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Manual lifting tasks involve repetitive raising, holding and stacking movements with heavy objects. These arm movements are notable risk factors for muscle pain, fatigue, and musculoskeletal disorders in workers. An upper-limb wearable robot, as a 6-DOF dual-arm exoskeleton, which was designed to augment workers’ strength and minimize muscular activation in the arm during repetitive lifting tasks. To adjust the robot joint trajectory, the user needs to apply an interactive torque to operate the robot during lifting tasks when a standard virtual mechanical impedance control structure is used. To reduce overshooting of the interactive torque on the user’s joint, a three-tier hierarchical control structure was developed for the robot in this study. At the highest level, a human arm movement detection module is used to detect the user’s arm motion according to the surface electromyography signals. Then, a Hammerstein adaptive virtual mechanical impedance controller is used at the middle level to reduce overshooting and yield an acceptable value of torque for the user’s elbow joint in actual lifting tasks. At the lowest level, the actuator controller on each joint of the robot controls the robot to complete lifting tasks. Several experiments were conducted, and the results showed that the interactive torque on the user’s elbow was limited and the muscular activations of erector spinae and biceps brachii muscles were effectively decreased. The proposed scheme prevents potential harm to the user due to excessive interactive torque on the human elbow joint, such as related muscle fatigue and joint injuries.

A safe human–robot interactive control structure with human arm movement detection for an upper-limb wearable robot used during lifting tasks