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In manufacturing, ergonomic and productivity benefits may result from combining the sensing and dexterity of the human workers with the strength of collaborative robots (cobots). Anyway, manual tasks requiring repetitive motion or working with robots can cause musculoskeletal disorders especially of the hands. In such a context, this paper proposes a novel solution that includes both a full body inertial system and a dedicated solution for hand tracking. This allows implementing the standard methods for assessing ergonomic indexes and to introduce new advanced task analyses based on gesture evaluation. The benefits reached by the integrated system for body and hand tracking can be exploited in the virtual prototyping of collaborative workstation in the manufacturing domain. Different software packages have been considered to model and simulate the collaboration between the operator and the cobot. In particular, Unity and ROS are used to develop the virtual scene and control the cobot behavior and the HTC Vive Head Mounted Display (HMD) to interact with the virtual environment. Physical ergonomics is evaluated by using both a full body suit (XSENS) and sensorized gloves (MANUS). The solution has been applied to the simulation of a virtual production line where the operator collaborates with a six-axis cobot (NIRYO ONE). Test tasks require the operator to move and manage different objects and tools by simulating different types of grasping. Real-time feedback about ergonomics, in terms of posture evaluation and alerts in case of critical condition, is shown to the operator as well as the automatic generation of reports for the post-process evaluation of the entire process. The results show how the use of these tools can be effective in the ergonomic evaluation of a collaborative robotic workstation which requires manual tasks.

The Natural User Interface (NUI), which permits a simple and consistent user’s interaction, represents a meaningful challenge for developing virtual/augmented reality applications. This paper presents a set of guidelines to design optimal NUI as well as a software framework, named FrameworkVR, which encapsulates the rules of presented guidelines. FrameworkVR allows developing NUI for VR/AR reality applications based on Oculus Rift, Leap Motions device and on the VTK open source library. An example of VR application for prosthesis design developed using FrameworkVR, is also described. Tests have been carried to validate the approach and the designed NUI and results reached so far are presented and discussed.

This paper presents a computer-aided environment to analyze postures and movements in order to ergonomically validate the design of potentially any device a man or woman may have to deal with. The proposed environment integrates virtual prototyping techniques with Digital Human Modeling and Motion Capture techniques to determine fatigue, stress and risk for workers’ health. We considered a vertical refrigerated display unit as case study to analyze the interaction of supermarket staff filling the shelves with goods with the main goal determining the suitability of operators’ working condition and, eventually, providing a feedback to the design step. The paper, after a brief description of the state of the art of the Motion Capture system and Digital Human Modeling, presents the architecture of the integrated environment developed and the working paradigm. At last preliminary results of the experimentation as well benefits and the limits of the outcomes achieved so far in the automation of ergonomics in machines design are presented.