Smart Ergonomics System ErgoJack

Exo + ErgoJack = Smart Exo

ErgoJack is a smart ergonomics system for exoskeletons

The system points out unergonomic postures and movements to the wearer, encouraging them to relieve the strain on their back and perform physically demanding tasks ergonomically.

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Smart exoskeletons and exosuits with ErgoJack

Smart ergonomics system ErgoJack

Ergonomics recognition during lifting movements in industrial use
© Fraunhofer IPK/Armin Okulla
Ergonomics recognition during lifting movements in industrial use
Ergonomics detection for forced postures in industrial use
© Fraunhofer IPK/Armin Okulla
Ergonomics detection for forced postures in industrial use
ErgoJack technology integration in exoskeletons
© Henning Schmidt
ErgoJack technology integration in exoskeletons

ErgoJack from Fraunhofer IPK adds real-time ergonomics analysis and support to an exoskeleton. 


The ErgoJack smart electronics and software system for exoskeletons and exosuits is a robotic system worn on the upper body. It supports workers during strenuous physical activities.

Specially developed algorithms, based on machine learning and AI, enable continuous ergonomics analysis in real time. Put simply, the ErgoJack's motion analysis distinguishes between ergonomic and non-ergonomic movements. 



  • Continuous increase in the average age of industrial workers
  • Increased risk of absences due to musculoskeletal disorders
  • Improving ergonomics as a key to maintaining health

The system detects a person's movements with small motion sensors, comparing them  to ergonomic movement patterns in real time, and providing customizable feedback. Via vibration, the wearer immediately receives a signal when they adopt postures or perform movements that are harmful to their health. This allows the person to adjust their posture or perform a movement correctly.

The softrobotic upper body orthosis is available in a purely sensory textile vest (exosuit) and a variant with power assistance (exoskeleton).


This enables a wide variety of applications to reduce physical stress:

  • Production
  • Logistics
  • Building trade
  • Physically demanding service occupations

ErgoJack works with artificial intelligence and machine learning methods and can be trained to any conceivable movement pattern.  The motion sensors integrated in the exoskeleton or exosuit are located on the shoulders, back and thighs.  In addition to these sensors, robust miniaturized electronics including an embedded controller, as well as a vibration module and a rechargeable battery are integrated into the orthosis.

Solution and customer benefits:

  • Innovative wearable system for production, logistics and services
  • Real-time motion measurement and analysis for immediate ergonomic improvement
  • Reduction of worker downtime

ErgoJack does not support unergonomic movements that redirect the wearer's load forces from overloaded to less stressed areas of the body.

The solution is interesting for these industries:


  • Production
  • Logistics
  • Service
  • Building trade
  • Manufacturers of exoskeletons
  • Manufacturers of wearables (e.g. smartwatch)


You're looking for:

  • Exoskeleton
  • Motion analysis
  • Ergonomics
  • Support robot
  • Action Recognition
  • Real-Time
  • Wearables
  • AI
  • Machine Learning
  • Smart Factory

Smart ergonomics system ErgoJack

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