Preventing worker’s musculoskeletal disorders with wearable inertial sensors: ergonomics and modelling of physical human-robot interactions

The most widespread work-related diseases are musculoskeletal disorders (MSD) caused by awkward postures and excessive effort to upper limb muscles during work operations. The use of wearable IMU sensors could monitor the workers constantly to prevent hazardous actions, thus diminishing work injuries. In this thesis, procedures are developed and tested for ergonomic analyses in a working environment, based on a commercial motion capture system (MoCap) made of 17 Inertial Measurement Units (IMUs). An IMU is usually made of a tri-axial gyroscope, a tri-axial accelerometer, and a tri-axial magnetometer that, through sensor fusion algorithms, estimates its attitude. Effective strategies for preventing MSD rely on various aspects: firstly, the accuracy of the IMU, depending on the chosen sensor and its calibration; secondly, the correct identification of the pose of each sensor on the worker’s body; thirdly, the chosen multibody model, which must consider both the accuracy and the computational burden, to provide results in real-time; finally, the model scaling law, which defines the possibility of a fast and accurate personalization of the multibody model geometry. Moreover, the MSD can be diminished using collaborative robots (cobots) as assisted devices for complex or heavy operations to relieve the worker's effort during repetitive tasks. All these aspects are considered to test and show the efficiency and usability of inertial MoCap systems for assessing ergonomics evaluation in real-time and implementing safety control strategies in collaborative robotics. Validation is performed with several experimental tests, both to test the proposed procedures and to compare the results of real-time multibody models developed in this thesis with the results from commercial software. As an additional result, the positive effects of using cobots as assisted devices for reducing human effort in repetitive industrial tasks are also shown, to demonstrate the potential of wearable electronics in on-field ergonomics analyses for industrial applications.

Efficient and low-computational predictive models for spectral sensors

Spectral sensors are a wide class of devices that are extremely useful for detecting essential information of the environment and materials with high degree of selectivity. Recently, they have achieved high degrees of integration and low implementation cost to be suited for fast, small, and non-invasive monitoring systems. However, the useful information is hidden in spectra and it is difficult to decode. So, mathematical algorithms are needed to infer the value of the variables of interest from the acquired data. Between the different families of predictive modeling, Principal Component Analysis and the techniques stemmed from it can provide very good performances, as well as small computational and memory requirements. For these reasons, they allow the implementation of the prediction even in embedded and autonomous devices. In this thesis, I will present 4 practical applications of these algorithms to the prediction of different variables: moisture of soil, moisture of concrete, freshness of anchovies/sardines, and concentration of gasses. In all of these cases, the workflow will be the same. Initially, an acquisition campaign was performed to acquire both spectra and the variables of interest from samples. Then these data are used as input for the creation of the prediction models, to solve both classification and regression problems. From these models, an array of calibration coefficients is derived and used for the implementation of the prediction in an embedded system. The presented results will show that this workflow was successfully applied to very different scientific fields, obtaining autonomous and non-invasive devices able to predict the value of physical parameters of choice from new spectral acquisitions.

Thermal and air quality modeling of an electric vehicle cabin with low-cost sensors and reinforcement learning

The design process of any electric vehicle system has to be oriented towards the best energy efficiency, together with the constraint of maintaining comfort in the vehicle cabin. Main aim of this study is to research the best thermal management solution in terms of HVAC efficiency without compromising occupant’s comfort and internal air quality. An Arduino controlled Low Cost System of Sensors was developed and compared against reference instrumentation (average R-squared of 0.92) and then used to characterise the vehicle cabin in real parking and driving conditions trials. Data on the energy use of the HVAC was retrieved from the car On-Board Diagnostic port. Energy savings using recirculation can reach 30 %, but pollutants concentration in the cabin builds up in this operating mode. Moreover, the temperature profile appeared strongly nonuniform with air temperature differences up to 10° C. Optimisation methods often require a high number of runs to find the optimal configuration of the system. Fast models proved to be beneficial for these task, while CFD-1D model are usually slower despite the higher level of detail provided. In this work, the collected dataset was used to train a fast ML model of both cabin and HVAC using linear regression. Average scaled RMSE over all trials is 0.4 %, while computation time is 0.0077 ms for each second of simulated time on a laptop computer. Finally, a reinforcement learning environment was built in OpenAI and Stable-Baselines3 using the built-in Proximal Policy Optimisation algorithm to update the policy and seek for the best compromise between comfort, air quality and energy reward terms. The learning curves show an oscillating behaviour overall, with only 2 experiments behaving as expected even if too slow. This result leaves large room for improvement, ranging from the reward function engineering to the expansion of the ML model.

Cross-sensors analysis of multispectral Earth observation data for environmental monitoring

Time Series Analysis of multispectral satellite data offers an innovative way to extract valuable information of our changing planet. This is now a real option for scientists thanks to data availability as well as innovative cloud-computing platforms, such as Google Earth Engine. The integration of different missions would mitigate known issues in multispectral time series construction, such as gaps due to clouds or other atmospheric effects. With this purpose, harmonization among Landsat-like missions is possible through statistical analysis. This research offers an overview of the different instruments from Landsat and Sentinel missions (TM, ETM, OLI, OLI-2 and MSI sensors) and products levels (Collection-2 Level-1 and Surface Reflectance for Landsat and Level-1C and Level-2A for Sentinel-2). Moreover, a cross-sensors comparison was performed to assess the interoperability of the sensors on-board Landsat and Sentinel-2 constellations, having in mind a possible combined use for time series analysis. Firstly, more than 20,000 pairs of images almost simultaneously acquired all over Europe were selected over a period of several years. The study performed a cross-comparison analysis on these data, and provided an assessment of the calibration coefficients that can be used to minimize differences in the combined use. Four of the most popular vegetation indexes were selected for the study: NDVI, EVI, SAVI and NDMI. As a result, it is possible to reconstruct a longer and denser harmonized time series since 1984, useful for vegetation monitoring purposes. Secondly, the spectral characteristics of the recent Landsat-9 mission were assessed for a combined use with Landsat-8 and Sentinel-2. A cross-sensor analysis of common bands of more than 3,000 almost simultaneous acquisitions verified a high consistency between datasets. The most relevant discrepancy has been observed in the blue and SWIRS bands, often used in vegetation and water related studies. This analysis was supported with spectroradiometer ground measurements.

Development of textile wearable chemical sensors

In this elaborate, a textile-based Organic Electrochemical Transistor (OECT) was first developed for the determination of uric acid in wound exudate based on the conductive polymer poly(3,4-ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS), which was then coupled to an electrochemically gated textile transistor consisting of a composite of iridium oxide particles and PEDOT:PSS for pH monitoring in wound exudate. In that way a sensor for multiparameter monitoring of wound health status was assembled, including the ability to differentiate between a wet-dry status of the smart bandage by implementing impedance measurements exploiting the OECT architecture. Afterwards, for both wound management as well as generic health status tracking applications, a glass-based calcium sensor was developed employing polymeric ion-selective membranes on a novel architecture inspired by the Wrighton OECT configuration, which was later converted to a Proof-of-Concept textile prototype for wearable applications. Lastly, in collaboration with the King Abdullah University of Science and Technology (KAUST, Thuwal, Saudi Arabia) under the supervision of Prof. Sahika Inal, different types of ion-selective thiophene-based monomers were used to develop ion-selective conductive polymers to detect sodium ion by different methods, involving standard potentiometry and OECT-based approaches. The textile OECTs for uric acid detection performances were optimized by investigating the geometry effect on the instrumental response and the properties of the different textile materials involved in their production, with a special focus on the final application that implies the operativity in flow conditions to simulate the wound environment. The same testing route was followed for the multiparameter sensor and the calcium sensor prototype, with a particular care towards the ion-selective membrane composition and electrode conditioning protocol optimization. The sodium-selective polymer electrosynthesis was optimized in non-aqueous environments and was characterized by means of potentiostatic and potentiodynamic techniques coupled with Quartz Crystal Microbalance and spectrophotometric measurements.