There is emerging evidence for the potential of occupational back-support exoskeletons (BSEs) to reduce physical demands, and thereby help control/prevent the risk of overexertion injuries associated with manual material handling. However, it is important to understand whether BSEs also introduce any unintended safety challenges. One potential risk associated with BSE use is increased risk of falls, since their extra weight, rigid structure, and external hip extension torque may increase demands on the postural control system. However, there is currently limited evidence on whether, and to what extent, BSE use alters postural stability and/or fall risk. The primary goal of this work was to understand the effects of exoskeleton use, and quantify the effects of exoskeleton design parameters, on balance and postural stability, with a focus on passive BSEs used for repetitive lifting work. A comprehensive evaluation of BSE use was performed under controlled laboratory conditions, focusing on three classes of human activity that form the basis of maintaining postural balance in diverse real-life scenarios: maintenance of a specified posture, voluntary movement, and reaction to an external perturbation. The first study demonstrated that during quiet bipedal stance, BSE use increased median frequency and velocity of the center of pressure in the anterior-posterior direction. In the second study on level walking, BSE use caused an increase in gait step width and gait variability, and decrease in the margin of stability. BSE use with high supportive torque led to adapted gait patterns in early-stance phase. Hip range of motion and peak hip flexion velocity also decreased, and participants exhibited different strategies to increase mechanical energy for propelling the leg in late-stance phase: these effects increased with increasing torque applied by the exoskeleton. In the final study, BSE use did not alter the maximal lean angle from which individuals could successfully execute single step balance recovery, following a forward loss of balance. However, several recovery responses were negatively affected by BSE use, including increased reaction time, impeded hip flexion, and reduced margin of stability in the high-torque condition. This is the first systematical investigation to quantify the effects of passive BSEs with multiple supportive torque levels on balance and postural stability. While exoskeleton effects on static balance were minimal, more substantial changes in gait spatiotemporal parameters, hip joint kinematics, and dynamic margins of stability were observed in the later studies. Our results indicate that postural stability deteriorated with exoskeleton use in dynamic conditions, and provide mechanistic insight into how stability is altered by different exoskeleton design factors such as added mass, restricted range of motion, and external hip extension torque. While our results are suggestive of increased fall risk, especially in the high-torque condition, fall risk in real life is moderated by a complex combination of individual and environmental conditions. Future work should consider more complex, realistic tasks and also include a more diverse sample that is studied under longer exposure durations, to further elucidate these findings. Our characterizations of a wide variety of postural responses as a function of exoskeleton torque settings are expected to contribute to improving both design and practice guidelines to facilitate the safe adoption of BSEs in the workplace. / Doctor of Philosophy / Occupational back-support exoskeletons (BSEs) – wearable mechanical systems designed to support, augment, and/or assist back extension – are expected to serve as an alternative workplace intervention to control and prevent overexertion injuries related to manual material handling tasks. While recent studies have shown the beneficial effects of BSE use in terms of physical load reduction on the low back, some concerns have also been raised on unexpected or unintended effects of exoskeletons. One potential risk associated with exoskeleton use is increased risk of falls, since a BSE's extra weight, rigid structure, and external hip extension torque are expected to place increased demands on the postural control system. Increase in fall risk is a critical safety concern, as occupational falls are a serious problem in terms of injuries, medical/industrial cost, and lost work time. However, there exists limited evidence on whether the use of a BSE alters postural stability and/or increases fall risk. Hence, the goal of our study was to quantify the effects of BSE use on postural stability in various conditions related to real-life scenarios, such as standing balance, walking stability and how one would respond to a loss of balance following an external perturbation. Our results showed that during quiet standing, BSE use slightly increased postural sway. In level walking tasks, BSE use had adverse effects on step length, step width, and dynamic stability. Furthermore, wearing a BSE with high supportive torque led to adapted gait patterns in early-stance phase, whereas participants showed different strategies to increase mechanical energy for propelling the leg in late-stance phase. In the final study investigating single step balance recovery following a forward loss of balance, we found that BSE use negatively affects balance recovery, mainly by impeding hip flexion. Thus, our work suggests that exoskeleton use can deteriorate balance and/or postural stability in situations of static standing, voluntary walking, and reacting to an external perturbation, thereby potentially leading to an increase in fall risk. These effects may be more pronounced among specific population sub-groups such as older workers, and may also affect individuals more severely under conditions of stress or fatigue. Hence, future studies must include more rigorous testing of BSE use using a variety of challenging and realistic scenarios, and also include more diverse population samples. The findings from this work are expected to contribute to improving design and practice guidelines to facilitate the safe adoption of BSEs in the workplace.

Work-related musculoskeletal disorders (WMSDs) due to overexertion and consequently the low back pain (LBP) are one of the most prevalent sources of nonfatal occupational injuries and illnesses in all over the world. In the past several years, the industrial exoskeletons especially the passive ones have been proposed as alternative intervention and assistive devices, which are capable of reducing the risk of WMSDs and LBP. However, more research is warranted to validate the applicability of these exoskeletons. In addition, because the majority of previous studies have been limited to specific lifting tasks using only one type of lift assistive exoskeleton, more research is needed to examine the effect of alteration of different lift-assistive exoskeletons on reducing the activity of back muscles and metabolic reduction. The main objective of this dissertation is to render an overview of three studies that attempt to improve the literature by providing comprehensive biomechanical evaluations and metabolic assessments of three passive lift-assistive exoskeletons (VT-Lowe's Exoskeleton (developed in ARLab at VT), Laevo and SuitX). This dissertation has been composed of three related studies. The first study aimed to investigate and examine the capability of a novel lift assistive exoskeleton, VT-Lowe's exoskeleton, in reducing the peak and mean activity of back and leg muscles. Findings revealed that the exoskeleton significantly decreased the peak and mean activity of back muscles (IL(iliocostalis lumborum) and LT(longissimus thoracis)) by 31.5% and 29.3% respectively for symmetric lifts, and by 28.2% and 29.5% respectively for asymmetric lifts. Furthermore, the peak and mean EMG of leg muscles were significantly reduced by 19.1% and 14.1% during symmetric lifts, and 17.4% and 14.6% during asymmetric lifts. Interestingly, the VT-Lowe's exoskeleton showed higher reduction in activity of back and leg muscles compared to other passive lift-assistive exoskeletons available in the literatures. In the second study, the metabolic cost reduction associated with the use of VT-Lowe's exoskeleton during freestyle lifting was theoretically modelled, validated and corresponding metabolic savings were reported. The metabolic cost and the oxygen consumption results supported the hypothesis that the VT-Lowe's exoskeleton could significantly reduce the metabolic demands (~7.9% on average) and oxygen uptake (~8.7% on average) during freestyle lifting. Additionally, we presented a prediction model for the metabolic cost of exoskeleton during repetitive freestyle lifting tasks. The prediction models were very accurate as the absolute prediction errors were small for both 0% (< 1.4%) and 20% (< 0.7%) of body weight. In the third study, the biomechanical evaluation, energy expenditure and subjective assessments of two passive back-support exoskeletons (Laevo and SuitX) were examined in the context of repetitive lifting tasks. The experimental lifting tasks in this study were simulated in a laboratory environment for two different levels of lifting symmetry (symmetric vs. asymmetric) and lifting posture (standing vs. kneeling). Results of this study demonstrated that using both exoskeletons during dynamic lifting tasks could significantly lower the peak activity of trunk extensor muscles by ~10-28%. In addition, using both exoskeletons could save the energy expenditure by ~4-13% in all conditions tested by partially offsetting the weight of the torso. Such reductions were, though, task-dependent and differed between the two tested exoskeletons. Overall, the results of all three studies in this dissertation showed the capability of passive lift-assistive exoskeletons in reducing the activity of back and leg muscles and providing metabolic savings during repetitive lifting tasks. / Doctor of Philosophy / Low back pain (LBP) due to overexertion is known as one of the most important sources of nonfatal occupational injuries especially for the workers or manual material handlers who are involved in frequent or repetitive lifting tasks. Every year, many workers are temporarily or permanently disabled due to overuse injuries at workplace. In the past several years, industrial exoskeletons have gained growing interest among biomechanist, roboticist, and other human factor researchers as potential assistive devices to reduce the risk of LBP. In general, the industrial exoskeletons are either “passive or “active”; Active exoskeletons are powered by mechanical/electrical motors and actuators, however, the passive exoskeletons often work using cheaper devices such as gas or metal springs, elastic elements, etc. The exoskeletons discussed in this dissertation are categorized as passive rigid lower-back exoskeletons and they function by storing energy in a spring when the wearer bends and returning the stored energy when the wearer lifts. This dissertation consists of three studies that attempt to provide comprehensive biomechanical evaluations and metabolic assessments of three passive lift-assistive exoskeletons (i.e., VT-Lowe’s Exoskeleton, Laevo and SuitX). The first study examined the efficacy of a novel lift-assistive exoskeleton, VT-Lowe’s exoskeleton, in reducing the peak and mean activity of back and leg muscles. The results of this study demonstrated that the exoskeleton reduced the peak and mean activity of back and leg muscles for symmetric and asymmetric lifting tasks. VT-Lowe’s exoskeleton also showed higher reduction in activity of back muscles compared to other passive lift-assistive exoskeletons available in the literature. In the second study, the metabolic cost reduction with VT-Lowe’s exoskeleton was theoretically modeled and the modeling outcomes were compared to metabolic costs measurements when the exoskeleton was worn. The experimental findings of this study supported the applicability of the exoskeleton by significantly reducing the metabolic cost and oxygen uptake during the freestyle repetitive lifting tasks. Moreover, the prediction metabolic cost model of the exoskeleton showed high accuracy as the absolute prediction errors were within 1.5%. In the third study, the biomechanical evaluation, energy expenditure and subjective assessments of two passive back-support exoskeletons (Laevo and SuitX) were examined in repetitive lifting tasks. The lifting tasks of this study were simulated in a laboratory environment for two different levels of lifting symmetry (symmetric vs. asymmetric) and lifting posture (standing vs. kneeling). Findings of this study showed that both exoskeleton significantly lowered the peak activity of back muscles during the dynamic lifting tasks. Moreover, using both exoskeletons provided metabolic cost savings in all of the studies conditions. Overall, results obtained from the three studies in this dissertation verified the capability of these passive lift- vi assistive exoskeleton in reducing the activity of back and leg muscles and providing the metabolic savings during repetitive lifting tasks.