Lumbar joint compression forces have been linked to the development of chronic low back pain, which is specially present in occupational environments. Offline methodologies for lumbosacral joint compression force estimation are not commonly integrated in occupational or medical applications due to the highly time-consuming and complex post-processing procedures. Hence, applications such as real-time adjustment of assistive devices (i.e., back-support exoskeletons) for optimal modulation of compression forces remains unfeasible. Here, we present a real-time electromyography (EMG)-driven musculoskeletal model, capable of estimating accurate lumbosacral joint moments and plausible compression forces. Ten participants performed box-lifting tasks (5 and 15 kg) with and without the Laevo Flex back-support exoskeleton using squat and stoop lifting techniques. Lumbosacral kinematics and EMGs from abdominal and thoracolumbar muscles were used to drive, in real-time, subject-specific EMG-driven models, and estimate lumbosacral joint moments and compression forces. Real-time EMG-model derived moments showed high correlations (R² = 0.76 - 0.83) and estimation errors below 30% with respect to reference inverse dynamic moments. Compared to unassisted lifting conditions, exoskeleton liftings showed mean lumbosacral joint moments and compression forces reductions of 11.9 - 18.7 Nm (6 - 12% of peak moment) and 300 - 450 N (5 - 10%), respectively. Our modelling framework was capable of estimating in real-time, valid lumbosacral joint moments and compression forces in line with in vivo experimental data, as well as detecting the biomechanical effects of a passive back-support exoskeleton. Our presented technology may lead to a new class of bio-protective robots in which personalized assistance profiles are provided based on subject-specific musculoskeletal variables.

Low back joint compression forces have been linked to the development of chronic back pain. Back-support exoskeletons controllers based on low back compression force estimates could potentially reduce the incidence of chronic pain. However, progress has been hampered by the lack of robust and accurate methods for compression force estimation. Electromyography (EMG)-driven musculoskeletal models have been proposed to estimate lumbar compression forces. Nonetheless, they commonly underrepresented trunk musculoskeletal geometries or activation–contraction dynamics, preventing validation across large sets of conditions. Here, we develop and validate a subject-specific large-scale (238 muscle–tendon units) EMG-driven musculoskeletal model for the estimation of lumbosacral moments and compression forces, under eight box-lifting conditions. Ten participants performed symmetric and asymmetric box liftings under 5 and 15 kg weight conditions. EMG-driven model-based estimates of L5/S1 flexion–extension moments displayed high correlation, R² (mean range: 0.88–0.94), and root mean squared errors between 0.21 and 0.38 Nm/kg, with respect to reference inverse dynamics moments. Model-derived muscle forces were utilized to compute lumbosacral compression forces, which reached eight times participants body weight in 15 kg liftings. For conditions involving stooped postures, model-based analyses revealed a predominant decrease in peak lumbar EMG amplitude during the lowering phase of liftings, which did not translate into a decrease in muscle–tendon forces. During eccentric contraction (box-lowering), our model employed the muscle force–velocity relationship to preserve muscle force despite significant EMG reduction. Our modeling methodology can inherently account for EMG-to-force non-linearities across subjects and lifting conditions, a crucial requirement for robust real-time control of back-support exoskeletons.