May 2024 Volume 6

FORGING RESEARCH

How Robotic Exoskeletons Can Be Used in the Forging Industry By FIA Staff

In the world of manufacturing, efficiency and safety are paramount concerns. The process of forging, especially in industrial applications, is a physically demanding task that requires skilled labor and can sometimes pose risks to workers' health. However, with advance ments in technology, specifically in the realm of robotic exoskeletons, forging producers and industry suppliers now have powerful tools at their disposal to enhance productivity, reduce injuries, and improve overall workplace conditions. Robotic exoskeletons are wearable devices that augment the strength and endurance of human workers by providing mechanical support to various parts of the body. These devices can range from full-body suits to more focused systems designed for specific tasks. In the context of forging, exoskeletons offer several key advantages. Ergonomic Support: Proper ergonomics is crucial for preventing workplace injuries and promoting long-term musculoskeletal health.

Exoskeletons can be designed to provide ergonomic support by aligning the body correctly during forging tasks, reducing strain on joints and muscles. By promoting better posture and movement mechanics, exoskeletons contribute to overall worker well-being and productivity. Increased Strength and Endurance: One of the primary benefits of robotic exoskeletons is the ability to enhance workers' physical capabilities. By supporting the arms, back, and legs, exoskeletons enable workers to lift and manipulate heavy tools and materials with reduced effort. This increased strength and endurance not only improve productivity but also reduce the risk of fatigue-related injuries. Precision and Consistency: Forging processes require a high level of precision to achieve desired product specifications. Robotic exoskel etons equipped with sensors and actuators can assist workers in main

Survey of Workers in a Forging Plant By Brian L. Davis and Grace Curtician Workplace injuries come at a great expense, to both workers and company. An injured worker can experience loss of income, pain and suffering, unaffordable medical bills, and even loss of life. A 1992 survey (Chaffin and colleagues) on over five million workers reported back pain from repeated activities at work such as lifting; over one million workers reported that they had stopped working, changed jobs, or made a major change in work activity because of pain/discomfort. A 2009 study (Nelson and Hughes) showed associations between back injuries and measures of spinal compression, lifting, lifting ratios, postures, and various combinations. This was in agreement with Punnett and colleagues (2005) who esti mated that 37% of back pain worldwide is attributable to occupational hazards. These findings led to the rationale for the current study, namely, to assess injury incidence and workplace procedures, including repetitive and awkward actions in a forging plant.

This study was approved by Cleveland State University Institutional Review Board. The survey included both demographic as well as job specific questions, with questions that included: 1. Which, if any, of your joints feel the most strained? (fingers, wrist/hand, elbow, shoulder, other) 2. How often do you perform repetitive actions, for example working with the same task? 3. Have you experienced a

workers felt safe while performing their work (average score 4.6 on a 1-to-6 scale, with 6 associated with feeling very safe). There was also a significant association between feeling safe and (i) lighting condi tions as well as (ii) having safety protocols in place. As expected, the number of painful joints was statistically significantly related to the number of hours of repetitive motion. While some workers reported multiple hours working in awkward postures, most spent less than 1 hour doing so (Figure 1).

chronic (long-term) injury during your employment? 4. Do you feel safe in your working environment? Surveys were distributed to workers through the manu facturing supervisor at their monthly safety review meeting. The study sample included 18 subjects (17 males and 1 female) who worked on the manufacturing floor in the forging plant. Despite the small sample size, the results showed that

Figure 1: Most workers reported spending less than one hour in an awkward posture.

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