How Drive Solutions From FAULHABER Move an Exoskeleton

Lifting, carrying and bending down are all part of the daily work routine in logistics warehouses, when delivering parcels or at airports. These activities are physically demanding and over time can also result in physical strain. Robotics cannot take over these tasks completely, but it can support humans where it counts: directly on the body and during work. 

To provide this support, SUITX has developed a smart exoskeleton: the IX BACK VOLTON. It combines advanced robotics, adaptive intelligence and industrial battery technology to form a lightweight system, which significantly relieves the back during manual labor. It is with repetitive movements where the exoskeleton reveals its strength — intuitively and efficiently. FAULHABER drive solutions ensure the natural range of movement. They enable ergonomic, powerful and dynamic movements that adapt to the human user. This creates a smart symbiosis between humans and technology: robotics that do not replace but rather support.

“The IX BACK VOLTON was developed in response to the desire to offer our customers more: a motorized solution that meets their needs beyond that which is possible with a purely passive exoskeleton,” explains Pascal Schwedhelm, head of Global SUITX Operations and R&D. “We wanted to develop a more intelligent device — optimized for dynamic activities, with minimum resistance when bending down and distinct support when straightening up.”

The result is an exoskeleton that actively relieves the spine and integrates seamlessly with natural movements of the body. With its slimline, ergonomic and optimally balanced design, the system fits discreetly against the body, providing all the support the wearer needs. With a total weight of just 5.7 kilograms including battery, the IX BACK VOLTON supports the wearer’s back with up to 17 kilograms per lifting operation.

At its core is an adaptive intelligence, which adjusts the support dynamically and in real time. The exoskeleton delivers exactly the right amount of force required for the situation. This ensures that the wearer feels supported rather than impeded, even in the case of highly dynamic tasks. This reduces fatigue and the risk of injury, but also increases efficiency and endurance in the work process.

The IX BACK VOLTON supports the hips of the wearer with a specific torque. This torque makes it easier for the upper body to return to an upright position after a bending activity. The result: the back muscles are significantly relieved, the strain on the spine is reduced and therefore also the risk of overexertion and injuries in day-to-day work. Since the exoskeleton is used directly on the human body, it must be comfortable, operate smoothly, function reliably and intuitively, and orient itself to the intended movement of the wearer. The system also meets all relevant safety requirements.

The IX BACK VOLTON also makes a measurable contribution to increasing efficiency. A major factor is the frame construction on the wearer’s back: It offers freedom of movement and a high degree of wearing comfort. At the same time, this design allows parcels and loads to be carried close to the upper body. 

Development of the IX BACK VOLTON is the result of interdisciplinary cooperation. The development team included experts from mechanical, electrical, software and biomechanical development. The clear objective: to create a motorized support that feels natural, is powerful and meets the demanding requirements of everyday industrial work. The engineering team from FAULHABER played a key role. A customer-specific motor solution was jointly developed which precisely combines those properties that are crucial for an exoskeleton: high performance, first-class manufacturing quality and the necessary scalability for subsequent serial deployment.

“We chose FAULHABER as a development partner because in our view there was no motor on the market that met our high demands,” Schwedhelm said. “With its expertise and well-known high quality standards, FAULHABER was our preferred partner right from the very beginning.” 

With a clear vision and profound understanding of the demands of the application, SUITX approached FAULHABER. In close cooperation, a drive solution was created that integrates seamlessly with the overall system.

The continuous advances in drive and motor technology for exoskeletons open up new possibilities: Systems are becoming lighter, more reliable and of a greater quality than ever before. It is exactly this development that forms the basis for not only supporting the back, but in future also other specific body joints – and for utilizing exoskeletons in new industries and completely new markets. Exoskeletons will increasingly support humans not only in physically demanding work or in convalescence, but also in daily life — wherever movement is made easier, safety will be ensured and the quality of life will be improved.

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