Conceptual Design of an Industrial Manipulator for the Prevention of Musculoskeletal Disorders: a Participatory Approach

Abstract

Background. This study outlines the conceptual design process of an innovative load manipulator adapted to the brewing industry, to mitigate ergonomic risk factors associated with manual handling of heavy loads, stacking, and manual palletizing. The aim. To design a load manipulator for the function of “low-pressure table assistant” within a brewery. Methods. A descriptive non-experimental study was accomplished, using an ergonomic and participatory approach, that is divided into three phases. Anthropometric adaptability and worker dimensions were assessed to determine the selected design. Finally, the given concept was thoroughly documented by creating drawings and technical data. Results. The mean measured height was 173.4 centimeters, with a standard deviation of 4.6 centimeters, spanning a range of 165.8 centimeters (5th percentile) to 178.5 centimeters (95th percentile). This range suggests a moderate adequacy of the evaluated workforce in terms of height. Four main functions were identified: transporting boxes within the workspace, providing load support, allowing operator control, and ensuring safety. In addition, with this lifting device, the operator can handle 2, 4, or even 6 boxes simultaneously, with speed, flexibility, and functionality. Conclusions. In particular, the developed concept introduces significant innovations, such as the ability to, simultaneously handle several heavy loads and the integration of double-jointed pivots, which extends its operational range. These innovations contribute to the prevention of forced postures and manual lifting of heavy loads. Keywords: ergonomics, equipment design, industrial manipulator, prevention, musculoskeletal disorders.