Application of Industrial Exoskeletons to Reduce Physical Load on Personnel

Heavy physical labor at production and warehouse facilities remains one of the main causes of occupational musculoskeletal disorders. At the joint venture RUSVIETPETRO, a significant portion of employees work in hazardous working conditions (Class 3.1) due to the severity of labor. An analysis of sick leaves showed that musculoskeletal system diseases take the leading positions, leading to increased fatigue, decreased productivity, and rising compensation costs. During the webinar, Timur Larionov, a specialist from the Production Control Service, analyzes a pilot project on implementing passive industrial exoskeletons as a systemic solution to this problem.

Work Mechanics and Biomechanical Protection

The target audience for the pilot project included warehouse storekeepers and oil and gas production operators who regularly carry heavy tools, such as high-pressure hoses and large wrenches. Using a passive model as an example, the speaker demonstrates how the system compensates for upper body weight and reduces spinal pressure when bending and lifting loads.

A key feature of the applied model is an auxiliary force of up to 50 kilograms when lifting a load to a height of up to 1.6 meters. According to test results confirmed by the Institute of Biomedical Problems (IBMP), the load on arm muscles is reduced by 22 – 46%, and the overall load when working in an exoskeleton drops by 62%. At the same time, the device physically blocks the ability to lift a load incorrectly (with a jerk from a deep bend), forcing the worker to move in a strictly physiological manner.

Overcoming Resistance and Evaluating Efficiency

The introduction of new personal protective equipment and mechanization often faces resistance from personnel. The presentation details the stage of initial rejection: workers complained about discomfort. However, this "discomfort" was caused by the fact that the exoskeleton prevents working in familiar but injury-prone postures. After an adaptation period, employees noted a significant reduction in fatigue by the end of the shift and a decrease in back pain.

Quality assessment was conducted by the workers themselves based on five practical criteria: stability, autonomy, comfort, controllability, and durability. Continuous feedback and the principle of voluntariness became key factors in the successful completion of the pilot.

Economic Feasibility and Impact on Special Assessment of Working Conditions (SAWC)

The direct payback of exoskeletons often raises questions due to long return on investment periods in standard equipment cost calculations. However, the speaker suggests evaluating the economics through the reduction of indirect losses: a decrease in the number of sick leaves and the prevention of costly downtime of qualified personnel.

An additional economic effect is achieved through a potential reduction in the working conditions class based on the results of the Special Assessment of Working Conditions (SAWC). Transferring workplaces from a hazardous class to an acceptable one allows the company to cancel the payment of a 4% additional tariff, which radically changes the payback calculation for the implementation.

What you will learn from this webinar:

• How to correctly calculate the reduction of load on the musculoskeletal system when using a passive exoskeleton?
• Why is initial discomfort when wearing an exoskeleton a sign that it is working correctly?
• By what five criteria do workers evaluate the efficiency and comfort of industrial exoskeletons in practice?
• How to justify the purchase of exoskeletons through reduced sick leave payments and changes in the SAWC class?