Design of a passive upper limb exoskeleton for the execution of industrial welding tasks

Abstract

This work presents the design and preliminary validation of a passive mechanical aid intended to assist arm elevation during naval welding tasks. Shipyard operations require sustained overhead postures, which increase the risk of developing musculoskeletal disorders (MSDs). The methodology included ergonomic analysis, biomechanical characterization using surface electromyography (sEMG), and engineering design tools. A concept based on a compression spring was selected and developed through CAD modeling, Denavit–Hartenberg kinematics, and finite element analysis (FEA). A TRL-3 level prototype was obtained, validating the structural feasibility of 3D-printed materials (PLA-CF and PC-PTFE). Initial tests confirm the preservation of mobility and structural strength of the design.