Combined Use of sEMG and Inertial Sensing to Evaluate Biomechanical Overload in Manufacturing: An On-the-Field Experience

Biomechanical overload is considered a significant occupational risk in manufacturing and a potential cause of musculoskeletal disorders. This research aims to introduce new methodologies for the quantitative risk evaluation of biomechanical risk by combining surface electromyography with a motion acquisition system based on inertial measurement units. Due to the lack of experimental data in the literature acquired in a real industrial environment during the working shift, an on-the-field study regarding an automotive assembly line workstation has been carried out in collaboration with Fiat Chrysler Automobiles Italy S.p.A. Data related to the trunk flexion forward and the erector spinae muscle activity have been acquired for several consecutive working cycles by considering three different workers. Data analyses indicated kinematic and muscular activity patterns consistent with those expected and that the proposed wearable technologies can be integrated and used simultaneously during work activities. Furthermore, the results demonstrated data repeatability, strengthening the feasibility and usefulness of the combined use of kinematic and electromyography technologies to assess biomechanical overload in production lines. This study could lay the bases for the future definition of a method for assessing biomechanical overload due to awkward postures.