DHM & REHABILITATION

DIGITAL HUMAN MODELLING DANIELE REGAZZONI, UNIVERSITY OF BERGAMO

CONTENTS

. THE CONTEXT

. THE PROBLEM

. EVOLUTION

. A TAXONOMY

. DESIGN AND MANUFACTURING

. WHAT NEXT?

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THE DIGITAL REVOLUTION

…… SMART COMPONENTS REFERENCE MODELS FOR INDUSTRY 4.0 SMART MACHINES THE HUMAN BEING AS ADDITIVE KEY ISSUE IN THE MANUFACTURING VIRTUAL/AUGMENTED DIGITAL FACTORY REALITY

CYBER‐SECURITY DIGITAL PLATFORMS FOR PRODUCT‐SERVICE BIG DATA & ANALYTICS SOLUTIONS

MEGA TRENDS

. HEALTH AND WELL BEING

. GLOBALIZATION

. SUSTENABILITY

. KNOWLEDGE

. DIGITALIZATION VIRTUALIZATION OF . VIRTUALIZATION PRODUCT, PROCESSES AND

J.T. Fokkema, Delft University of Technology, “Challenges and answers for competitive engineering” TMCE 2008

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THE CONTEXT

… FROM REAL TO VIRTUAL

. PRODUCT DESIGN

HUMAN BEINGS

. MANUFACTURING

&

4.0 UMANS H ORKER W IRTUAL V

Image Courtesy

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THE PROBLEM DESIGN

HUMAN CENTRED DESIGN  INVOLVING THE HUMAN PERSPECTIVE IN ALL STEPS OF THE DESIGN PROCESS

. … MOVINGTOWARDSACUSTOM‐BASED DESIGN THAT HAS TO TAKE INTO ACCOUNT ALONG THE PRODUCT LIFE CYCLE Earplugs – USABILITY AND COMFORT – HUMAN BEHAVIOR (PHYSICAL AND PHYSIOLOGICAL) – POPULATION AND AGEING – DIFFERENT CATEGORIES OF USERS – CULTURAL AND SOCIAL CONTEXTS – ….

BMW Workers’ custom‐fit glove Mouthguard Immobilization device – Xkelet

THE PROBLEM MANUFACTURING

HUMAN CENTRED MANUFACTURING  DESIGN MANUFACTURING PROCESS AND PLANTS TAKING INTO ACCOUNT THE OPERATORS AND THEIR TASKS (MANUAL)

… DESPITE THE INCREASING AUTOMATION OF THE PRODUCTION PROCESSES

THERE STILL THE NEED OF HIGH‐SKILLED OPERATORS FOR COMPLEX MANUAL TASKS BUT …. . THE DESIGN OF MANUAL OPERATIONS IS OFTEN LACKING OR NOT OPTIMIZED WITH RESPECT TO THE PERSON – HUMAN INTERVENTION IS NOT EVALUATED OVER THE ENTIRE PRODUCT LIFE CYCLE OF THE PRODUCT BUT STOPS AT THE COMPANY, EXTERNAL OPERATORS AND END USERS OFTEN EXCLUDED . A POOR DESIGN OF MANUAL OPERATIONS CAUSES – INEFFICIENCIES (ALSO DUE TO EXCESS OF PRECAUTION) – CHRONIC MUSCULOSKELETAL DISEASES

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… IN ORDER TO DESIGN . SIMULATE AND EVALUATE PRODUCT‐HUMAN BODY INTERACTION - DIFFERENT MORPHOLOGIES AND POPULATIONS ACCORDING TO THE APPLICATIVE CONTEXT . ERGONOMICS ASSESSMENT ( ANALYSIS SYSTEMS SUCH AS RULA, NIOSH, ETC.) . EVALUATE THE BODY RESPONSE IN THE INTERACTION WITH THE PRODUCT - AUXILIARY AND REHABILITATION DEVICES . PRODUCT SIZING ACCORDING TO TARGET POPULATION - ANTHROPOMETRIC CHARACTERIZATION (AUTOMOTIVE, CLOTHING, …)

… IN ORDER TO MANUFACTURING

. SIMULATE AND EVALUATE WORKPLACE (PRODUCTION PLANT) TAKING INTO ACCOUNT: - DIFFERENT POPULATIONS, DIFFERENT CULTURES AND HABITS, … . SIMULATE AND EVALUATE POSTURES  ERGONOMICS  OCCUPATIONAL MEDICINE . PLAN OPERATIONS . EVALUATE HUMAN‐MACHINE INTERACTION  COLLABORATIVE ROBOTS . …

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HUMAN IN THE LOOP

NEW DESIGN PARADIGM MAN MACHINE BETTER DESIGN OF WORKERS’ EMBEDDING DHM INTERACTION DATA TASKS SIMULATION TOOLS IMPROVED EFFICIENCY, SAFETY, RISK PREVENTION

HUMAN CENTERED DESIGN & PRODUCT DEVELOPMENT MANUFACTURING GUIDELINES

BETTER PRODUCTS … MAKING (VIRTUAL) HUMANS FOR ANY CATEGORY OF THE CENTER OF WORK DESIGN OPERATORS AND USERS SYSTEM…

TECHNOLOGIES

Impossibile v isualizzare l'immagine. . DIGITAL HUMAN MODELLING – STANDARD KINEMATIC – FROM 3D SCANNERS – FROM MEDICAL IMAGING

. VIRTUAL/AUGMENTED REALITY – HEAD MOUNTED DISPLAY – HAND TRACKING DEVICES – HAPTICS DEVICES – OLFACTORY DEVICES – …

. MOTION CAPTURE SYSTEMS

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’60s "Boeing Man"

A TAXONOMY

VIRTUAL HUMANS

VIRTUAL HUMANS/ VIRTUAL HUMAN MODELS VIRTUAL DETAILED MANIKINS FOR HUMANS/ACTORS – FROM MEDICAL HUMANS/MANIKINS BIOMECHANICAL ERGONOMIC ROWD MAGING FOR CLOTHING MODELS C I & 3D ANALYSIS SIMULATOR SCANNING

. OPTITEX . GARMENT . SANTOS . JACK . POSER . MOVIES . ODARIS . MIMICS . MESHLAB M DESIGN . RAMSIS . DHAIBA . . MASSIIVE . VIDEOGAMES . INVESALIUS . BLENDER CLO3D . VIRTUAL . PTC CREO WORKS CROWDIT . EMERGENCY . AMIRA . GEOMAGIC . MARVELLOUS SHOP . MADYMO MANIKIN . D‐GUY SITUATIONS . AEMART . OSIRIX . RHYNOCEROS K . CATWALKS . HUMANCAD . ANYBODY . … . ‐‐ . … AND V&K . … . …. . … . THALMANN

DESIGN DESIGN DESIGN DESIGN MANUFACTURING MANUFACTURING

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PRODUCT DESIGN VIRTUAL HUMANS FOR CLOTHING . STANDARD MANNEQUINS (BASED ON ATHROPOMETRIC DB)

Image courtesy Optitex Image courtesy Image courtesy CLO3D www.zilvostalova.com/ . CUSTOMISED VIRUAL HUMANS  CUSTOM FIT GARMENT FROM BODY SCANNERS

PRODUCT DESIGN VIRTUAL HUMANS FOR CLOTHING ‐ VIRTUAL CATWALKS

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PRODUCT DESIGN VIRTUAL HUMANS & MOCAP FOR CLOTHING

. FROM CUSTOMER BODY ACQUISITION TO CUSTOMISED «ANIMATED» AVATAR

2 3D RIGGING 3 3D GARMENT MODELLING AND SIMULATION

1 BODY AND GAIT ACQUISITION

PRODUCT DESIGN VIRTUAL HUMAN FOR ERGONOMICS VIRTUAL MANIKIN: A KINEMATIC CHAIN COMPOSED BY A NUMBER OF RIGID LINKS CONNECTED BY JOINTS DESIGN REQUIRES THAT A STANDARD POPULATION CAN INTERACT SUCCESSFULLY WITH THE PRODUCT PRODUCT MUST BE COMPLIANT WITH DIFFERENT SIZES OF MEN AND WOMEN SUPPOSED TO USE IT

. VISIBILITY . REACH & GRASP . COMFORT AND POSTURE PREDICTION . TASK EVALUATION AND SAFETY . MULTI‐USERS INTERACTION . …. DRIVER’S CAR SEAT REQUIRES A NUMBER OF REGULATION TO COMPLY WITH REQUIREMENTS FOR: . DRIVING: REACHABILITY OF PEDALS, WHEEL, CONTROLLERS . VISIBILITY: FRONTAL, LATERAL, DASHBOARD, REAR MIRRORS . SAFETY: SAFETY BELT POSITION, DISTANCE FROM AIR BAGS . COMFORT: LOWER BACK POSTURE, ARMS POSITION,… . …

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PRODUCT DESIGN VIRTUAL HUMANS FOR ERGONOMICS

EXAMPLE OF TARGET POPULATION OF DIFFERENT HEIGHTS AND BMI

PRE‐RECORDED POSTURES IN JACK

PRODUCT DESIGN VIRTUAL HUMANS FOR ERGONOMICS CASE STUDY : DESIGN OF A DISPLAY UNIT . CATEGORIES OF USERS  TARGET POPULATIONS

OPERATORS MAINTENANCE WORKERS CUSTOMERS

. VISIBILITY . VISIBILITY . VISIBILITY . REACHABILITY . REACHABILITY . REACHABILITY . AFETY S . SAFETY . GRASPING . POSTURE COMFORT . PREVENT MUSCULOSKELETAL DISEASES

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PRODUCT DESIGN VIRTUAL HUMANS FOR ERGONOMICS AS‐IS Female Female Male Male CASE STUDY : DESIGN OF A DISPLAY UNIT LOWEST SHELF 5% 50% 50% 95% REACHABILITY % reached 80 85 100 100 . CATEGORIES OF USERS POSTURE Owas class 2244 L4L5 (Nm) 25 80 120 125 Spinal Lower 800 1500 2400 2600 OPERATORS Forces(N) Back Muscle analysis 200 520 1100 1100 Load tension (N) 1 Kg Static force 390 390 450 430 Cycles 30 30 26 25 Fatigue ‐ Recovery F recovery Time (s) 0,45 0,57 10,16 11,95 A T L4L5 (Nm) 75 85 125 130 I Spinal Lower 1500 1600 2600 2900 G Forces (N) Back U Muscle Load analysis 520 600 1200 1250 . VISIBILITY E tension (N) 3 Kg . REACHABILITY Static force 410 410 465 470 Cycles 28 28 18 13 . SAFETY Fatigue ‐ Recovery recovery . POSTURE COMFORT Time (s) 4,48 4,536 30,28 37,89 . PREVENT RWL(1) 3,88 3,65 3,37 3,65 MUSCULOSKELETAL NIOSH LI (2) 0,39 0,41 0,45 0,41 (3) DISEASES CLI 1,393 1,478 1,605 1,478 (1) Reccommended Weight Limit; (2) Lifting Index; (3) Composite Lifting Index

PRODUCT DESIGN VIRTUAL HUMANS FOR ERGONOMICS CASE STUDY : DESIGN OF A DISPLAY UNIT . CATEGORIES OF USERS

OPERATORS SHORT TERM SOLUTION NEW AUXILIARY DEVICE OPTIMIZING ERGONOMIC REQUIREMENTS

. VISIBILITY . REACHABILITY . SAFETY . POSTURE COMFORT . PREVENT MUSCULOSKELETAL DISEASES

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PRODUCT DESIGN VIRTUAL HUMANS FOR ERGONOMICS CASE STUDY : DESIGN OF A DISPLAY UNIT . CATEGORIES OF USERS LONG TERM SOLUTION OPERATORS NEW DESIGN CONCEPTS OPTIMIZING ERGONOMIC REQS

. VISIBILITY . REACHABILITY . SAFETY . POSTURE COMFORT . PREVENT MUSCULOSKELETAL DISEASES

CASE STUDIES

CASE 1 COSTAN LION HF295 N22 PERFORMED ANALYSES HIGH TEMPERATURE REFRIGERATOR (0‐4°C) FOR FRESH GOODS OWAS JACK LBA

CASE 2 COSTAN ELEPHANT GV PERFORMED ANALYSES LOW TEMPERATURE REFRIGERATOR (‐25°C) FOR FROZEN GOODS JACK

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TEST CAMPAIGN

. REACHABILITY TESTS – CASE STUDY 1: WITH DIFFERENT POSTURES ON DIFFERENT SHELVES – CASE STUDY 2: INTERFERENCESANALYSISDUETODOORSAND FRAMES

. VISIBILITY TESTS – CASE STUDY 1: FROM THE AISLE AND CLOSE TO THE DISPLAY UNIT – CASE STUDY 2: OCCLUSIONS DUE TO DOORS AND FRAMES

REACHABILITY ANALYSIS: CASE STUDY 1 Given avatar gender and size dealing with each shelf (from the base to the 5th) and with eventual different posture for each shelf (kneeling down, squat, on tiptoe, etc.)

Accessibility Visibility Posture Distance from OWAS LBA [N] Rate Distance Rate back [mm] Normal standing 37,91 18% 0 100% 1 661 5° shelf On tiptoe 32,15 30% 0 100% 1 746 On the step 0 100% 0 100% 1 839 Normal standing 14,3 69% 0 100% 2 832 4° shelf On tiptoe 0 100% 0 100% 2 1080 On the step Normal standing 0 100% 26 43% 2 1351 3° shelf On tiptoe On the step Normal standing 0 100% 0 100% 3 1831 2° shelf On tiptoe Normal standing 0 100% 0 100% 4 2592 Same knee as hand 0 100% 0 100% 4 2662 1° shelf Opposite knee 0 100% 0 100% 4 3025 Squat 0 100% 0 100% 4 3257 Kneeling two knees 0 100% 0 100% 4 3064 Same knee as hand 13,2 80% 0 100% 4 3168 Opposite knee 0 100% 0 100% 4 3115 Base shelf Squat 0 100% 0 100% 4 3138 Kneeling two knees 0 100% 65 0% 4 2815

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REACHABILITY RESULTS: CASE STUDY 1

M95

M75

M50

F50

F25

F5

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REACHABILITY ANALYSIS: CASE STUDY 2

. INTERFERENCE BETWEEN AVATAR AND DISPLAY UNIT (E.G., DOORS AND FRAMES) . 5TH AND 6TH SHELVES ONLY FOR TALL AVATARS . AVATAR ROTATION AT 4TH SHELF . 1TH SHELF KNEELING DOWN

REACHABILITY RESULTS: CASE STUDY 2

Shelf divided with a 50x50 mm mesh and analysis on each cell of the mesh

H‐S11

Legenda H‐SH‐SH‐SH‐SH‐SH‐D10 Gray: not reachable H‐SH‐SH‐SH‐DH‐DH‐DH‐DH‐D9 Red: colllision H‐SH‐SH‐DH‐DH‐DH‐D8 Yellow: proximity Green: good reachability H‐DH‐D7

A‐FH‐D6 H: head A: arm A‐FH‐D5 F: frame A‐F 4 S: shelf A‐F 3 D: door A‐FA‐F2

A‐FA‐F1

14 13 12 11 10 9 8 7 6 5 4 3 2 1

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VISIBILITY

. WALKING IN THE SUPERMARKET AISLE . STANDING IN THE MIDDLE OF THE AISLE . INFRONTOFTHESHELVES

VISIBILITY ANALYSIS: CASE STUDY 1

M95

M75

M50

F50

F25

F5 100012501000

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VISIBILITY ANALYSIS: CASE STUDY 2

. SIDE VIEW – SHELVES INTERFERENCE 1000

1250

1500

2000

VISIBILITY ANALYSIS: CASE STUDY 2

x [mm] 1 2 3 4 5 . TOP VIEW 0 45° 10° 52° 9° 9° y=350 50 41° 11° 55° 9° 10° – DOOR INTERFERENCE [mm] 100 37° 11° 58° 10° 11° 150 33° 11° 61° 10° 12° – FRAME INTERFERENCE 0 44° 9° 50° 9° 11° y=400 50 40° 9° 52° 9° 11° [mm] 100 36° 9° 55° 9° 12° 150 33° 9° 57° 10° 13°

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MANUFACTURING VIRTUAL HUMANS FOR ERGONOMICS

. HUMAN FACTORS – BODY SIZES, MUSCULAR FORCES, MOVEMENT RANGES, SENSES (TOUCH, SIGHT, HEARING, …) – CULTURE, TALENT, INCLINATION . WORKPLACE ‐ MANUFACTURING FACILITIES – DESIGN SHOP FLOOR TO PROVIDE FUNCTION AND ARRANGEMENT, ASSEMBLY, SERVICING, RELIABILITY, MANUFACTURABILITY . TASK DESIGN – MANAGEMENT OF TIME, EASE OF USE, INFORMATION OVERLOAD, TASK SCHEDULING

MANUFACTURING VIRTUAL HUMANS FOR ERGONOMICS

OCCUPATIONAL SAFETY AND HEALTH «FITTING THE WORK TO THE WORKERS»

Vukica Jovanovic, M. Tomovic et al., Ergonomic Design of Manual Assembly Workplaces

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MANUFACTURING VIRTUAL HUMANS FOR ERGONOMICS

. OPTIMIZE MANUAL HANDLING OF MATERIAL, GOODS AND TOOLS – MAP AND SIMULATE OPERATORS’ TASKS . FIX INEFFICIENCIES DUE TO LACK OR EXCESS OF PREVENTION

Image courtesy ESI, data copyright Wolksvagen, Digital Human: RAMSIS ESI's VR Technical Highlights Video #11 ‐ Evaluating Human Worker Ergonomics

CASE: LIFT ASSIST DEVICE

CAMPAIGN OF TASKS SIMULATION WORKER POINT OF VIEW

FRONT GRASPING STRAIGHT ARMS

OWAS OK: level 1

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CASE: LIFT ASSIST DEVICE

LOWER BACK ANALYSIS

MANUFACTURING VIRTUAL HUMANS FOR ERGONOMICS

. LAYOUT DESIGN

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… INTEGRATING MOCAP

MOTION CAPTURE DESIGN AND MANUFACTURING SYSTEMS . PRODUCTS ‐ OPTICAL ‐ INERTIAL

DIGITAL HUMAN . WORKSPACE, TOOLS, MODELS PRODUCTION PROCESSES)

… INTEGRATING MOCAP

RGB CAMERA VIEW JOINTS POSITIONS LIFEMODELER AVATAR

PSEYE + IPISOFT + LIFEMODELER

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… INTEGRATING MOCAP

KINECT + JACK DEPTH JOINTS CAMERA VIEW POSITIONS JACK Lowest shelf Middleshelf

BIOMECHANICAL MODELS

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BIOMECHANICAL MODELS

WEBCAM 1 WEBCAM 2

WEBCAM 3 WEBCAM 4 I PASSO

BIOMECHANICAL MODELS

II PASSO III PASSO IV PASSO

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INTEGRATION WITH VR/AR

INTEGRATION WITH VR/AR

. INCLUDING – VISION – TOUCH – SMELL – …

Image courtesy Gruppo Kaemart, Politecnico di Milano

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MANUFACTURING HUMAN ROBOT INTERACTION

. SIMULATE THE COLLABORATIVE TASKS BETWEEN HUMANS AND ROBOTS

. SECURE HUMAN TASKS – BUILDING A HUMAN MODEL ON LINE

. DESIGN COOPERATIVE ROBOTS

Carlos Morato, Krishnanand Kaipa, Boxuan Zhao, Satyandra K. Gupta, Safe Human Robot Interaction By Using Exteroceptive Sensing Based Human Modeling

CROWD SIMULATORS

. EVACUATION PLAN . EMERGENCY EXIT

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HUMAN MODELS FROM MEDICAL IMAGING AND 3D SCANNERS

. DESIGN OF HIGHLY CUSTOMISED PRODUCTS COINCEIVED AROUND THE HUMAN BODY  DETAILED MODEL OF THE HUMAN BODY OR OF INVOLVED ANATOMICAL DISTRICTS

. MERGING MODELS FROM DIFFERENT SOURCES

LOWER LIMB PROSTHESIS DESIGN

. DESIGN AND TEST OF LOWER LIMB PROSTHESIS IN A VIRTUAL * image Cortesy ENVIRONMENT . REPLACE MANUAL PROCEDURE COMMONLY ADOPTED TO DESIGN AND

MANUFACTURE SOCKET* Ottobock Manual Digital

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RESEARCH CONTEXT cortesy . NON‐CORRECT SOCKET MAY: – REATE DISCOMFORT OR PAIN C Images – LIMIT PROSTHESIS USABILITY – AFFECT GAIT QUALITY

. PROVIDE BETTER SOCKETS BY IMPROVING THE Bad fitting Bad alignment www.rogerwolfsonandassociates.co.za/ UNDESTANDING OF SOCKET – RESIDUAL LIMB INTERACTION . PROVIDE TECHNICIANS WITH TOOLS TO ASSESS GAIT PERFORMANCE . IMPROVE DESIGN ENVIRONMENT

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BACKGROUND AND APPROACH

STATE OF THE ART COMMON PRACTICE NEW PROPOSED SOLUTION SOLUTION

Stand alone contact Pressure acquisition (static COM FORT Patient’s Interview pressure and dynamic) and mapping measurement on DHM

Motion tracking and Merging of pressure data GAIT Visual observation manual data and gait analysis data on elaboration patient model

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METHODOLOGY

. THREE MAIN STEPS: – SCANNING PATIENT’S RESIDUAL LIMB • WITH AND WITHOUT PRESSURE SENSORS – PRESSURE ACQUISITION • IN STANDING POSITION • DURING GAIT ON A STRAIGHT LINE – VISUALIZATION OF RESULTS ON 3D MODEL • COLOR MAP FOR EASY AND QUICK EVALUATION

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RESIDUAL LIMB SCANNING

. NEED FOR THE CREATION OF A DETAILED PATIENT‐BASED MODEL OF THE RESIDUAL LIMB

Optical 3D MRI scanner

Pros : Internal structure Pros: Undeformed geometry Cons: Only skin geometry Cons: Flattening due to contact

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PRESSURE ACQUISITION

. TESCAN F‐SOCKET PRESSURE SENSORS – SENSORS CALIBRATION – DISPOSITION INSIDE THE SOCKET – PRESSURE MEASURE

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VISUALIZATION TOOL

. AD‐HOC DEVELOPED TOOL TO DATA FROM Sensel n(i,j) – 3D SCANNING – PRESSURE ACQUISITION SYSTEM . DEFINE SENSOR STRIPE POSITION . MAP SENSELS POSITION – COLOR SENSEL ACCORDING TO PRESSURE VALUE . MAP OF PRESSURE ON 3D MODEL

Sensor stripe n

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APPLICATION

. PATIENT – MALE, 53 YO, TRANSFEMORAL . SCANNING – MICROSOFT KINECT V.1 – ARTEC EVA . PRESSURE ACQUISITION – STATIC (VERTICAL BODY WEIGHT LOAD) – DYNAMIC (DURING GAIT)

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RESULTS ACHIEVED Heel strike Midstance Toe off Midswing

Static load

Frontal view Side view Rear view

Dynamic load

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OUTCOMES

. PATIENT’SHUMANMODELISUSEDBOTHASINPUTDATAFORSOCKETDESIGNANDASA MEANS TO REPRESENT PROSTHESIS PERFORMANCE – IN STANDING POSITION – DURING PATIENT’S GAIT . THE METHOD TO VISUALIZE PRESSURE DATA BY A COLOR SCALE ON THE 3D MODEL OF RESIDUAL LIMB OF AMPUTEE PATIENT ALLOWS – ANYONE INVOLVED IN THE PROCESS TO UNDERSTAND PRESSURE TREND AND PRESSURE PEAKS AT THE SOCKET‐RESIDUAL LIMB INTERFACE – TECHNICIANS TO EASILY EVALUATE THE SOCKET, PROVIDE EVENTUAL CHANGES, AND VALIDATE THE DESIGN

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WHAT’SNEXT?

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WHAT’SNEXT?

. VIRTUAL HUMAN MODEL MORE AND MORE DETAILED  MULTI‐SCALE MODELS TO REPRODUCE HUMAN BEHAVIOUR

. DIGITAL HUMAN MODEL FOR PEOPLE WITH SPECIAL NEEDS – OLDER PEOPLE – LIMITED CAPABALITIES – DISABLED PEOPLE – … . LOW‐ COST TECHNOLOGIES . SUPPORTING METHODOLOGIES

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