Exoskeleton concept

Andreas Seegen | Günter Herkommer,

What's behind the 'chairless chair'

An innovative exoskeleton concept from a Swiss start-up company makes it possible: workers can carry out tasks virtually sitting down without needing a chair.

© Audi

Many activities in production and manufacturing only have to be carried out standing up because a chair would block the way on site. By the end of the working day, not only do employees' legs and backs ache, but their concentration and performance are also impaired by the unnecessary standing. For some time now, there have therefore been approaches in various sectors to relieve the strain on people with an additional exoskeleton (external skeleton). These exoskeleton solutions look a little like something out of a science fiction movie, but they are modeled on nature. In contrast to vertebrates, arthropods such as insects have a stabilizing exoskeleton instead of an internal skeleton.

Artificial exoskeletons help where muscle strength alone is not enough, or not enough in the long term - for example to lift heavy parts or to work overhead with a clunky grinding machine for long periods of time. People with paraplegia can walk again with an exoskeleton or - as in Brazil in 2014 - kick off at the opening game of the World Cup. Until now, however, these exoskeletons have had significant disadvantages: they are very heavy, usually weighing over 20 kg, which has a negative impact on their battery life. The operating time often barely reaches two hours - which is insufficient for widespread everyday use.

This is where the start-up company Noonee comes in with its exoskeleton concept. Keith Gunura, CEO of Noonee, researched exoskeletons before founding the company in Rüti near Zurich together with Olga Motovilaova: "We wanted to build an assistive system that is very light and very simple, does not break down in continuous operation and offers a solution to a widespread, everyday problem," says Gunura.

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Retain skilled workers by reducing workload

Gunura was familiar with the discomfort caused by standing for long periods from his own experiences during a student job at a packaging service provider in England. "The older female colleagues in particular had a hard time. I heard the exclamation 'oh my legs' every evening there," he recalls. At a workshop for start-up entrepreneurs at the Swiss Federal Institute of Technology in Zurich (ETH), the two founders learned that this problem also affects the management of large corporations. One of the exercises here was to call potential customers and ask about their interest in a product. "The workshop leader typed in a number and handed us the phone, telling us that someone from one of the biggest car manufacturers in the world would pick up," says Keith Gunura.

To the surprise of the two founders, these phone calls were not met with skepticism, but with great interest, even though they did not even have a prototype to show. And even when the first prototype failed during the demonstration, the car managers only asked when they could meet again. "German companies in particular see demographic trends and the increasing shortage of skilled workers as a key strategic challenge," says Keith Gunura, explaining the great interest shown by potential users. "They are keen to do something to relieve the pressure on their skilled workers in production and create the conditions for employees to remain active for longer."

First tests at Audi

A joint at knee height ensures mobility.

© Noonee

The first prototype generation was tested in practice at the Audi plant in Neckarsulm. The subsequently optimized version is currently proving its practical suitability in three-shift operation at the Ingolstadt plant. The managers had initially expected skepticism from the employees. Instead, they volunteered to take part in the trial. It only took a few minutes to learn how to operate each one.

The structure of the 'chairless chair': A supporting strut, which also serves as a seat at its upper end, is attached to the back of each leg.

© Noonee

The structure of the 'chairless chair' is easy to understand: A supporting strut, which also serves as a seat at its upper end, is attached to the back of each leg. In the prototypes, this strut was made of titanium. In future, however, it could be made of carbon fiber and therefore even lighter. A joint at knee height provides mobility, while the shock absorber element behind the lower leg can be locked continuously at the touch of a button when the user wants to sit down.

The shock absorber element behind the lower leg can be locked continuously at the touch of a button when the user wants to sit down.

© Noonee

The 'chairless chair' can be fastened to the hips, knees and ankles with straps. When seated, the weight pressure is then transferred directly to the floor. The legs and lower back are relieved. The whole construction weighs only a few kilograms, is easy to put on and hardly disturbs the user when walking.

The human legs are still responsible for movement - an advantage over active exoskeletons, which can cause the muscles to regress due to 'overloading'. Users can now sit down anywhere and at any time, for example while attaching parts to a chassis. They can move around freely and still always have their seat available.

Lightweight DC flat motor with low power consumption

To turn the movable structure into a stable seat, the operator only has to press a switch attached to the belt. Two motors then close the stop valve in the hydraulic elements of the shock absorbers and the support locks in the desired position. When standing up, the lock is released again. "For this application, we needed a very flat motor with a high torque that positions as precisely as possible," explains Keith Gunura. "Of course, it had to be as light as possible and have minimal power consumption."

Two of these cogging-free DC flat motors with gearboxes ensure that the exoskeleton can operate for several days without recharging.

© Faulhaber

These requirements were met by a cogging-free DC flat motor with gearbox from Faulhaber's portfolio. In addition to its small dimensions (26 mm diameter and 19 mm length) and high dynamics due to the minimal moment of inertia of the rotor, the DC micromotor also scored points with its low current consumption and low starting voltage. In the practical test, it was not necessary to recharge the small 6-volt battery even after a week of continuous operation. The motorized lock also passed the stress test - two full shifts in a row - with flying colors.

The product is not yet ready for series production, but development is in full swing with active support from potential users. The first 'chairless chairs' ready for series production are due to be delivered from the middle of the year.

Author: Andreas Seegen is Head of Marketing at Faulhaber.

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