A Posture Prediction and Digital Standard Human Integration Method for Complex Equipment Operations

NIU Jianwei; ZHAO Furui; ZHANG Yating; WANG Zhihu; ZHANG Xin; ZHAO Jing

doi:10.19554/j.cnki.1001-3563.2026.16.002

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Packaging Engineering ›› 2026, Vol. 47 ›› Issue (16) : 22-35. DOI: 10.19554/j.cnki.1001-3563.2026.16.002

Special subject: Key Technologies and Applications of Digital Humans in Complex-Equipment Scenarios

A Posture Prediction and Digital Standard Human Integration Method for Complex Equipment Operations

NIU Jianwei^1,*, ZHAO Furui¹, ZHANG Yating¹, WANG Zhihu¹, ZHANG Xin², ZHAO Jing²

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Abstract

To address the difficulty of quantifying operators' dynamic postures during complex equipment operations, the work aims to propose a task-parameter-based posture prediction and digital standard human integration method to support ergonomic optimization in the equipment design stage. Parametric descriptions were performed for typical control panel operation tasks, and task parameters such as the height, depth, direction and duration of operation points were extracted. Digital standard human skeleton models were established based on anthropometric parameters at different percentiles. The Forward and Backward Reaching Inverse Kinematics (FABRIK) algorithm was used to predict key joint postures of the shoulder, elbow, wrist and trunk, and a cost function was introduced to optimize reachability and comfort. The Analytic Hierarchy Process (AHP) was applied to determine the weights of reachability, comfort and trunk load, and the predicted postures were mapped to digital standard human models for ergonomic evaluation across different body types. Validation with upper button pressing, middle knob adjustment and lower maintenance-port operation showed that the P5 female model was prone to insufficient reachability and excessive trunk flexion in high-and low-position operations. The P50 male model showed better overall adaptability, whereas the P95 male model showed a slight increase in trunk load in constrained spaces. A human-subject calibration test showed that the measured major joint angles were generally consistent with the simulated trends. The proposed method integrates posture prediction, digital standard human mapping and quantitative ergonomic evaluation, and can provide a reference for multi-body-type adaptability analysis and equipment layout optimization.

Key words

complex equipment operation / posture prediction / digital standard human / reachability / comfort / ergonomic evaluation / Analytic Hierarchy Process (AHP)

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NIU Jianwei, ZHAO Furui, ZHANG Yating, WANG Zhihu, ZHANG Xin, ZHAO Jing. A Posture Prediction and Digital Standard Human Integration Method for Complex Equipment Operations[J]. Packaging Engineering. 2026, 47(16): 22-35 https://doi.org/10.19554/j.cnki.1001-3563.2026.16.002

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