The use of virtual reality (VR) techniques for industrial training provides a safe and cost effective solution that contributes to increased engagement and knowledge retention levels. However, the process of experiential learning in a virtual world without biophysical constraints might contribute to muscle strain and discomfort, if ergonomic risk factors are not considered in advance. Under this scope, we have developed a digital platform which employs extended reality (XR) technologies for the creation and delivery of industrial training programs, by taking into account the users and workplace specificities through the adaptation of the 3D virtual world to the real environment. Our conceptual framework is composed of several inter-related modules: 1) the XR tutorial creation module, for automatic recognition of the sequence of actions composing a complex scenario while this is demonstrated by the educator in VR, 2) the XR tutorial execution module, for the delivery of visually guided and personalized XR training experiences, 3) the digital human model (DHM) based simulation module for creation and demonstration of job task simulations avoiding the need of an actual user and 4) the biophysics assessment module for ergonomics analysis given the input received from the other modules. Three-dimensional reconstruction and aligned projection of the objects situated in the real scene facilitated the imposition of inherent physical constraints, thereby allowed to seamlessly blend the virtual with the real world without losing the sense of presence.

Virtual simulations of operating tasks provide knowledge on a variety of parameters, useful for preventive ergonomic analysis, that helps to improve safety, quality and promote human-centered design. This paper presents the development of a biophysics-based simulation tool that is used for the evaluation of virtual interactions in different synthetic 3D scenes. Evaluation is based on the simulation of the motion of a digital human skeletal model interacting with virtual 3D objects, followed by inverse dynamics simulation of multi-body systems. This tool can be used for the estimation of body joints loads and energy expenditure during tasks' operation in different environments, thereby allowing to detect potential risks in repetitive movement patterns and to adjust accordingly the object's arrangement. Comparative results of spatiotemporal energy distribution support the validity of the simulation framework.

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