Exosuit technology is rapidly evolving and offers solutions that enhance human strength, endurance, and mobility across various industries. While there are a number of ways to classify these systems, they can generally be bucketed into powered vs. passive.
A passive (unpowered) exosuit redistributes the forces of the user’s movement, but doesn’t provide an external supply of energy. Instead, it uses mechanical components, such as springs or braces, to store energy during one phase of a movement (bending down) and release it during another phase (lifting). This allows the user to decrease peak muscle strain by 10–20% for a variety of movements.
In contrast, a powered exosuit relies on batteries, motors, and sensors to provide dynamic support, directly contributing energy to each movement. In the case of the SafeLift exosuit, the batteries power a high-torque motor connected to a high-strength flexible ribbon that serves as an artificial back muscle bridging the user’s upper and lower body.
The additional force from this ribbon assists the user’s natural movement when lifting and lowering, reducing the strain on their lower back by up to 40%. SafeLift provides this assistance without restricting a user’s natural range of motion, making it an ideal fit for environments requiring frequent and varied movements – such as warehouses, distribution centers, and manufacturing operations.
To learn more about the differences between powered and passive exosuits, read our article, The Competitive Landscape for Exosuits and Exoskeletons.
Our engineers chose to power SafeLift with lithium-ion batteries, a scaled-up version of the kind found in most consumer products. In comparison to other types of batteries (such as lead-acid and nickel–metal hydride), lithium-ion batteries are highly energy-dense, meaning they can deliver equivalent amounts of power at a smaller size and much lighter weight.
SafeLift takes full advantage of these benefits, and its lithium-ion batteries are:
While SafeLift’s lithium-ion batteries are built to last 10–12 hours on a full charge, if it does become necessary to change them, their small form factor and user-friendly system allow users to quickly and safely swap depleted batteries for fully charged replacements in less than 30 seconds.
Central to this system is SafeLift’s battery charging module, part of the overall SafeLift kiosk, locker, and battery charging infrastructure system where exosuits are stored between shifts. The dedicated battery charging module minimizes downtime by ensuring that fully charged batteries are always accessible, eliminating delays typically associated with waiting for battery charging cycles and leading to less disruption in daily operations.
For more information on SafeLift’s infrastructure, please read our blog post, Floor-Ready Infrastructure for a Smarter, Safer Workplace.
Batteries also allow for the addition of various powered accessories and add-ons that can complement or improve an exosuit.
For example, for workers operating in warm environments, such as warehouses without air conditioning, the SafeLift exosuit can be equipped with an add-on Active Cooling fan kit. The fan’s added airflow makes a large difference in workers’ comfort, particularly in hot or humid conditions.
The presence of batteries makes adding new accessories much easier, and as we learn even more about our users’ environments and needs, we can provide them with solutions specific to their job.
In addition to providing physical assistance during lifting and lowering operations, the SafeLift exosuit's powered design utilizes three embedded inertial measurement units (IMUs) as sensors. The IMUs monitor and record various movements that are linked to back injuries, such as excessive torso bending, twisting, side bending, and prolonged bending.
At the end of a shift, the data collected by the IMUs is uploaded to Verve Logic™, Verve Motion's software platform that provides robust safety data analytics and management tools that elevate industrial worker safety and optimize operations.
In addition to tracking and flagging unsafe movements that could put a worker at risk of injury, the data collected by these powered sensors helps track and analyze safety and utilization trends over time – scaled to every level from individual workers to the company as a whole.
Read more about how this data helps workers to avoid unsafe lifting habits, ensure ergonomic support, and improve safety assessments and operations through our blog article on Verve Logic.
Curious about how the SafeLift powered exosuit can reduce injuries, increase productivity, and improve worker satisfaction at your facility? Schedule an on-site demonstration and discover Verve Motion’s cutting-edge technology for yourself.