Fraunhofer study: Exoskeleton reduces activity of back muscles by up to 41.5 percent

The Fraunhofer Institute for Manufacturing Engineering and Automation has, on behalf of Jungheinrich Profishop and the exoskeleton manufacturer Hunic, investigated the ergonomic effects of an exoskeleton during lifting operations. In measurements conducted under practical industrial working conditions, the utilized exoskeleton "Hunic Softexo Lift" reduced the activity of individual back muscles by up to 41.5 percent. At the same time, the researchers documented less spinal curvature and reduced torso rotational movements under load. The study, presented in October 2026, thus provides measurement data on the mechanical support of physically demanding tasks in logistics.

 

During the investigation, experienced logistics professionals conducted lifting operations with construction material bags in different retrieval and placement situations. (Image source: Jungheinrich Profishop)
During the investigation, experienced logistics professionals conducted lifting operations with construction material bags in different retrieval and placement situations. (Image source: Jungheinrich Profishop)
For the study, the researchers examined typical lifting processes at the building materials manufacturer Knauf. Experienced logistics professionals moved bags of building materials in different picking and placing situations. The work processes were carried out both with and without support from the exoskeleton to compare the physical strains. To measure muscle activity, the scientists used electromyography. Additionally, they analyzed body posture using three-dimensional motion capture. The combination of both measurement methods allowed for the examination of changes in spinal position and trunk movements, in addition to the strain on individual muscle groups. According to the Fraunhofer Institute, the study is distinguished by the combination of scientific measurement methods with practical industrial work processes. Unlike a sole focus on muscle activity, the movements and postures during the lifting processes were also recorded.

Muscle Activity Significantly Reduced When Lifting

According to the statement, the measurements showed reduced muscle activity in all investigated scenarios when using the exoskeleton. The greatest relief for individual back muscles was 41.5 percent. This value was determined during a lifting process involving a deep extraction and subsequent deep placement of construction material bags.

The results indicate that mechanical support can reduce muscular strain, especially during physically demanding lifting movements. However, the stated maximum reduction refers to individual back muscles and a specific work situation. Therefore, it cannot be directly applied to the entire back musculature or all lifting activities.

Reduced Spinal Curvature and Torso Rotation

In addition to muscle activity, the researchers examined how the exoskeleton affected body posture. The curvature of the spine when lifting with mechanical assistance was on average up to 35 percent less than during comparable movements without an exoskeleton.

The scientists also observed changes in upper body rotation under load. Torso rotation decreased by up to ten degrees. According to the sponsors, the exoskeleton thus supported a more upright posture and reduced pronounced rotational movements during the handling of loads.

Such body positions are relevant for the ergonomic assessment of manual lifting activities, as the interaction of load weight, body posture, and movement particularly influences the strain on the musculoskeletal system. According to the report, the tested exoskeleton did not restrict the freedom of movement of the employees.

Significance for Physically Strenuous Logistics Processes

The study concerns a work area where numerous manual activities remain despite increasing automation. This includes tasks such as removing, lifting, relocating, and placing loads. Such burdens occur not only in logistics but also in industry and crafts.

According to the clients, heavy physical labor is part of the professional routine for about every fourth working person in Germany. At the same time, the shortage of skilled workers and demographic changes increase the importance of ergonomic working conditions.

The economic consequences of physical strain are also a subject of discussion. According to a press release, back pain and musculoskeletal disorders caused an economic loss of 58.4 billion euros in the year 2025. However, the announcement does not specify a concrete data basis or calculation method for this information.

Results Show Ergonomic Potential

The measurement data indicate that exoskeletons can reduce muscular strain and certain unfavorable body postures during manual lifting operations. This opens up possible applications for workplaces where heavy loads have to be moved by hand regularly.

The clients also see potential for reducing physical fatigue as well as stabilizing concentration and work quality.

Translated automatically from German.
Printer Friendly, PDF & Email

Branchenverzeichnis

22.09.2026
Schmalz presents two solutions for manual handling at the Arbeitsschutz Aktuell in Stuttgart (October 20 to 22, Hall 1, Stand J1.001): the torso-bending exoskeleton "Nexo Pro" and the battery-powered...
04.09.2026
No battery and no external power supply: The "Nexo Pro" uses a mechanical spring system to assist with bending and lifting movements and is designed, among other things, for warehouse logistics and...
31.08.2026
Contrinex combines several measurement functions for spindle monitoring in one device. In addition to a measuring range of up to 20 millimeters, the sensor offers programmable switching points.
23.10.2026
Dr.-Ing. Timo Lehmann has received the Logistics Science Award 2026 from the German Logistics Association. The jury honored the scientist on October 21 at the BVL Supply Chain CX in Estrel Berlin for...
14.10.2026
The INC Innovation Center plans to open the "Future Robotics Exploration Hub" in Stuttgart in January 2027, in collaboration with industrial companies. The proposed facility is intended to enable...
21.08.2026
From the compact entry-level device to the model for longer transport distances, the new program offers a range. There are differences, among other things, in load capacity, lift height, initial lift...