TEST
Exoskeletons: are they exotic or necessary?
Science fiction movies with mechanisms turning humans into powerful robots: most people perceive exoskeletons that way. The reality is far from this image. For example, developers are not tasked with creating an industrial exoskeleton to make it easy for an employee to lift 200 pounds.
The task of modern exoskeletons, which are used at plants, is to facilitate routine labor, reduce the load on the body, and preserve health. Take the test to learn more about the current application of exoskeletons in modern production environments, their design, and their stage of development.
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What are industrial exoskeletons utilized for?
Pathologies of the musculoskeletal system caused by lifting and moving heavy objects dominate occupational diseases in industrial production. The most traumatic are moments of lifting a load off the surface, holding it in a static position for a long time, and moving it with body tilts and turns.
There are proper weight lifting techniques that prevent injuring the intervertebral discs. For instance, weightlifters are very adept at it. But it in no way relieves from high fatigue and general wear and tear of the musculoskeletal system, which are inevitable for people doing hard physical labor.
Replacing all these jobs with robots is a matter of the distant future. Moreover, that's hardly entirely possible. A flat warehouse is one thing, but a mining and metallurgical production with winding shafts, narrow passages, endless descents and ascents is quite another one. Nothing can replace the flexibility and mobility of the human body. That's why exoskeletons help to reduce the load.
There are proper weight lifting techniques that prevent injuring the intervertebral discs. For instance, weightlifters are very adept at it. But it in no way relieves from high fatigue and general wear and tear of the musculoskeletal system, which are inevitable for people doing hard physical labor.
Replacing all these jobs with robots is a matter of the distant future. Moreover, that's hardly entirely possible. A flat warehouse is one thing, but a mining and metallurgical production with winding shafts, narrow passages, endless descents and ascents is quite another one. Nothing can replace the flexibility and mobility of the human body. That's why exoskeletons help to reduce the load.
Pathologies of the musculoskeletal system caused by lifting and moving heavy objects dominate occupational diseases in industrial production. The most traumatic are moments of lifting a load off the surface, holding it in a static position for a long time, and moving it with body tilts and turns.
There are proper weight lifting techniques that prevent injuring the intervertebral discs. For instance, weightlifters are very adept at it. But it in no way relieves from high fatigue and general wear and tear of the musculoskeletal system, which are inevitable for people doing hard physical labor.
Replacing all these jobs with robots is a matter of the distant future. Moreover, that's hardly entirely possible. A flat warehouse is one thing, but a mining and metallurgical production with winding shafts, narrow passages, endless descents and ascents is quite another one. Nothing can replace the flexibility and mobility of the human body. That's why exoskeletons help to reduce the load.
There are proper weight lifting techniques that prevent injuring the intervertebral discs. For instance, weightlifters are very adept at it. But it in no way relieves from high fatigue and general wear and tear of the musculoskeletal system, which are inevitable for people doing hard physical labor.
Replacing all these jobs with robots is a matter of the distant future. Moreover, that's hardly entirely possible. A flat warehouse is one thing, but a mining and metallurgical production with winding shafts, narrow passages, endless descents and ascents is quite another one. Nothing can replace the flexibility and mobility of the human body. That's why exoskeletons help to reduce the load.
Pathologies of the musculoskeletal system caused by lifting and moving heavy objects dominate occupational diseases in industrial production. The most traumatic are moments of lifting a load off the surface, holding it in a static position for a long time, and moving it with body tilts and turns.
There are proper weight lifting techniques that prevent injuring the intervertebral discs. For instance, weightlifters are very adept at it. But it in no way relieves from high fatigue and general wear and tear of the musculoskeletal system, which are inevitable for people doing hard physical labor.
Replacing all these jobs with robots is a matter of the distant future. Moreover, that's hardly entirely possible. A flat warehouse is one thing, but a mining and metallurgical production with winding shafts, narrow passages, endless descents and ascents is quite another one. Nothing can replace the flexibility and mobility of the human body. That's why exoskeletons help to reduce the load.
There are proper weight lifting techniques that prevent injuring the intervertebral discs. For instance, weightlifters are very adept at it. But it in no way relieves from high fatigue and general wear and tear of the musculoskeletal system, which are inevitable for people doing hard physical labor.
Replacing all these jobs with robots is a matter of the distant future. Moreover, that's hardly entirely possible. A flat warehouse is one thing, but a mining and metallurgical production with winding shafts, narrow passages, endless descents and ascents is quite another one. Nothing can replace the flexibility and mobility of the human body. That's why exoskeletons help to reduce the load.
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Why do we need GOST for industrial exoskeletons?
In Russia, large-scale production of industrial exoskeletons began in 2021. Sales require supporting documentation, including clear standards and classifications.
In 2023, there first became effective GOST R 12.4.306-2023 ”System of Work Safety Standards (SSBT) Personal protection equipment for musculoskeletal system.
Industrial exoskeletons. Classification. Terms and definitions.” It specifies general requirements for labeling exoskeletons, their operational and maintenance manuals.
The State Standard also contains the industrial exoskeleton definition. It is a wearable personal protection device for the musculoskeletal system that compensates and/or redistributes the load.
Under GOST, industrial exoskeletons are classified by the anatomical area they protect. For example, upper or lower limbs, cervical, thoracic or lumbosacral spine. The devices can protect against dynamic or static loads or both loads simultaneously.
Depending on the method of energy source utilization, exoskeletons can be active, semi-active, and passive.
In 2023, there first became effective GOST R 12.4.306-2023 ”System of Work Safety Standards (SSBT) Personal protection equipment for musculoskeletal system.
Industrial exoskeletons. Classification. Terms and definitions.” It specifies general requirements for labeling exoskeletons, their operational and maintenance manuals.
The State Standard also contains the industrial exoskeleton definition. It is a wearable personal protection device for the musculoskeletal system that compensates and/or redistributes the load.
Under GOST, industrial exoskeletons are classified by the anatomical area they protect. For example, upper or lower limbs, cervical, thoracic or lumbosacral spine. The devices can protect against dynamic or static loads or both loads simultaneously.
Depending on the method of energy source utilization, exoskeletons can be active, semi-active, and passive.
In Russia, large-scale production of industrial exoskeletons began in 2021. Sales require supporting documentation, including clear standards and classifications.
In 2023, there first became effective GOST R 12.4.306-2023 ”System of Work Safety Standards (SSBT) Personal protection equipment for musculoskeletal system.
Industrial exoskeletons. Classification. Terms and definitions.” It specifies general requirements for labeling exoskeletons, their operational and maintenance manuals.
The State Standard also contains the industrial exoskeleton definition. It is a wearable personal protection device for the musculoskeletal system that compensates and/or redistributes the load.
Under GOST, industrial exoskeletons are classified by the anatomical area they protect. For example, upper or lower limbs, cervical, thoracic or lumbosacral spine. The devices can protect against dynamic or static loads or both loads simultaneously.
Depending on the method of energy source utilization, exoskeletons can be active, semi-active, and passive.
In 2023, there first became effective GOST R 12.4.306-2023 ”System of Work Safety Standards (SSBT) Personal protection equipment for musculoskeletal system.
Industrial exoskeletons. Classification. Terms and definitions.” It specifies general requirements for labeling exoskeletons, their operational and maintenance manuals.
The State Standard also contains the industrial exoskeleton definition. It is a wearable personal protection device for the musculoskeletal system that compensates and/or redistributes the load.
Under GOST, industrial exoskeletons are classified by the anatomical area they protect. For example, upper or lower limbs, cervical, thoracic or lumbosacral spine. The devices can protect against dynamic or static loads or both loads simultaneously.
Depending on the method of energy source utilization, exoskeletons can be active, semi-active, and passive.
In Russia, large-scale production of industrial exoskeletons began in 2021. Sales require supporting documentation, including clear standards and classifications.
In 2023, there first became effective GOST R 12.4.306-2023 ”System of Work Safety Standards (SSBT) Personal protection equipment for musculoskeletal system.
Industrial exoskeletons. Classification. Terms and definitions.” It specifies general requirements for labeling exoskeletons, their operational and maintenance manuals.
The State Standard also contains the industrial exoskeleton definition. It is a wearable personal protection device for the musculoskeletal system that compensates and/or redistributes the load.
Under GOST, industrial exoskeletons are classified by the anatomical area they protect. For example, upper or lower limbs, cervical, thoracic or lumbosacral spine. The devices can protect against dynamic or static loads or both loads simultaneously.
Depending on the method of energy source utilization, exoskeletons can be active, semi-active, and passive.
In 2023, there first became effective GOST R 12.4.306-2023 ”System of Work Safety Standards (SSBT) Personal protection equipment for musculoskeletal system.
Industrial exoskeletons. Classification. Terms and definitions.” It specifies general requirements for labeling exoskeletons, their operational and maintenance manuals.
The State Standard also contains the industrial exoskeleton definition. It is a wearable personal protection device for the musculoskeletal system that compensates and/or redistributes the load.
Under GOST, industrial exoskeletons are classified by the anatomical area they protect. For example, upper or lower limbs, cervical, thoracic or lumbosacral spine. The devices can protect against dynamic or static loads or both loads simultaneously.
Depending on the method of energy source utilization, exoskeletons can be active, semi-active, and passive.
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How many types of exoskeletons are used at Nornickel?
Nornickel uses two types of industrial exoskeletons in its operations. Active-passive, or semi-active according to GOST, are equipped with an auxiliary electric drive. Passive ones are without it. The active-passive exoskeleton is designed to lift and hold heavy objects and takes up to 90% of the load.
X-Rise passive exoskeletons are designed for the upper part of the body. Through flexion-extension mechanisms of their parts, they redirect the load from the musculoskeletal system to the leg muscles, the strongest ones of the human body. They protect the lower back from excessive twisting and virtually eliminate displacement of the intervertebral discs.
These exoskeletons weigh only 2-3 kg and increase endurance by 83%. Vostok-Service Company, which supplies X-soft exoskeletons to Nornickel's production facilities, even has a female model designed with due regard for women's anatomy.
X-Rise passive exoskeletons are designed for the upper part of the body. Through flexion-extension mechanisms of their parts, they redirect the load from the musculoskeletal system to the leg muscles, the strongest ones of the human body. They protect the lower back from excessive twisting and virtually eliminate displacement of the intervertebral discs.
These exoskeletons weigh only 2-3 kg and increase endurance by 83%. Vostok-Service Company, which supplies X-soft exoskeletons to Nornickel's production facilities, even has a female model designed with due regard for women's anatomy.
Nornickel uses two types of industrial exoskeletons in its operations. Active-passive, or semi-active according to GOST, are equipped with an auxiliary electric drive. Passive ones are without it. The active-passive exoskeleton is designed to lift and hold heavy objects and takes up to 90% of the load.
X-Rise passive exoskeletons are designed for the upper part of the body. Through flexion-extension mechanisms of their parts, they redirect the load from the musculoskeletal system to the leg muscles, the strongest ones of the human body. They protect the lower back from excessive twisting and virtually eliminate displacement of the intervertebral discs.
These exoskeletons weigh only 2-3 kg and increase endurance by 83%. Vostok-Service Company, which supplies X-soft exoskeletons to Nornickel's production facilities, even has a female model designed with due regard for women's anatomy.
X-Rise passive exoskeletons are designed for the upper part of the body. Through flexion-extension mechanisms of their parts, they redirect the load from the musculoskeletal system to the leg muscles, the strongest ones of the human body. They protect the lower back from excessive twisting and virtually eliminate displacement of the intervertebral discs.
These exoskeletons weigh only 2-3 kg and increase endurance by 83%. Vostok-Service Company, which supplies X-soft exoskeletons to Nornickel's production facilities, even has a female model designed with due regard for women's anatomy.
Nornickel uses two types of industrial exoskeletons in its operations. Active-passive, or semi-active according to GOST, are equipped with an auxiliary electric drive. Passive ones are without it. The active-passive exoskeleton is designed to lift and hold heavy objects and takes up to 90% of the load.
X-Rise passive exoskeletons are designed for the upper part of the body. Through flexion-extension mechanisms of their parts, they redirect the load from the musculoskeletal system to the leg muscles, the strongest ones of the human body. They protect the lower back from excessive twisting and virtually eliminate displacement of the intervertebral discs.
These exoskeletons weigh only 2-3 kg and increase endurance by 83%. Vostok-Service Company, which supplies X-soft exoskeletons to Nornickel's production facilities, even has a female model designed with due regard for women's anatomy.
X-Rise passive exoskeletons are designed for the upper part of the body. Through flexion-extension mechanisms of their parts, they redirect the load from the musculoskeletal system to the leg muscles, the strongest ones of the human body. They protect the lower back from excessive twisting and virtually eliminate displacement of the intervertebral discs.
These exoskeletons weigh only 2-3 kg and increase endurance by 83%. Vostok-Service Company, which supplies X-soft exoskeletons to Nornickel's production facilities, even has a female model designed with due regard for women's anatomy.
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How many kilos can Nornickel's most powerful exoskeleton lift?
The first Russian active-passive industrial exoskeleton with a “load capacity” of 60 kg was presented to Russian Prime Minister Mikhail Mishustin during his visit to the Nadezhda Smelter in 2023. Since 2019, Nornickel has been developing the model with the Rokad Science and Technology Center and Kursk-based ExoMed.” The challenge is to create a design tailored to the specifics of production and harsh Arctic conditions.
The company's Digital Technology Development Center and the scientists from the Izmerov Research Institute of Occupational Health Care conducted numerous tests and created several prototypes. As a result, the ExoHeaver Active Electric emerged. It weighs 22 kg, but its movement is almost unrestricted. The ExoHeaver helps to lift and hold loads and supports the body of a person who works long hours in a reclined position or with bent legs.
The latest exoskeleton models are equipped with an on-board computer and multiple sensors. They measure sulfur oxide and chlorine in the atmosphere, light levels, and temperature. It costs about RUB 1 mln, but the price will drop sharply with serial production.
The company's Digital Technology Development Center and the scientists from the Izmerov Research Institute of Occupational Health Care conducted numerous tests and created several prototypes. As a result, the ExoHeaver Active Electric emerged. It weighs 22 kg, but its movement is almost unrestricted. The ExoHeaver helps to lift and hold loads and supports the body of a person who works long hours in a reclined position or with bent legs.
The latest exoskeleton models are equipped with an on-board computer and multiple sensors. They measure sulfur oxide and chlorine in the atmosphere, light levels, and temperature. It costs about RUB 1 mln, but the price will drop sharply with serial production.
The first Russian active-passive industrial exoskeleton with a “load capacity” of 60 kg was presented to Russian Prime Minister Mikhail Mishustin during his visit to the Nadezhda Smelter in 2023. Since 2019, Nornickel has been developing the model with the Rokad Science and Technology Center and Kursk-based ExoMed.” The challenge is to create a design tailored to the specifics of production and harsh Arctic conditions.
The company's Digital Technology Development Center and the scientists from the Izmerov Research Institute of Occupational Health Care conducted numerous tests and created several prototypes. As a result, the ExoHeaver Active Electric emerged. It weighs 22 kg, but its movement is almost unrestricted. The ExoHeaver helps to lift and hold loads and supports the body of a person who works long hours in a reclined position or with bent legs.
The latest exoskeleton models are equipped with an on-board computer and multiple sensors. They measure sulfur oxide and chlorine in the atmosphere, light levels, and temperature. It costs about RUB 1 mln, but the price will drop sharply with serial production.
The company's Digital Technology Development Center and the scientists from the Izmerov Research Institute of Occupational Health Care conducted numerous tests and created several prototypes. As a result, the ExoHeaver Active Electric emerged. It weighs 22 kg, but its movement is almost unrestricted. The ExoHeaver helps to lift and hold loads and supports the body of a person who works long hours in a reclined position or with bent legs.
The latest exoskeleton models are equipped with an on-board computer and multiple sensors. They measure sulfur oxide and chlorine in the atmosphere, light levels, and temperature. It costs about RUB 1 mln, but the price will drop sharply with serial production.
The first Russian active-passive industrial exoskeleton with a “load capacity” of 60 kg was presented to Russian Prime Minister Mikhail Mishustin during his visit to the Nadezhda Smelter in 2023. Since 2019, Nornickel has been developing the model with the Rokad Science and Technology Center and Kursk-based ExoMed.” The challenge is to create a design tailored to the specifics of production and harsh Arctic conditions.
The company's Digital Technology Development Center and the scientists from the Izmerov Research Institute of Occupational Health Care conducted numerous tests and created several prototypes. As a result, the ExoHeaver Active Electric emerged. It weighs 22 kg, but its movement is almost unrestricted. The ExoHeaver helps to lift and hold loads and supports the body of a person who works long hours in a reclined position or with bent legs.
The latest exoskeleton models are equipped with an on-board computer and multiple sensors. They measure sulfur oxide and chlorine in the atmosphere, light levels, and temperature. It costs about RUB 1 mln, but the price will drop sharply with serial production.
The company's Digital Technology Development Center and the scientists from the Izmerov Research Institute of Occupational Health Care conducted numerous tests and created several prototypes. As a result, the ExoHeaver Active Electric emerged. It weighs 22 kg, but its movement is almost unrestricted. The ExoHeaver helps to lift and hold loads and supports the body of a person who works long hours in a reclined position or with bent legs.
The latest exoskeleton models are equipped with an on-board computer and multiple sensors. They measure sulfur oxide and chlorine in the atmosphere, light levels, and temperature. It costs about RUB 1 mln, but the price will drop sharply with serial production.
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What mechanism does Nornickel's active-passive exoskeleton use to lift cargo?
The winch proved the optimal engineering solution to reduce weight and battery size. The power source should be energy-intensive but not very large or heavy. Otherwise, the application of the exoskeleton would be completely irrelevant. Thus, the ExoHeaver load-bearing frame has no drives but a winch as an optional extra equipment item. This age-old mechanism has an electric drive system with battery power.
The employee approaches the load, releases the ropes, squats down, secures the load, stands up, and the winch lifts the weight no higher than his chest level. The winch is controlled by buttons on the remote console. The worker manipulates the load in various ways, keeping the exoskeleton's lights on. Thus, it is possible to see the “loaded” person as soon as possible.
The winch has an installed sensor which prevents winches from handling weights over 60 kg. It is not because it cannot lift this weight but for safety reasons. A too heavy load can overbalance the person with all resulting consequences, but a counterweight will increase the exoskeleton's dimensions.
The employee approaches the load, releases the ropes, squats down, secures the load, stands up, and the winch lifts the weight no higher than his chest level. The winch is controlled by buttons on the remote console. The worker manipulates the load in various ways, keeping the exoskeleton's lights on. Thus, it is possible to see the “loaded” person as soon as possible.
The winch has an installed sensor which prevents winches from handling weights over 60 kg. It is not because it cannot lift this weight but for safety reasons. A too heavy load can overbalance the person with all resulting consequences, but a counterweight will increase the exoskeleton's dimensions.
The winch proved the optimal engineering solution to reduce weight and battery size. The power source should be energy-intensive but not very large or heavy. Otherwise, the application of the exoskeleton would be completely irrelevant. Thus, the ExoHeaver load-bearing frame has no drives but a winch as an optional extra equipment item. This age-old mechanism has an electric drive system with battery power.
The employee approaches the load, releases the ropes, squats down, secures the load, stands up, and the winch lifts the weight no higher than his chest level. The winch is controlled by buttons on the remote console. The worker manipulates the load in various ways, keeping the exoskeleton's lights on. Thus, it is possible to see the “loaded” person as soon as possible.
The winch has an installed sensor which prevents winches from handling weights over 60 kg. It is not because it cannot lift this weight but for safety reasons. A too heavy load can overbalance the person with all resulting consequences, but a counterweight will increase the exoskeleton's dimensions.
The employee approaches the load, releases the ropes, squats down, secures the load, stands up, and the winch lifts the weight no higher than his chest level. The winch is controlled by buttons on the remote console. The worker manipulates the load in various ways, keeping the exoskeleton's lights on. Thus, it is possible to see the “loaded” person as soon as possible.
The winch has an installed sensor which prevents winches from handling weights over 60 kg. It is not because it cannot lift this weight but for safety reasons. A too heavy load can overbalance the person with all resulting consequences, but a counterweight will increase the exoskeleton's dimensions.
The winch proved the optimal engineering solution to reduce weight and battery size. The power source should be energy-intensive but not very large or heavy. Otherwise, the application of the exoskeleton would be completely irrelevant. Thus, the ExoHeaver load-bearing frame has no drives but a winch as an optional extra equipment item. This age-old mechanism has an electric drive system with battery power.
The employee approaches the load, releases the ropes, squats down, secures the load, stands up, and the winch lifts the weight no higher than his chest level. The winch is controlled by buttons on the remote console. The worker manipulates the load in various ways, keeping the exoskeleton's lights on. Thus, it is possible to see the “loaded” person as soon as possible.
The winch has an installed sensor which prevents winches from handling weights over 60 kg. It is not because it cannot lift this weight but for safety reasons. A too heavy load can overbalance the person with all resulting consequences, but a counterweight will increase the exoskeleton's dimensions.
The employee approaches the load, releases the ropes, squats down, secures the load, stands up, and the winch lifts the weight no higher than his chest level. The winch is controlled by buttons on the remote console. The worker manipulates the load in various ways, keeping the exoskeleton's lights on. Thus, it is possible to see the “loaded” person as soon as possible.
The winch has an installed sensor which prevents winches from handling weights over 60 kg. It is not because it cannot lift this weight but for safety reasons. A too heavy load can overbalance the person with all resulting consequences, but a counterweight will increase the exoskeleton's dimensions.
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Exoskeletons sound like something out of a sci-fi movie to you.
Not for long, hopefully. Exoskeletons began their triumphant journey in medicine, then made their way to industry, and may soon expand their reach to every home or dacha. Drones were once unheard-of too. Today Polar State University offers drone education programs to aspiring metallurgists.
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It is great that you stay on top of emerging technology trends.
You might think that exoskeletons look bulky and their current application in manufacturing is too complicated. But this is work in progress, and new features and possibilities are just around the corner. In a similar vein, innovative uses for palladium in water treatment were found.
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You are already living in the future.
In the five past years, the industrial exoskeleton market has grown significantly. The need for exoskeletons in manufacturing has become evident. In Russia, more than 5 million people engage in hard physical work, and not all such tasks can be automated. It is a case of demand-driven supply.
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Фотобанк «Норникеля», Andrey Suslov/Shutterstock/FOTODOM, Gorodenkoff/Shutterstock/FOTODOM
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