoskeletons, it’s equally important that the motor has a high power-to-weight ratio. A compact motor ensures the exoskeleton is light to wear and has minimal bulk. Power must be delivered for the entire working day, so high efficiency is essential for a long battery life.

Exoskeleton manufacturers must work with a trusted motor supplier to find a well-rounded motor that exhibits all of these qualities. EMS is the sole UK supplier of Faulhaber motors, which display a superior power-to-weight ratio. In particular, the Faulhaber BXT motor series is ideally suited to exoskeleton applications. Its flat construction minimises space requirements, while its innovative winding technology allows it to deliver torque up to 134mNm.

The motors can be combined with a complementary encoder to achieve precise speed control. They can also be paired with the Faulhaber GPT planetary gearheads to achieve high torque at low speed, allowing the motor to run more efficiently. The GPT range is welded to the motor at the factory with no need for an adapter kit to mount it, which keeps the system compact.

Manufacturers should take inspiration from the protection and enhanced performance animals receive from their exoskeletons. Occupational exoskeletons allow employees to perform with increased stamina and power, while also improving their wellbeing, providing the ultimate blend of man and machine.

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This results in an average decrease in the ergonomic scores of 30% for the shoulder in static position and 25% for dynamic movements of the shoulder, even when considering the handling of small loads.

This certification proves Comau meets the expectations of companies that need to understand concretely how an industrial exoskeleton like MATE can impact their operations. More specifically, to what degree it can reduce the physical stress of their employees, helping them to carry out their tasks in a more comfortable way, reducing the risk of developing musculoskeletal pathologies over time.

“Comau is proud that the MATE exoskeleton is awarded EAWS certification from the Ergo Foundation,” explains Duilio Amico, Marketing and Network Development Director of Comau Robotics and Automation Products. “This result is a further confirmation of the importance of investing in the development of innovative devices, as wearable robotics, to improve the way operators work and make production processes safer and more sustainable”.

Developed by Comau in partnership with IUVO, a spin-off of the BioRobotics Institute of the Scuola Superiore Sant’Anna in Pisa, and ÖSSUR, a leading Icelandic company in the field of non-invasive orthopedic devices, MATE is a passive mechanical exoskeleton that stands out for its capacity to support the shoulders and arms in their natural movement. It allows workers to feel less physical fatigue, thus improving the overall quality of their activities.

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