Task Safety with Human Augmentation Interfaces in Logistics Warehouse Operations: Finite Element Modeling

Abstract

The rapid expansion of global e-commerce has significantly intensified manual material handling demands within logistics warehouse operations, leading to an increased prevalence of occupational musculoskeletal disorders. Human augmentation technologies, particularly wearable exoskeletons, have emerged as a promising intervention to mitigate physical strain among warehouse workers. However, the physical interface between the mechanical structure and the human body introduces novel safety risks, including localized tissue ischemia, pressure ulcers, and neuromuscular compression. This paper presents a comprehensive safety assessment of human augmentation interfaces using advanced finite element modeling techniques. By simulating the complex biomechanical interactions between the rigid exoskeleton components and the deformable human soft tissues during typical warehouse tasks, this study provides quantitative evidence on contact pressure distributions and internal tissue strains. The methodology employs hyperelastic constitutive models to represent human skin, adipose tissue, and muscle, subjected to dynamic loading conditions representative of repetitive lifting and carrying. The results indicate that peak contact pressures frequently exceed physiological capillary closure thresholds under heavy loads, highlighting significant risks of soft tissue injury over cumulative shifts. Furthermore, the analysis reveals that subdermal shear stresses are concentrated at the edges of the physical interfaces, necessitating immediate design optimizations. The findings offer critical insights for ergonomists and engineers, establishing finite element modeling as an essential tool for evaluating and certifying the task safety of human augmentation systems prior to widespread industrial deployment.