Smooth movement: with plastic plain bearings in the exoskeleton

iglidur® bearings are lightweight and work reliably even under high loads

The American company Pathway has developed a lightweight, portable technology to make repetitive arm movements in the work process more comfortable for employees: The AIRFRAME floating exoskeleton relieves muscle strain, supports movement sequences and prevents tension in the neck, shoulder and upper back. Particular attention was paid to the rotation mechanisms, which must be able to rotate effortlessly even under high axial loads. A large number of different iglidur® bearings are installed in the mechanical support system, including sleeve bearings with and without flange and thrust washers. They ensure its gradual activation with every arm movement.

The application was honoured with the golden manus® Award in 2017.

Profile

What was needed: Various plain bearings, flange bearings, sleeve bearings and thrust washers
Requirements: The product required frictionless yet lubrication-free and extremely lightweight materials, a compact design and the ability to rotate smoothly under high axial loads, often up to 100 kilograms.
Industry: Medical technology
Success for the customer: Users benefit from lightweight rotating joints that operate lubrication-free and without noticeable friction, reducing fatigue and the risk of repetitive load injuries. In addition, the plastic bearings fulfil the design requirement for non-corrosive materials.

Problem

With this exoskeleton, Pathway has designed and developed a lightweight wearable technology. The AIRFRAME was developed to support the arms of professionals and skilled workers who are exposed to repetitive arm movements and/or static lifting of the arms.

To realise the idea, Pathway engineers sought solutions for the design of the rotation mechanisms. To be effective, the exoskeleton must move effortlessly with the user without intruding into the workspace or restricting movement or dexterity.

Therefore, the product required extremely lightweight materials, a compact design and the ability to rotate smoothly under high axial loads, often up to 100 kilograms.

Solution

Today, the exoskeleton consists of a large number of plain bearings, flange bearings, sleeve bearings and thrust washers from the iglidur® product portfolio. These are installed in the various joints and points in the entire airframe skeleton and fulfil all design and performance criteria in order to achieve low-friction rotary movement with high axial loads.
Due to the diversity of the portfolio and bearing components, engineers were able to develop a compact and lightweight design that fulfils design requirements that would not be achievable with conventional bearing options.

The mechanical support system is activated gradually as the arm is raised and released gradually and without noticeable friction as the arm is lowered, reducing fatigue and the risk of repetitive strain injuries. Users carrying the device thus benefit from lightweight rotating joints that provide imperceptible friction without lubrication. In addition, the plastic bearings fulfil the design requirement for non-corrosive materials, allowing the exoskeleton to be used in harsh environmental conditions without any problems. The technology is both durable and cost-effective.