The University of Cincinnati is working with Ohio’s Bureau of Workers’ Compensation to use digital-twin technology to make workplaces safer.
UC College of Engineering and Applied Science professors Manish Kumar and Sam Anand are developing tools that employers can use to prevent worker injuries from accidents, repetitive stress and other common causes.
In a demonstration at UC’s Digital Futures, they provided proof of concept using cameras to create a live, virtual representation of a worker in their actual workspace such as a warehouse or factory floor that can provide real-time feedback to workers about everything from potentially risky motions such as straining to reach something to immediate warnings that can avoid a disastrous collision with moving equipment.
Researchers in UC’s Industry 4.0/5.0 Institute are partnering with industrial collaborators such as Siemens, Innovative Numerics, Worthington Steel and thyssenkrupp Bilstein, which makes high-performance shock absorbers and suspension systems. The research team’s proof-of-concept demonstration attracted interest from dozens of other companies.
“We could not have pulled a better team from UC to do this project,” Kumar said.
Ohio recorded 76,800 nonfatal workplace injuries in 2023. More than half of them were considered severe, involving days away from work, job transfers or work restrictions while workers recuperated.
The system uses cameras to capture the movements of workers in real time to create a virtual representation called a digital twin. The system is so advanced that it can send real-time warnings to an employee’s smartwatch, alerting them about proximate dangers such as an approaching forklift behind them or around a corner, or even reminders that they might be stressing certain parts of their bodies through repetitive motions.
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