A systematic review on digital human models in assembly process planning

Simulating the behavior of operators through a digital human model (DHM) is an intuitive way to reflect the human factors in the assembly process, which is important for ergonomics research in Industry 4.0. The efficiency of digital human assembly simulation has become the main bottleneck restricting the application of DHMs in assembly planning for a long time. With the development of artificial intelligence algorithms, it has become more realistic and efficient to build a human-cyber-physical system (HCPS) and achieve efficient digital human assembly planning. This paper has considered the leading technologies, advanced methods, and challenges related to digital human assembly. In terms of digital human modeling, we summarized the limitations of existing construction methods and discussed the potential of innovative methods in the field of robotics and computers for digital human motion modeling to improve the efficiency of digital human posture planning. In terms of assembly ergonomics evaluation with DHMs, we reviewed the classical assembly ergonomics evaluation methods and pointed out the parts to be improved in the existing evaluation systems. In terms of digital human assembly operation planning with DHMs, we discussed and identify the limitations of existing planning methods. And in terms of human-robot collaborative assembly with DHMs, we proposed the difficulties and the future development trends at the practical application. It is foreseeable that by improving the efficiency of the digital human posture planning and the comprehensiveness of ergonomics evaluation with DHMs, DHMs will have the potential to be more in-depth to help the operators and designers in whole process of product manufacturing industry.

Automated summary

Simulating the behavior of operators using digital human models is an important aspect of ergonomics research in Industry 4.0. The efficiency of digital human assembly simulation has been a major obstacle in using digital human models for assembly planning. With the advancement of artificial intelligence algorithms, it is now more realistic and efficient to build a human-cyber-physical system and achieve efficient digital human assembly planning. This paper discusses the leading technologies, advanced methods, and challenges related to digital human assembly, including digital human modeling, assembly ergonomics evaluation, assembly operation planning, and human-robot collaborative assembly.