Design and Control of Lower Limb Exoskeleton System

Abstract

Manual handling tasks, such as lifting, carrying, and stacking loads ranging from 10 to 25 kg, are integral to industries including warehousing, construction, and logistics, placing substantial physical demands on workers globally. Research indicates that these activities contribute to approximately 60% of work-related musculoskeletal disorders (MSDs), with a 30% increase in joint stress per lift for loads around 20 kg, exacerbating fatigue and injury risk, particularly in labor-intensive regions like Pakistan. Existing mitigation strategies, such as ergonomic training and mechanical aids (e.g., forklifts), exhibit significant limitations—training effectiveness diminishes under fatigue, and mechanical solutions are impractical in confined or dynamic settings. Commercially available industrial exoskeletons, while capable of reducing physical strain by 15% to 25%, typically exceed 10 kg in weight, cost thousands of dollars, and are optimized for loads above 50 kg, rendering them inaccessible to small-scale operations and misaligned with moderate load requirements. This project presents the design and development of a lower limb exoskeleton aimed at assisting healthy workers in manual handling tasks involving 20 kg loads, focusing on reducing physical effort.