Exoskeleton

Using technology to help improve the working environment is nothing new at Audi, and the newest ergonomic aid, the exoskeleton is providing protection for workers against an age old issue – that of back strain and injury.

With more than a passing resemblance to something employed by a super hero – or super villain for that matter – the exoskeleton provides support with lifting and carrying heavy material and reduces the strain on back muscles. Audi employees are testing the exoskeleton at selected workstations in logistics, the press shop and assembly at the plants in Ingolstadt and Neckarsulm. 

The lifting aid is worn on the body and weighs around three kilograms. A metal frame with elements on the upper body, lower back and thighs is connected with a support structure. To fit the exoskeleton, the worker first pulls it over his or her head like a jumper and straps it to the hips. Two hand-sized plates that spread the load are then placed on the thighs.
The exoskeleton provides support especially with activities that require bending forward to pick up or put down components. Carrying heavy materials is also easier with this ergonomic construction, because it transfers the load of the heavy elements from the back into the stronger thigh muscles. This reduces the strain on the back by 20 to 30 percent and also promotes a healthy posture. The ergonomic construction helps the assembly workers in their daily work without restricting their freedom of movement. Thanks to the exoskeleton’s flexible structure and low weight, the workers can walk, turn and stretch as normal.

This pilot project is being supported by an interdisciplinary team of process and workplace planners and also medical experts. The tests are being carried out in collaboration with the manufacturer Laevo, which specialises in exoskeletons. The goal after the test phase is to integrate the device gradually into series production at all Audi plants worldwide.