Operational risk assessment for spinning frame tenders based on WMSD

Currently, the risk of work-related musculoskeletal disorders (WMSDs) in the textile industry is on the rise annually. Effectively assessing the risk of WMSDs caused by the operational behaviors of spinning frame tenders has become a critical issue demanding urgent resolution in the textile sector. Taking the task of replacing roving bobbins by spinning frame tenders as an example, this paper proposes a risk assessment method for WMSDs among spinning frame tenders. Firstly, a motion capture system is employed to accurately collect real-time working condition data during the tenders' operations. Second, the tenders' movement characteristics are analyzed, and a rigid-body dynamics theoretical model for their roving replacement actions is established based on the Newton–Euler method. Subsequently, real-time operational data are used to drive the OpenSim simulation model to validate the accuracy of the theoretical model. Finally, a risk assessment method suitable for spinning frame tenders' operations is developed by integrating a WMSD assessment model. The results indicate that, under the same workload, as the roving bobbin weight gradually increases within the range of 1–3 kg, the WMSD risk level for tenders also rises. When the roving bobbin weight exceeds 2 kg, the risk values all reach level 4. Given that risk levels above 4 can adversely affect tenders' health, measures such as optimizing rest schedules or providing auxiliary operational devices are recommended to reduce the risk of occupational musculoskeletal disorders. This study offers a feasible approach for preventing occupational musculoskeletal disorders in the future textile industry.