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Purpose

The purpose of this paper is to introduce a new manipulator structure to configure power‐assist devices in order to protect the operator from suffering musculoskeletal disorders. The mechanical structure and the control system along with their main features are presented.

Design/methodology/approach

The new structure was designed under the criterion of minimizing the torques required for handling payloads up to 75 kg as well as to configure a system to be controlled easily.

Findings

A new structure based on electrical AC motors and capable of handling high payloads exerting low motor torque is provided.

Originality/value

The paper describes how application of the criterion of minimizing the required torques to handle heavy payload produced a new manipulator structure. This structure is patent protected.

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