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BME 4910 Final Report

1. Figure 15 R 4 Programmable Remote Receiver Kill Switch The parental remote control will feature a mushroom button kill switch This mushroom button will be used as a safety precaution in case of any motor or speed controller malfunction Once it is pressed all outputs from the receiver will be stopped and will thus cause the device to stop moving The kill switch is a popular feature on the remote and will be colored red for quick and easy recognition Mechanical System Frame Dimensions 4 Vertical Beams 1 5 x 1 5 x 72 inch 1515 Lite Smooth T Slotted Aluminum Extrusions 12 Horizontal Beams 1 5 x 1 5 x 33 inch 1515 Lite Smooth T Slotted Aluminum Extrusions 1 Horizontal Crossbar 1 5 x 1 5 x 33 inch 1501 Lite Smooth T Slotted Aluminum Extrusions 21 Figure 16 SolidWorks model of frame design 1 10 scale of actual size 80 20 15 series T slotted aluminum extrusions are used for supporting the columns of the frame The four vertical 72 inch 1515 Lite Smooth T Slotted Aluminum Extrusions are bound together with 80 20 anchor fasteners and economy T nuts to the twelve horizontal 33 inch 1515 Lite Smooth T Slotted Aluminum Extrusions LG A Figure 17 1515 Lite Smooth T Slotted Aluminum Extrusions 22 Figure 18 1501 Lite Smooth T Slotted Aluminum Extrusions All of the connection parts needed to hold the frame together and to give the frame the necessary stability will be ordered from 80 20 I
2. 2 Morgan Templeton Mike Fitzpatrick Marek Wartenberg University of Connecticut NSF 2010 Engineering Senior Design Projects to Aid Persons with Disabilities Accessed on October 9 2010 http www bme uconn edu sendes Spring10 Teamb Optimal9e20Design pdf 3 Programming Differential Drive Society of Robots Accessed on October 9 2010 lt http www societyofrobots com programming_differentialdrive shtml gt 4 Radio Remote Controls Miratron Accessed on October 9 2010 lt http www miratron com radio html gt 5 IF Robotics Speed Controllers The Robot MarketPlace Accessed on October 17 2010 lt hittp www robotmarketplace com products IFI V884 html gt 6 Kristie Astoria Farrukh Rahman Nathan Storie University of Connecticut NSF 2010 Engineering Senior Design Projects to Aid Persons with Disabilities Accessed on October 4 2010 lt http www bme uconn edu sendes Spring10 Team4 optimal pdf gt 7 EXOFIT HARNESS White Cap Construction Company Accessed on October 4 2010 http www whitecap com dbi sala 9214 EXOFIT HARNESS 8 JOUBERT Adjustable Bungee Cords 2 Pack Homer TLC Inc Accessed on October 4 2010 http www homedepot com h d1 N 5yc1vZ1xga R 100401412 h d2 ProductDisplay langld 1 amp storeld 10051 amp catalogld 10053 gt 11 Acknowledgements Dr Enderle e Rod Seely amp Miratron Inc e Ryan Zettle amp 80 20 Inc e Victor Mott amp Air Inc
3. Figure 28 Photo of the final Joshua s Jumper device Control System 29 30 Transmitters The transmitters being used for this design were created for us by Miratron Inc Two controllers are being implemented in the prototype one for Joshua to use and the other which will be used by his parents As mentioned in the Optimal Design both sets of controls are very simple to use and contain a number of safety features The T 1 standard Belly Pack Transmitters were used for both controls The control for Joshua was designed as it was pictured in Figure 29 with a simple ON OFF switch and a joystick to control the device The transmitter also contains an LED that lights up blue when the controller is in use Because Josh s controls were mounted to the frame the handles were removed for easier use of the joystick Figure 29 Joshua s control courtesy of Miratron Inc The parental controls contained the same features but with the addition of an emergency stop button which would cut all power to the motors The parental controls also had the ability to override any movement of Joshua s joystick This ensures that there is parental supervision when the device is in motion As a final safety feature the power would be cut to the motor if for some reason either controller was disconnected from their cable or out of range of the receiver The parental controls are pictured below in Figure 30 31 Figure 30 Parental control with emergenc
4. learn receiver address license Free Pre certified POC no license required Standard Batteries Operates from standard D cell alkaline or rechargeable batteries No downtime waiting for specialty battery packs to charge Internal charger option available www miratron com Radio Receiver Datasheet 65 OPERATION Radio Operation Up to 17 factory installed outputs can be any combination of digital bang bang proportional current ratiometric or unamplified Can directly drive a wide range of coils and other DC loads Up to 7 of the available output channels may be configured as inputs with popular voltage ranges suitable for reading sensors or switches Programmable Logic Receiver can be ficld programmed to adjust min max ramping PWM frequency and other User specified parameters Pushbutton Tether Learn Transmitter and receiver are married to permit operation of multiple radios in the same area without cross control ransmitters and receivers can be married in the feld by pushing a button in the receiver or momentarily connecting the optional tether cable Safety Features Receiver automatically detects when transmitter is out of range and returns outputs to a safe condition Normally closed E Stop output also available Monitored receiver electronics disables outputs on fault condition ORDERING INFORMATION Programmable Standard range 16 channel receiver Programmable E
5. a Figure 14 Parental Remote Control Design Receiver The receiver that will be used is the R 4P 1 17 Channel Field Programmable Receiver This receiver will take the radio frequency from the transmitter and convert it into useable data to control the pulse width modulation being sent to the speed controller and motor combination Since this receiver has up to 17 available outputs it will be used at the microcontroller of the entire remote and motor system All of the programmable embedded code will be written to the receiver and the outputs will be configured to control the amount of voltages being passed to the speed controllers and motors This particular receiver is compatible with the tethering capabilities of the transmitter so that it will be able to learn which set of controls is sending a signal An important safety feature is that the receiver can automatically detect when it is out of range from the transmitter and then output a safe condition which can be programmed to automatically shut down the device This is more beneficial with other devices such as go karts and scooters but it is still a unique and important safety feature It is also compact in size and built with a rugged sealed enclosure to protect the components from environmental damage Figure 15 depicts the R 4 Programmable Receiver The datasheet for this device can be found in the Appendix 20 tH m Pon LIN acu m eus e ee anm ee ET aira cum am he
6. age e Figure 2 Amby Baby Bed Accessory Figure 3 Evenflo Johnny Jump Up with Metal Cross Strut Frame For the standing motorized part of the device that will be created there are some previous inventions that have aspects desirable for this project AbleData was used to search through these products where the Rifton Large Dynamic Stander model K170 Figure 4 was found It is a mobile device that fully supports the individual with body supports straps fleece and a seat pad The idea of the platform underneath the individual with a frame with four wheels is a concept that may be used in the production of Joshua s Jumper The Rifton is a stander that can be used with fully dependant individuals and also with ones that have some weight bearing abilities A difference in this product and the one that will be created is that Joshua s legs need freedom to strengthen them rather than restrictive braces This device can also carry a larger amount of weight much greater than Joshua in fact which would allow him to grow into it The price is 2147 00 for the Rifton Figure 4 The Rifton Large Dynamic Stander The Lifestand Compact LSC is a motorized wheelchair that allows the user to sit or stand with power operated changes and can be for children or adults A stiff back frame provides the supine support for the rear wheel drive machine This is a very expensive product at about 22995 00 because of its compactness power
7. and ability to change positions of the user Mobility4kids makes a product called The Go Bot which is another motorized device that is specifically for children and allows them to sit or stand It can be operated by children from 1 year of age or older but under 43 inches tall or 100lbs It can be used both indoors and outdoors on flat surfaces and has front wheel drive A joystick or series of switches are used to operate the Go Bot with an emergency remote for an adult to use to shut off the power This device has many of the features necessary for Joshua s Jumper except that he would be too tall and too restricted unable to jump Additionally it is not necessary for him to be able to sit in the device which will allow for the design to permit jumping motions The Go Bot is priced at about 5315 00 Figure 5 Mobility4kids Go Bot The Universal Exercise Unit UEU is a device that utilizes elastic bands attached through the Therasuit and the Spider cage a suspension like system Josh s parents have told the team that he has used a cage system in physical therapy which is most likely this product The unit facilitates jumping much like Joshua s Jumper will However it is stationary and a relatively large device Additionally it does not appear to provide the upper body support that Josh would need in a unit he would use very frequently The UEU works to improve strength muscle flexibility and active range of motion wh
8. stopped when the lever is pushed down The motor system Is placed in the middle of the wheels and the wheels are placed at each corner of the platform The motor system 16 will provides four wheel drive to further enable the maximum terrain mobility for the device The harness is similar to a kid s swing seat where Joshua will slip his legs through the seat at the bottom of the seat harness The seat of the harness raises much higher than normal swing seats would Instead of cutting off at the hips the harness seat will raise to just below the armpits Joshua is properly secured into the harness seat with over the shoulder strap from the back to the front The straps will be buckled on after Joshua is lowered into the seat Near the small of his back there is a slightly popped out metal ring where the chain and spring suspension system will attached The lower section of the frame is composed of telescoping shafts The lower shafts encompass the upper sectional shafts which allow the lengthening of the frame to prolong the useful period of the device as Joshua continues to grow The telescope nodes will protrude from two sides on the frames along the horizontal axis to ensure the maximum stability as the frame extends to its full height Clamps maybe used around the telescoping shafts to produce more strength to the frame at supporting Joshua s weight A remote control belt is attached to harness it can be detached from the harness to be used
9. Authorization Phone Contact Mame 63 Date Team Student Name Total Expenses Ship to University of Connecticut Lab Admin only Biomedical Engineering FRS U 2247 260 Glenbrook Road Student Initial Budget Storrs CT 06259 2247 Student Current Budget Attn Elyssa Polomski Project Sponsor Project Name ONLY ONE COMPANY PER REQUISITION Catalog Description Umt QTY Unit Price Amount VideoSecu Articulating LCD LED TV Wall Mount Aluminum 1 1998 19 99 Alloy Bracket for VESA 100 Flat Screen Monitor TV 1EC Steelex D2598 3 Inch 150 Pound Swivel Double Lock 3 ao 32190 Rubber Plate Caster Gra LT 80 00 80 00 880 00 som 000 o 80 00 000 000 sow 000 000 Comments Price Quote 0 00 FileName 41 89 Yes ar No Vendor Address Authorization Phone Contact Name 12 3 Other Datasheets etc Transmitter Datasheet 64 OPERATION Radio Operation Models available with outdoor range of 1500 feet or more Frequency hopping spread spectrum FHSS transceiver uses two way communication for maximum reliability and safety Operates on 902 928MHz USA or 2 4 2 4835GHz International unlicensed ISM band No end user license required Controls combinations of toggle switches joysticks potentiameters paddles and LCD are possible to customize transmitter functions
10. Joystick to the maximum and minimum positions This can be done m any order and as many times as dezired 4 While contmumz to hold the Cal button retum the joystick to center neutral position 5 Release the Cal button A fa hmg GREEN indicator confirms a successful calibration 7 A flashme RED indicator denotes an unsuccessful calibration An unsuccessful calibration occurs when either a Insufficient joystick travel was detected m forward and or reverse b The tnm tab 15 too far from center Resetting Calibration to Factory Pre calibration l Power OFF the speed controller 2 Press and hold the Cal button 3 While contimumng to hold the Cal button Power ON the speed controller 4 A flazlung GREEN indicator denotes calibration 1 reset Release the Cal button Brake Coast Configuration The Brake Coast jumper is used to set the speed controller s action during a neutral condition The Brake provides zigmificant resistamce to motor rotation and 1s recommended for motors dnving linkages and arms that can be back dnven by gravity or other external forces The speed controller checks the status of the jumper approximately 60 times per second This allows the user to change from brake to coast during operation A limit switch may be connected to the Jumper connector instead of the gmmper The lmit switch can be tnggered by various means includmg the use of a servo Brake Coast Guidelines Reference Di
11. T Slotted Aluminum Extrusions four 28 inch 1503 Lite Smooth T Slotted Aluminum Extrusions and two 28 inch 1501 Lite Smooth T Slotted Aluminum Extrusions are used the make up the horizontal beams of the frame Anchor fasteners are used as the connections between all the 80 20 15 Lite series beams to one another The anchor fasteners require pre drilled holes in the 15 Lite series beams which were already done by 80 20 prior to shipping The anchor fasteners are tightened using hex wrenches and they provide sufficient stability and strength to the frame so that it may withstand up to hundreds of pounds of weight which is more than enough for what have prepared for this device 35 Figure 36 Finished 80 20 Frame Platforms The frame houses two platforms which will be referred to as the top and bottom platforms The platform dimensions are 31 inches long by 28 inches wide by 0 5 inches thick Notches were pre cut on the corners by 80 20 Inc prior to shipping so the platforms would fit into the slots of the horizontal poles of the frame The bottom platform cannot move along the frame and it has two motor mount plates welded to each of the 31 inch 1501 Lite Smooth T Slotted Aluminum Extrusions at the back two corners of the frame The top platform can be adjusted in height along the vertical axis of the frame which allows the platform to be raised for easier access to the motor components housed between the bottom and top platforms The platfo
12. The amount of voltage input into the controller determines the speed of the motor To operate a differential motor as will be used in this design two speed controllers will be used Each controller will be independent of the other and will be controlled by the embedded code of the receiver As the signal is received from the transmitter it will be distributed between the two controllers depending upon the positioning of the joystick on the remote The signal sent from the controller will determine how fast each motor must turn in order to maintain straight movement as well as how much more power one motor must receive in order to execute a turn This particular controller is specifically designed for robotic applications and therefore matches many of the specifications desired for this project It is able to withstand currents up to 40A and has a low voltage drop and ideal peak surge capacity It operates on voltages between 6V and 15V and is also extremely light weighing in at 4oz per unit Excerpts from the user manual can be found in the Appendix of this report Figure 23 VEX Pro Victor 884 Speed Controller Motor The motor that will be used for the device is the NPC 41250 Depicted in Figure 24 this motor is a 12 V DC motor capable of providing a maximum of 260 in lbs of torque at a rate of 93 RPM This motor also only requires approximately 6 78 A of 26 current to achieve the desired torque required to move this device At thi
13. can be adjusted along the vertical 80 20 15 series beams if necessary This option was determined to be cleaner and simpler than adding a tray table in the front of the device It would be much more difficult to keep out of reach when Josh is jumping and would also be hard to move close enough to his body for him to operate it N Figure 40 Control mount attached to the back of Josh s transmitter o Figure 41 Control mount screwed into the 80 20 frame and attached to the transmitter Wheels Two 12 inch wheels were left over from a previous senior design year and were perfect for our project Couplers were manufactured to securely attach the wheels to the motor shaft These couples were cylindrical in shape with key slits made on the outer and inner surfaces When keys or small rectangular prism metal objects are pushed in these slots between surfaces they promote the connection and allow for the motor and wheel to turn in unison The couplers were threaded to allow for a large screw to be placed through the wheel and into the coupler Figure 44 Coupler with inner and outer key slots 39 40 Figure 45 Motor Coupler Wheel connection In addition to the two large wheels four small swivel wheels were added to the front of the frame The slots in the bottom of the lower horizontal poles provided the connection of small caster wheels to the frame Two wheels were placed on the ends of the front bar while one w
14. covered with non skid carpet padding to provide cushioning under Josh s feet Additionally plastic sheeting may be put on top of this to make cleaning easier for Josh s caretakers It will have to be decided whether the plastic will be too slippery or if the cushioning can function on its own The photo below shows the padding that will be purchased Figure 21 Padding for the platform on which Josh will stand 24 The space in between the two platforms will serve as the place to house the motor components needed to make the device movable from place to place without the need to disassemble the device first The upper platform can be adjusted upwards or downwards along the frame which allows easy access to the motor units in times of trouble Ideally the sides of the motor units space needs to be blocked in with sheets but such remains to be decided once the motor units arrive To test the platform different amounts of weights will be placed at different regions of the platform to ensure that the platform will be able to support Joshua s weight Additionally a more long term test will be done to be sure it can bear stress for long periods of time Testing will be done before and after the platform is put together with the rest of the frame Table Top for Controls It has been decided that the control that Joshua will use while in the device will be removable This tray will also allow Josh to have stimulating objects in front of him
15. design the team projected the project would cost just under 2000 and 2000 was then accepted by the project sponsor Since the optimal design of this project changed after previous reports the parts and their prices have also changed Parts have also changed during the second semester of this project when the team was actually putting it altogether and troubleshooting previous ideas Additionally the group received the news of a donation of the transmitters and receiver from Miratron Inc This saved the team a lot of money and allowed for the change in materials from aluminum poles to the 80 20 Erector Set materials The 80 20 materials were purchased from a distributor Air Inc with a 3096 discount because 80 20 does not sell parts directly Without this generous donation the team would not have been able to use the 80 20 parts and be under budget 51 Table 1 below shows the complete list of parts purchased how many of them were bought at what price shipping or tax costs and the total cost of products bought from that distributor Table 1 Complete Budget Shipping Vendor NPC 41250 Motor 2 16832 33604 EVEX Pro Vietor 894 o o o RR T pT f 23o 568 84 MEN E a Leni BACKPAD BACK amp WAIST D RINGS 140 22 140 22 pT 1422 T 1 Standard Belly Pack Transmitter ee eee 80 00 160 00 Eee R 4P Field Programmable Receiver 1 40 00 40 00 L000 1 000 ine Frame and Platforms ___ _ _ 68
16. e Marek Wartenberg our teaching assistant e Serge amp Pete of the machine shop e Jen amp Kerrie of the BME office Crossroads Physical Therapy he Bouchard Family 99 12 Appendix 12 1 Updated Specifications Physical 80 20 Aluminum 1515 S T Slotted Frame Mechanical Size 31 x 33 x 72 inches L x W x H Max Speed 3mph Weight Total Structure Weight 135 lbs Chassis Weight Capacity 75 lbs Harness Weight Capacity 60 Ibs Turn Angle 360 Degrees Incline Capacity 20 Degrees Power 1 30 HP Environmental otorage Temperature 40 100 Degrees Fahrenheit Operating Temperature 60 90 Degrees Fahrenheit Operating Environment Indoors Hardwood floors Outdoors Pavement Electrical Voltage Range 12 V Current Range 4 56 A Battery Deep Cycle Batter 12V Battery Life 4 8 years Software User Interfaces Parental Remote Control Attached Transmitter Safety Could flip over if used at an improper angle Motor could be damaged from overuse Maintenance Replace D Cell batteries in remote controls Cleaning especially after outdoor use 96 12 2 Purchase Requisitions Date Student Name Ship to Attn Project Name Catalog NPC 41250 IFI V884 Comments Price Quote File Name Yes or No Vendor Address Phone Contact Name January 20 2011 Team 21 Elyssa Polomski Total Expenses 50 00 University of Connecticut Lab Admin only Biomedical Engineerin
17. far in any direction from the middle of the jumper The motor for this system will be positioned in the middle underneath the platform A center driven wheel system will be employed where two larger wheels on the left and right side of the circular platform will be attached to the motor and steering Two smaller swivel wheels will be placed on the front and back to add extra stability and movement A brake system will be created where the device is stationary when the joystick controls are not being employed A joystick for Josh to use will be put on a removable tray This tray will attach to the two front poles and can be removed when Josh strictly wants to stay in one place and jump around The joystick will be able to simply plug into the controller when Josh wants to move around the house Figures 9 11 below are diagrams made in Microsoft Visio that display different views of this design Bungee Chords Attached to Harness Joystick Detachable Joystick Tray Rope hooked from platform to harness to prevent too much lateral Figure 9 Front View of Alternative Design 2 14 Top View of Platform and Frame Metal platform covered with padding wi E FK a m i Figure 11 Top View of Design 2 Alternative Design 3 The frame of this design will be shaped like the structure shown in Figure 12 below 15 Figure 12 Amby baby bouncer frame The construction material for the frame will be carbon fib
18. harnesses were not sufficient because they did not have enough support and padding In order to make the harness fit Josh extra holes were put into the leg straps and waist belt This was accomplished using a grommet kit purchased from Mansfield Supply Four extra belt holes were put in each of the leg straps and two additional holes were put in the waist belt The SafeWaze harness contains shoulder strap padding as well as a strong back support to help hold Joshua in an upright position while maintaining comfort Josh must be able to stay in this harness for long periods of time if he so desires As described in the bungee connection section two bungees will connect to each waist ring on the harness which will be hooked to the frame Additionally the two longer bungees will be fastened from the back d ring to the top of the frame Figure 52 below shows the harness as advertised on 44 allsafetysupplies com where it was purchased The actual harness used in system is shown in Figure 53 Figure 52 SafeWaze SMALL HARNESS W ADJ BACKPAD BACK amp WAIST D RINGS Figure 53 Actual harness 45 Safety Strap A safety strap was made using a leash purchased from Mansfield Supply A small black clip that is used to adjust backpack straps was added onto this to provide for a change in length that can be done manually but will not come undone while Josh is in the system The strap is looped through a U bolt which is screwed through the bott
19. the bungees allow for quick connections from the frame to Josh s harness making it easy for his guardians to place him in the device Images of the purchased bungees are in Figures 47 and 48 Additionally an image with the bungees connected in the system is in Figure 49 Figure 47 Nite Ize amp KnotBone Adjustable Bungee Cord Figure 48 Keeper 24 in Carabiner Style Bungee Cord oun Figure 49 Bungees in the Suspension System Bungee Frame Connection In order to attach the bungee cords from the harness to the frame a connection was needed on the 80 20 poles Using extra bolts provided by Air Inc and eye bolts purchased from Mansfield Supply this connection was made possible The black nut was inserted into the 80 20 slot and then the eye bolt was screwed into the nut These eye hooks provide easy connections of the carabiners on the bungees to the frame Figures 50 and 51 below display the eye hook and nut in addition to the eye hook inserted into the 80 20 beams 42 43 903 Figure 50 Eye hook and nut Figure 51 Eye hook in beam with carabineer attached Harness In order to leave more room in the budget for other materials a cheaper yet high quality harness was purchased The SafeWaze SMALL HARNESS W ADJ BACKPAD BACK amp WAIST D RINGS from Global Stores Group Industrial amp Safety Division was chosen Josh has a very lean yet long build requiring special adjustments to the harness Children s
20. to prevent any extreme lateral or vertical movement the safety strap that runs from the center of the platform to Josh s harness will anchor him to the center of device This is to be engaged when Josh will be using the motorization to move around the house He should not be moving the whole device if this strap is not connected to him Additionally if the device is powered off the control attachment should be pushed and strapped out of the way It is important that Josh cannot come into contact with this to turn the device on while he is jumping freely The presence of the parental control adds a safety feature that does not allow Josh to be moving when a parent is not around The parental control also contains an emergency stop button that when engaged cuts the power to the motors immediately and halts the device 48 Another safety hazard is concerned with the electrical equipment used to control and power the differential motor To prevent any accidental interaction with the electrical and motorized components they are housed within a centralized and enclosed casing with adequate ventilation to prevent overheating of the components and a potential fire hazard There are no bare wires exposed and all components are rated at levels higher than their intended use to ensure that overheating of the components will not occur and the risk of a fire hazard is minimized Chemical hazards are also present due to the batteries being used to power the m
21. 0 00 _____ 471 00 EE 1810000 8571 00 meum Du Automotive p 550CCA 64 95 129 90 5033 18023 PETION T GM VT NR Home Depot Bungee Cords 24in 4 431 amp 724 Ee e e eis ess 1212x21 4inhhWhels 2 00 000 Oo S Mansfeld Supply Small Parts LES a EE ___ O goo 2483 iic NN PT NN MN NN Connectors Wire 20 84 20 84 000 2084 Fell PP O Cable 2 15 00 30 00 20 8720 cae p isoo soo Cable 2 15 00 30 00 820 3720 Mom ngBrcket 1 so o Caster Wheels O Z o 3 730 a ERN MP 9 m 7 37 opereme mei o omm mm Safety Strap 25 00 25 00 80 2500 aneor p oel mal Cabela s 2 9 99 19 98 D o 0 GeLCIS Spray paint from Mansfield Supply Lo g 429 815 00 TOTAL po 1 716 57 52 8 Team Members Contributions to the Project Team Member Elyssa Polomski Elyssa s main responsibilities included the ordering of the parts filling out all purchase requisition forms and the updating of the budget She created the PowerPoint presentations for all of the meetings and also for the final presentation Elyssa was the main contact with the Bouchards making sure they were updated and the project was meeting their needs She arranged meeting times with the family in order to accomplish tasks such as harness fittings and more information on what they wanted As far a
22. 0 fS CASES coe OSZ Srl EE NE 7 oog e 7 ele al OE a Fil eri LEA SS Lb 31 J CHONSL MWuwShNCMW 3WF AB Ae 70 Drawing From Ryan Zettle of 80 20 80 20 i ics Ph ekea o Fax 0 Bis 6009 a Quote from pUTT Zettle of 80 20 NOTES ydp E PESE ue 71 x AutoQuoter Bill of Materials amp Q f 20 Inc of Kits 1 The industrnal Erector Set Req Del Date 11 22 2005 1701 South 400 East Dist PO Columbia City Indiana 48725 8753 Contact 1 F 260 245 8030 F 280 248 BD28 5 www 3020 net Dist Email Distributor Customer Cust Ref Cust Contact Cust Email TAG Part ANM cm Mote all extrusion dimensions start at tme lett end A 1501 L3 1 33 000 IN 2 74 FOS in A Lefts 7040 in A Right 14 850 15 Ah B il5ib L5s 4 T2 000 IN gdd A 1 5 X 1 57 LITE SMOOTH T SLOTTEP EXTRUSION 32 400 1429 60 c l5Lb5 L5 l2 33 000 IN 33 45 FOSO in C Lefts FOND in C Right 4 850 474 20 P Sbl3 T 2 3 000 FT 30 460 174 Black Haircell ABS Textured Side Up 4 5 S00 49 00 PER PRAMINGTt AD JEIM x 45 ALIN FOO om corner A TEOD en corner B4 TOO en cerner C4 B D an corse Tea PER BRAWINGt 7E on side AH 4 500 T amp L on side AB amp 18 0005 TELE on side AB B 31 5003 75313 on side BC B 44 5005 7541 on side BC B 18 0005 7511 on side BC B 314 5005 7511 on side CP 4 e00 FELL on side CD B 14 0005 7511 on side CD B 31 5003 T5ll on side D B 4 5003 TSI on side BA 18 0005 7511 on
23. 081 58 Date TOPE team ses SE Student Name Elyssa Polomski Total Expenses Ship to University of Connecticut Lab Admin only Biomedical Engineering FRS as U 2247 260 Glenbrook Road Student Initial Budget EE Storrs CT 06269 2247 Student Current Budget CT Attn Project Sponsor ay Project Name ONLY ONE COMPANY PER REQUISITION Catalog Description Unit QTY Amount CEN 26 75 Centennial BCI Group 26 Sealed 12V Automotive D 80 00 Comments fT Price Quote File Name Yes or Mo Vendor Accepts Purchase Orders Vendor Batteries in a Flash Address http www batteriesinaflash com Authorization Phone 800 515 2423 Contact Name Date Student Name Ship to Attn Project Name Catalog Comments Price Quote File Name Yes or No Vendor Address Phone Contact Name 99 January 31 2011 Team Elyssa Polomski Total Expenses 003 29 University of Connecticut Lab Admin only Biomedical Engineering FRS U 2247 260 Glenbrook Road Student Initial Budget Storrs CT 06269 2247 Student Current Budget Elyssa Polomski Project Sponsor ONLY ONE COMPANY PER REQUISITION Description Unit QTY Unit Price Amount 90 20 Industrial Erector Set Components Po 8471 00 SS 80 00 80 00 80 00 80 00 80 00 80 00 80 00 80 00 80 00 80 00 E 80 00 80 00 Ask for Victor Mott He has the order and is just waiting on a form of p
24. Joshua s Jumper BME 4910 Final Report Team 21 Elyssa Polomski Michael Ballintyn and Tianyi Xu Client Name Joshua Bouchard Client Contact s Sue and Ron Bouchard soupanony aol com 508 823 6113 Table of Contents Velo NE Ee ea ee ne ere EE 2 inse lm eem 2 LU size xe ro P uror REP Hr x 2 1 2 Purpose or ne FO CCl ocio Sorsc im ines PUn cut am bemde oa Idus 3 1 3 Previous Work Done by OtherS 00 ccccce eee e eee eee ees 4 INN UOoln I T 4 1 3 2 Patent Search Results 7 1 4 Map for the Rest of the Report ssseesusuuessuueuss 7 XN iie eBI io EE 7 2 Optimal DESIGN keserenan E ESE ISEN 16 2 2 T TOlOLVDO sisses cacegsicagadased Saioecddawe r e modu add Medi 28 3 Realistic ConStar a a EO 45 A Salety ISSUES enne E AAEE TEER 47 5 Impact of Engineering Solutions esses 48 6 IEME IONGIE Can E EE MM 49 L 0 0 0 n rr 50 8 Team Members Contributions to the Project ssuus 52 EGRE TT UI TT T ur 53 10 SIRE ITI LL UTE 54 TT 3ACKHnOWledgelmellls estire nen eq S etd gece 54 TZ SADDCNOIX Gs sceteeccieac casecasesisceactuccsedsaesetacnatssacesmimesedseeneteucscce 55 12 1 Updated SpeciliCallOhs oo DER Rene 55 12 2 Purchase RequiSitions ccccccceeeeeeeeeeeseeeeseeeeens 56 12 9 ON e c uiu clt Mn icu ace Cc toes eae 64 Abstract The client has expressed a need for a mo
25. MO6 12SA l2 6 RED Power 10 30VDC as lt Frame Ground 18 6 SEOW 6 A LEFT SERVO SIGNAL or SB torr RIGHT SERVO SIGNAL E n enD gray U lt JOUT ENABLE Not used BLU 1N4002 DO 41 Z100075 Z100208 CUSTOMER WIRING STANDARD R4 24 PIN WIRING DIAGRAM Document Number CMD16 1363 Joshua
26. Name Elyssa Polomski Total Expenses 1 485 12 University of Connecticut Lab Admin only Biomedical Engineering FRS U 2247 260 Glenbrook Road Student Initial Budget Storrs CT 06263 2247 Student Current Budget Elyssa Polomski Project Sponsor ONLY ONE COMPANY PER REQUISITION Description Unit QTY Unit Price Amount IFI VEX Pro 36 Inch PWM Signal Driver Cable 2 s1500 3000 oL 80 00 Shipping 7 20 37 20 Authorization Date Student Name Ship to Attn Project Name Catalog IFIVV SIG36 62 March 4 2011 Team Elyssa Polomski Total Expenses 1 572 01 University of Connecticut Lab Admin only Biomedical Engineering FRS U 2247 260 Glenbrook Road Student Initial Budget Storrs CT 06263 2247 Student Current Budget Elyssa Polomski Project Sponsor ONLY ONE COMPANY PER REQUISITION Description Unit QTY Unit Price Amount IFI VEX Pro 36 Inch PWM Signal Driver Cable 2 1500 3000 80 00 Gs L 800 o poo o EL 8000 bo po fL 000 O T f YOS owo O T LL 800 o bo Po j 000 po po fL 000 8 LLL LLL pL so0 o o LLL 000 bo Po j P 000 LLL LL LLL LL 900 o doo LLL LL LLL 8000 Comments Price Quote FileName J Total Yes or Ma nad ccepts Purchase Orders Check or Credit Card Vendor Address http www rabotmarketplace com products IFIW SIG36 html
27. Use the product configurator to specify functions and labeling Every transmitter ships with custom engraved front panel and user specified controls Transmitter Matching Momentarily connecting transmitter to receiver using tether cable allows transmitter to learn receiver address Matching the trans mitter to the receiver prevents cross communication in applications where multiple radios are in use This feature also allows the transmitter to be replaced without changing the receiver Ba Operates from 3 x D cell batteries Rechargeable types can also be used Internal battery charger available Batteries are easily acces sible ORDERING INFORMATION mu jsambrinngebdypxkmansmiter mE mo Add XL suffix for jumbo belly pack option Add EX suffix for explosion proof version Consult factory MIRATRON 866 417 5008 503 352 0654 Fully Customizable Controls FEATURES Long Range Reliability Up to 1 500 feet range line of sight Monitored radio link keeps equipment under control Customizable Transmitter is available with toggle switches joysticks potentiometers paddles or combinations Choose the ideal combination of controls for your application Rugged Construction Environmentally sealed for harsh off highway applications Ex rated intrinsically safe models available Tether Tether cable allows transmitter to operate without batteries Also allows transmitter to
28. agram l The jumper should always be m talled If vou lose the jumper a standard computer pamper will work 2 The Coast condition Jumper on Inner two Pins sets the output to an open circuit during neutral 3 The Brake conditon Jumper on Outer two pins sets the output to a short across the motor lead durmg neutral 67 IFIROBOTICS 12V Victor 384 25 Sept 06 www JFilrobotics com Users Manual Page 3 Troubleshooting Indication No ORANGE indicator on power up Problem Input power issue or joystick tum tab off center Possible Solutions l Disconnect PWM cable 2 If indicator bhnk ORANGE the PWM value that was being received 15 either between neutral and full forward or between neutral and full reverse Check joystick tom tab to ensure the controller is mot m a partal forward or a partial reverse condinon If no change check that the joystick and receiver channels match If indicator remams off check W or GND connections for voltage and proper polanty hata Indication Flashing ORANGE indicator on power up Problem No PWM signal Possible Solutions l Ensure the transmitter and receiver are powered ON 2 The PWM cable may be improperly connected Check wire color coding at each end Check that the connector 1s not off a pin at the recerver end Check for a good PWM signal by connecting a known good servo to the PWM extension cable If the servo does not mov
29. anchoring strap may become a resistant adjustment strap used for resistance exercises when his legs become more fit The frame is made of aluminum and the platforms of a sturdy plastic that do not contain sharp edges Sustainability The frame of this device is constructed with the least amount of movable components to lessen the possibilities of error thus increasing the sustainability of the device The motor is attached with sturdy aluminum plates welded to the frame to decrease the amount of torque placed on the platform 80 20 Inc assured the team that the frame material was strong enough to withstand the weight applied by Joshua jumping as well as the motor components and battery stored below The motorized portion of the device is battery powered and it will be important for the batteries to remain charged and ready for use An additional deep cell marine battery will be provided for the jumper and can be simply changed according to the directions in the manual 47 The only portion of the design that may be difficult and more expensive to sustain would be the internal components of the motor If the one major component was to malfunction it could be quite costly to replace and re install the part A complete list of all components and their manufacturers will be provided in the unlikely case that a malfunction should occur Manufacturability To make fabrication of this device simpler and safer prefabricated products were purchased
30. and assembled to the specifications outlined above These components such as the motors speed controllers harness and bungee cords are easily accessible and can all be purchased from online vendors However parts such as the platform and frame required custom production to account for Josh s unique body type as well as any growth that he might experience Apart from this custom modification a vast majority of the design would be able to be easily manufactured If desired it would be possible to mass produce this device and make it available on the market 4 Safety Issues oafety is the primary concern when designing this device It is essential that it remains both safe for Josh while he is using the device as well as for those around the device while it is in use An obvious concern for this type of bouncing device is the stability and structure of the frame For this reason the strength and rigidity of 80 20 15 series Aluminum was chosen to construct the frame By creating an adjustable frame the platform can be raised only to the required level preventing any top heavy tilting that may occur Also by adjusting the length of the bungees supporting the harness the range of bouncing can be drastically reduced thus preventing any chance of severe lateral movements that may cause the frame to tip To prevent any injury from an unlikely but possible collision with the frame the steel poles can be encased in lightweight durable foam Also
31. and emotions It is clear though that he thoroughly enjoys being in a standing position and being able to use his legs to jump when he is assisted by his parents Due to his physical limitations Joshua is wheelchair bound and unable to support his own weight or maintain balance when placed into a standing position Because he spends a vast majority of his time in the wheelchair his core and leg muscles which are required to stand and maintain balance are not as developed Aside from affecting his ability to stand and jump without assistance Joshua s condition also affects his fine motor skills and ability to manipulate controls with his hands His therapist and parents have indicated that ideally Joshua would be transferred to a motorized wheelchair in the future This would require a great deal of therapy and practice but could be accomplished over time Figure 1 Photo of Joshua Bouchard November 2010 Courtesy of Sue Bouchard 1 2 Purpose of the Project The purpose of this project is to provide Joshua with a means to have more freedom to do what he loves while keeping him safe and allowing for muscular development and coordination The client has expressed a desire for Joshua to have the ability to remain unassisted in a standing position while providing him with enough support to allow him to jump and bounce on his own The client has also stated that it would be beneficial if the device were motorized to allow for easier transport
32. ayment Also the shipping is an estimate not exact prici Shipping 100 00 571 00 8 Forge Pk Franklin MA 02038 Authorization 800 341 2800 Victor Mott 60 Date February T 2011 Team Student Name Elyssa Polomski Total Expenses 31 460 29 Ship to University of Connecticut Lab Admin only Biomedical Engineering FRS U 2247 260 Glenbrook Road Student Initial Budget Storrs CT 06269 2247 Student Current Budget Attn Elyssa Palomski Project Sponsor Project Name ONLY ONE COMPANY PER REQUISITION Catalog Description Uniti QTY Unit Price Amount Fastener O 2 0135 027 Fastener O 2 0063 013 Fastener O 2 045 090 TemRg o S 2 S 2511 502 TemRg o O 1 S251 251 Conn Butt S 1 224 224 Disem S y 15 J 8251 251 1 80 162 016 1 o 105 1 0105 105 PO 80 00 Comments Price Quote File Name Yes or Na Vendor Accepts Purchase Orders Check or Credit Card Vendor Mansfield Suppl Address Authorization Shipping 0 00 24 83 Phone Contact Name Date Student Name Ship to Attn Project Name Catalog IFIVW SIG36 Comments Price Quote File Name Yes or No Vendor Address Phone Contact
33. be Joshua s parents and it can be attached to the frame via clamps to make sure Joshua will not accidentally brush against it The remote control features a Joystick that controls the motor system at the bottom of the device to reduce the effort required to move the device as needed The remote also has a kill switch which shuts off the motor system completely in case of an emergency This design provides a very simple design which gives the opportunity to further enhance each component of the device The frame is extremely sturdy and light due to carbon fiber material and the telescoping shafts The motor system on the bottom of platform will need some covering as the device is capable of all terrain movement The spring and chain of the suspension line needs to be inspected regularly to avoid rusting or coating need to be covered on the components The harness seat keeps Joshua s back straight while he uses the device and the raised seat aspect will further provide safety to Joshua should something happen 2 1 Optimal Design 2 1 1 Objective The optimal design was created using different ideas from the alternative designs shown in the previous section of this report It contains the best parts that will be brought together to build one functioning device that fits within the limits of the budget and the environment in which the jumper will be operated The main goal is to safely allow Joshua to jump and stand in a secure harness attached to bungee c
34. both around the house and wherever the device is taken Therefore a device that is both remotely controlled and easy to transport will make things easier on the parents and caregivers This machine could make Joshua at ease with the idea of using a motorized wheelchair in the future The device must be strong enough to fully support Joshua and adjust to any growth in height or weight while remaining lightweight and portable In this way both Joshua and his entire family will have more freedom 1 3 Previous Work Done by Others 1 3 1 Products There are several products that facilitate the jumping and standing of babies while keeping them secure One of these is made by Amby and it consists of a frame with a spring and attached harness Figure 2 However products like these do not support weights over 29lbs and are intended for children under one year of age Joshua s length and build are much different from the younger children who use these products Similar to this there are baby bumpers that are fastened in doorways Evenflo has created models such as Johnny Jump Up Figure 3 which is a portable device that clamps onto doorways utilizes springs and has a seat frame that completely surrounds the baby It is complete with a removable washable seat pad and adjustable straps to account for growth Again this product could not be used for Joshua because it has a maximum weight of 24lbs and is intended for babies 4 months old to walking
35. connection Trim the shroud comers slizhthy 1f necessary for insertion into the Victor The PWM extension cable should be mstalled with the black wire towards the fan Standard Radio Controlled PWM connector are fagile Use caution when mserimg and removing the PWM cable so the contacts on both connector are not damaged Mounting Guidelines You will need 2 4 or 6 screws P 1 l The Victor can be mstalled in any orientation 2 The speed controller must have adequate space above the fan for anflow a minimum of 2 inches 3 Do not over tghten the mounting screws through the speed controller A snug connection will hold the speed controller m place without crushing the Case Calibration Instructions The Victor 15 pre calibrated to values compatible with an IFI Control System and re calibrahon is not needed You can re calibrate to achieve full forward reverse from your joystick movement 1f necessary NOTE While in cahbraton mode the Victor will record the max PWM value detected as full forward the mm PWM value as full reverse and neutral will be the PWM value recorded at the release of the Cal button The following steps will guide User Calibration l Power ON the speed controller 2 Press and hold the Cal button After a moment the LED indicator on the Victor will begm alternating between RED and GREEN to mdicate a cal mode 3 While contmume to hold the Cal button move the
36. d be angled towards one another this will reduce the airspace taken up by the frame and cut down on some of the metal used Telescope poles will be utilized to account for the eventual growth of Joshua This will also allow for the breakdown of the frame for transportation and storage The poles will be covered and padded to make sure Josh does not hurt himself The four poles will be set in a rectangle formation into a round base platform This platform will also be made of metal with padding attached on top Suspended from the top corners of the frames with hooks will be two systems of ropes and bungee cords A limited length of bungee cord will be used to ensure Joshua does not extend too far from the center of the device Ropes will be used where the bungee cord is not allowing for the necessary length from the top of the frame to Josh s harness The harness used will be a child s rock climbing harness This will provide the hooks and attachments needed to hold Josh up Additionally it will allow for freedom of his legs to jump and stand Increased back supports or straps may be essential however this will be determined during testing The harness will be detachable so that Joshua s parents or caregivers can put it on in advance while he is sitting to make for easier placement into the device A preventative option that will be utilized is a strap that hooks from the center of the platform to Josh s harness This would inhibit Josh from moving too
37. draw Two motors were purchased to create a differential drive system that could be used to make the device more maneuverable To align the two motors properly one was flipped around so that the 1 2 inch shaft diameters were in alignment Figure 33 shows one of the motors Later sections will describe and show the motor in system with the wheel and mount A LE o et K Du y FEES amp A 2 P S l l Na i PS C a P i E y d AN M Mut IN Figure 33 NPC 41250 Motor p A Fe t opeed Controllers To power the two motors two separate IFI VEX Pro Victor 884 speed controllers were purchased The controller is capable of withstanding a maximum current draw of 33 40 amps while maintaining a low voltage drop and can be powered by a wide voltage range of 6 to 15 V Upon movement of the joysticks the speed controllers input a pulse width modulation PWM signal from the receiver Once this signal is received it is converted to a voltage which powers the motors These particular speed controllers are capable of ramping the speed of the motors by gradually increasing the output voltage as well as having an adjustable maximum speed at which the motors will be powered Both of these features are vital to the safe operation of the device Difficulties were incurred with these devices as the team was later informed of their inconsistency of function Once a working speed controller is received it will function as des
38. e this can indicate either a afaulty recerver b animproperly connected cable c abad PWM extension cable Note The servo requires that 5V be present on the center pin of the PWM cable This connecton is not required for the Victor Indication Flashme RED indicator after calibration Problem Calibration Failed Possible Solutions l Inadequate travel in forward or reverse Repeat the calhbraton procedure and move the joystick further forward and or further reverse The joystick tum tab i5 NOT centered Neutral cannot be extremely far from center Indication No power output from the speed controller although the mdicator LED works Problem Possible mternal damage Possible Solutions If the mdicator on the Victor 1s operatmg properly and there 15 no output the Victor may be internally damaged This condition 15 typically caused by a short circuit on the output or there has been an over current condition to caused a failure Check the following l Ensure the mdicator is changing between ORANGE RED and GREEN with joystick movement 2 LDhsconnect the motor and check the output M to M with a voltmeter The meter should read between Battery voltage with corresponding full If the indicator is working properly and the output are not working properly the speed controller is probably damaged The final test to determine if the Victor is damaged 15 to replace 1t with another Victor Indication No powe
39. e and explore more of the engineering field that they have not yet been exposed to Troubleshooting skills were acquired when the motors did not function with the entire system connected to power It was learned that too much voltage went through the PWM cables so new ones were ordered When only one speed controller functioned the other one was returned as it was not the fault of the team for this malfunction Also especially during the design process of this project the team members have acquired a much better understanding of multiple software packages available to them Among these packages is the SolidWorks CAD program allowing the team to draw and visualize the design through 3 D engineering drawings Proficiency using Microsoft Visio and Dreamweaver programs has also been acquired by the team members Learning these programs and other software packages will have long term 90 benefits for the members allowing them to become proficient in similar software packages and become a well rounded member of their future work organization Presentational skills became very necessary for the success of this project Initially the team needed to present their ideas to convince involved individuals of the importance of this device The team had to demonstrate the need for certain parts and as a whole a specific amount of money to successfully create this device Throughout the year presentations on the progress of the project were created weekly usi
40. er The advantages of carbon fiber are its high tensile strength and low density which will reduce the overall weight of the device considerably compared to metals such as aluminum or steel However carbon fiber is more brittle compared to metals which make it a disadvantage The structure of the frame supports one strap attached at the peak of the frame The Strap is in the form of a metal spring The spring will provide Joshua with more bouncing freedom The spring is attached to a chain covered in rubber to avoid the possibility of anything getting stuck in between in holes of each chain piece The spring and chain combination is completely capable of supporting Joshua when he is both stationary and in motion The angle away from the vertical plane for the back arc of the frame is advantageous because the angled arc provides more spring like stability to support Joshua while using the device The platform of the device cannot be detached from the device because the wheels and motor system is attached to the bottom of the platform The platform is a square shape to match the bottom cross section of the device The square platform allows enough area to have a motor system and four wheels all of equal size to be attached underneath the platform The wheels are rather large to enable even proper support on different terrains such as hardwood floors carpets grass or sand Each wheel is equipped with a manual brake lever that will keep the wheel completely
41. esigns amongst the team and with the client s parents an optimal design was chosen using different components of the three designs This design was thought to be the final design but was then altered again to be composed of 80 20 Erector set aluminum materials versus the original idea of aluminum or steel poles This new material was more expensive but it was easier to put together and did not require extensive welding Additionally 80 20 Inc has ensured that it will be sturdy enough and much more lightweight than the previous design A change in the harness was also made because one equivalent in quality was found at a lower price The Alternative Designs are described below followed by the Optimal Design completed at the end of the first semester containing subunits which detail the different parts of the device and why they were chosen as the most suitable for this project The Prototype section contains all of the parts that were actually used and how they function as a complete system in the final product Alternative Design 1 This design will be composed of three primary components the frame the harness and elastic straps and the motorized platform Each component must be fabricated and adjusted to fit Joshua s unique body type This device must be built especially stable and structurally sound to support Joshua s weight and bouncing motion To account for these factors an aluminum frame will be constructed into a rectangular box Hori
42. g FRS U 2247 260 Glenbrook Road Student Initial Budget Storrs CT 06263 2247 Student Current Budget Project Sponsor ONLY ONE COMPANY PER REQUISITION Description Unit QTY UnitPrice 168 32 336 64 NPC 41250 Motor 199 90 MM IFI VEX Pro Victor 884 EN a NN 38000 BEENDEN 38000 80 00 o P P P 000 80 00 8000 o oo LL 900 80 o o LL 8900 o oL Ll 900 o J P P P 000 j 80 00 8000 Leer eLeenenee Shipping 532 30 Make sure the 15 cable is not added to the IFI Vex Vendor Accepts Purchase Orders The Robot MarketPlace www RobotMarketPlace com Authorization 341 749 6030 Date Student Name Ship to Attn Project Name Catalog 24 1311 S Comments Price Quote File Name Yes or No Vendor Address Phone Contact Name 57 January 20 2011 21 Elyssa Polomski Total Expenses 563 84 l University of Connecticut Lab Admin only Biomedical Engineering FRS y U 2247 260 Glenbrook Road Student Initial Budget LF Storrs CT 06269 2247 Student Current Budget 17 Elyssa Polamski Project Sponsor rd Joshuas Jumper ONLY ONE COMPANY PER REQUISITION SafeWaze SMALL HARNESS WADJBACKPADBACK 1 140 22 140 22 amp WAIST D RINGS po 80 00 Coo S S Soo 80 00 80 00 80 00 80 00 80 00 80 00 80 00 E a 000 80 00 80 00 80 00 a eee ee Shipping 0 00 pU 140 22 Authorization 858 172 1
43. he axel of the powered wheels will extend slightly behind the platform on which the frame will stand To maintain stability the front two wheels will be similar to those used on wheelchairs and will be able to swivel to allow for easier turning of the device and will have manual handbrakes to allow for the device to be parked and remain stationary This motor will be controlled by both a remote control and a joystick that can be used by Josh The device will remain around walking speed to ensure safety and controlled movement around the house It will be a challenge to keep the motorized platform as light and portable as possible but 10 selecting the proper motor will play a key role in succeeding A sketch of the design is shown below in Figure 8 for easier visualization Alternative Design 1 Front View Faur Elastic Straps Suspended from Aluminum Frame Suspension Trauma Safety Harness Protective jumping Barrier Swivel Wheels E e O Platform 5 Motor in rear of device not pictured here Figure 8 Microsoft Visio Drawing of Alternative Design 1 Alternative Design 2 11 For this design it was decided that steel would be used for the frame It is probable that rust resistant galvanized steel would be used in a frame that would resemble swing set poles The setup would have two parallel A frames connected at the top of the peak with another bar If found to be a more favorable system the poles coul
44. heel was placed on each of the left and right bars This configuration allowed for added stability and movement Each small wheel also contains a small brake to provide extra security when the device is to be stationary for a significant amount of time Figure 46 Figure 46 Small caster wheel with brake Support System Bungee Cords The original bungee cords for this experiment were deemed too difficult to use due to the connection ends The Joubert Adjustable cords did not have a way to securely close the ends Additionally the team decided that the adjustable mechanism teeth that clamped onto the cord would ultimately wear the bungee cords making them unsafe Instead Keeper 24 in Carabiner Style Bungee Cords were purchased at Home Depot There were advertised as having super duty strength ideal for large weight applications Although this does not involve a great amount of weight the idea is to make sure the bungees could support Josh without wearing quickly or breaking Four of 41 the 24 in bungees are used in connection with the waist rings on the harness to the four vertical poles After additional research better adjustable bungee cords that contain closeable ends were found and purchased from Cabela s The Nite Ize KnotBone Adjustable Bungee Cord adjust from 10 in to 48 in These bungees are used on the horizontal top back pole and connected to the top back ring on the harness The caribeeners attached on either side of
45. him to strengthen his fine motor skills through the use of the joystick controls The design of the jumper also required a lot of research into materials that could sufficiently support a child s weight during the bouncing motion After researching several materials it was determined that the frame would be built of strong durable steel and a full body suspension harness would be used to support Josh Researching these materials showed how many different types of materials are available for use in numerous applications Although this was the initial plan the team decided steel would be too heavy and its incredible strength was unnecessary The material switched to aluminum poles instead However the team was turned onto aluminum parts from 80 20 erector set This allowed for easier assembly using a simple tool The remote control and motor system has also been an area of great learning and research The design team has not had much prior experience in this area and have therefore been learning and attempting to understand the detailed workings of a differential motor From the radio frequency communication between the transmitter and receiver to the programming required to correctly output the PWM signals the remote communication has been an area of great interest and learning Also converting this electrical energy to mechanical work through the use of speed controllers and DC motors has required the team to step out of their normal comfort zon
46. hons The high current capacity low voltage drop and peak surge capacity make the Victor ideal for dive systems while its braking options and precise control meet the demandmg needs of arms and lift systems This controller safely handles the high continuous cumnent draws and extreme curent surges produced by Competihon robots The mnovative FET TO BATTERY GNU TO BATTERY 12 Fan 12V REDI was pN PWM EXTENSION CABL TO RECEIVER PWM i Brake Coast Jumper Cal Button Innovatian Firs Lx d Bm i uer ic TA veion aaa switchmg architecture and an integral cooling fan ensures cool FET junction temperatures The low voltage drop high switching speed ensures the motor receives maximum power providmg significant improvements im accelerathon direction changes and hftmg torque The LED indiator will be GREEN m ful forward condihon RED m full reverse and ORANGE while m neutral Fan GND BLK TO MOTOR LED Indicator Status Green Full Forward Orange Neutral Brake Red Full Reverse Flashing Orange no PWM LED Indicator g Guidelines l The fan must be wired so it is always ON when the Victor 15 ON a Attach the fan wires and connect to the appropmate voltage 3 The mput and output wires should be LOAWG wire munimum and firmly connected to ensure low voltage and minimal temperature rise i1 Use circle lug designed for your wire size The lug should ha
47. ht Larger amounts of weight will be tested to account for Joshua s increase in body weight as he grows Through the contacts with 80 20 they ensure the group that the 15 series will be strong enough to accommodate up to hundreds of pounds therefore they recommended the 15 Lite series to our group instead The Lite series materials are cheaper and lighter both characteristics are perfect for the construction of the frame for our device The connection parts used for the frame are recommended to the group by 80 20 these parts are subjected to change mostly due to the pricing of the parts and or the necessities of them since the framework would not need to support more than 100 pounds in weight Platform Dimensions 33 x 33 x 0 5 inches Length x Width x Thickness The frame design houses two platforms one is secured at the bottom of the frame and it will not be adjustable and the second platform is secured to the middle horizontal beams This platform will be adjustable to move vertically along the frame The second platform is adjustable via the horizontal beams which are connected to the frame with modifiable connectors The second platform also has a hole near its center where a ring like anchor is inserted to provide the anchoring mechanism for the harness The platforms will be made of aluminum or potentially a different material that is lightweight and still has enough strength to withhold the weights placed upon it The top platform will be
48. ich Joshua s Jumper will also accomplish for Josh Figure 5 below shows the UEU in Advanced Pediatric Physical Therapy center with the user in a seated position E Figure 6 The Universal Exercise Unit 1 3 2 Patent Search Results There are no patent equivalents to what this group is trying to design The closest that could be found were for infants to toddlers and they were not motorized Walkers are similar instruments however they do not provide the ability to jump that Joshua will have with this powered jumper PatentStorm shows that Mattel Inc holds the patent on a free standing jumping design that is somewhat similar to the group s design The Mattel design includes an unattached frame that supports a seat and resilient members and sleeves at the front and back sections of the device to maintain Stability The position of the seat is adjustable with the resilient members that attach to It and the support frame This design is similar to the team s design in that it provides a supporting frame thus making it independent of being mounted on a door frame like other baby jumpers However this design by Mattel is very different from what the team is creating This senior design project differs in the replacement of the seat with a harness which will secure Josh better than a seat and provide his legs with more degrees of motion Josh s Jumper will be much larger in size compared to Mattel s design because Mattel s device is meant for
49. ies on his body ouspension A system that Josh has been introduced to before in a physical therapy session is known as the Universal Exercise Unit UEU as described in the previous work section This unit has what the company calls elastic bands that attach to a harness at the waist area This idea would not work for Joshua because he needs more upper body support However Eurofitness Pediatric Rehabilitation a center that utilizes the UEU expressed to the team that the elastic bands they used were purchased at Home Depot While Home Depot s website does not have any products relating to this under the key word elastic they do have a wide variety of bungee cords Before testing it has been decided that Home Depot s Joubert Adjustable Bungee cords Model 2S9CON Store SKU 766922 will be used for this design Each package comes with two adjustable bungee cords that can range from 6 to 48 inches in length This could be valuable because not only will they be able to grow with Joshua but in preliminary measurements it is difficult to decide exactly how long the bungees will need to be Additionally the cords are water repellent water resistant abrasion resistant and UV 28 resistant The patented adjustable hook will provide for changes to easily be made by Joshua s caretakers Figure 26 Joubert Adjustable Bungee Cords from Home Depot Testing will be done with attaching weights similar to Joshua s to the bungee cords Whi
50. imarily within the client s house and is therefore constrained to indoor usage Although it can be brought outdoors the design is not intended for extended outdoor use and many of the components may deteriorate if left exposed to the elements The outer parts of the device are water proof however they should not be exposed to great amounts of moisture because seeping down to the motor components could possibly occur It would be best to refrain from contact with water Because the motorized portion of the design is battery powered the device will have little impact on the environment It does not emit harmful gases nor does it require extensive electrical power If any components malfunction and need to be replaced it is important to dispose of them properly so as to reduce the impact of this device Health and Safety Because Josh is a young boy and has these developmental issues his health and safety are especially important for this project It was necessary for the team to consider every possible movement Josh could make while in this device in order to make sure it is safe for his use This includes the height and lateral distance his body could reach while jumping and moving about in the device It is important that his head and body cannot be injured by contact with the frame or any other component of the jumper The anchoring strap serves the purpose of grounding any extreme lateral or vertical movements that Joshua might make Also the
51. infants Josh s jumper will also be motorized with a platform that helps to keep Josh from any debris he may step on in the different environmental surfaces his jumper may be placed on Unlike an infant who may not be able to support his her weight Josh can support his body with his legs therefore the team s device will also allow Josh to perhaps exercise his lower limbs as well as provide him with entertainment 1 4 Map for the rest of the report This report will contain the three designs that were originally created the optimal design that was chosen and the final prototype that was made Within the optimal design and prototype sections are subunits which are comprised of explanations of the components of Joshua s Jumper and why these parts were preferred Constraints safety issues and engineering lessons will then be discussed to explain the device s limitations and what knowledge has been gained from the project The complete budget is expressed in tabular form as well as a written description Finally the report includes the contributions of the different team members as well as the acknowledgements of outside assistance Attached at the end are the references purchase requisitions and additional information on some of the parts 2 Project Design The Project design consists of three alternative designs that were thought to suit this project and create a final product that would function to meet the objective After discussing these d
52. ired However several speed controllers were received that did not function in the system initially causing return shipping hassles Figure 34 below shows a wired speed controller attached to the bottom platform Figure 34 IFI VEX Pro Victor 884 Speed Controllers Battery To power the motor components for this device a 12V automotive deep cycle battery was used Due to the deep cycling the battery can provide sufficient power to the system for an extended period of time The battery is rated to last anywhere from four to eight years It was determined that maximum current can be drawn for approximately five to six hours before the battery would be drained We have also provided a replacement battery with the device Figure 35 shows this automotive battery 34 Figure Centennial BCI Group 26 Sealed 12V Automotive Battery 550CCA The circuit diagram provided by Miratron Inc that was used to wire the entire system is attached in the Appendix Mechanical System Frame The frame is constructed from 80 20 erector set 15 Lite series aluminum beams The vertical height of the frame is at 72 inches which is composed of four 72 inch 1502 Lite Smooth T Slotted Aluminum Extrusions The dimensions for the horizontal beams have been reduced to 33 inch Length X 31 inch Width to allow the device to maneuver through the doors in the client s house Four 31 inch 1502 Lite Smooth T Slotted Aluminum Extrusions two 31 inch 1501 Lite Smooth
53. ive to some therapy practices The jumper also allows the individuals to become comfortable with the use of controls giving them practice for a wheelchair in a more enjoyable setting than simply sitting Globally people would become more understanding of those with disabilities With the production of this device along with multiple other devices designed to provide children with disabilities a way to enjoy every day kid activities more people would be exposed to the need for such devices From this design other devices could be invented and modified to increase the quality of life for many disabled people These projects create a greater awareness of the need for such designs and can only help to expose the world to such a great cause More interest and money can be generated and the research and funding can then be focused on advancing the equipment available to those with disabilities 49 6 Life Long Learning Many different lessons can be learned from the design of this device From the initial meeting with the client this project required a great deal of research and learning about cerebral palsy and the numerous effects it can have on an individual Knowing the limitations of the client was very important in beginning to design the device By researching and learning about Josh s physical abilities the team was better able to design the device in a way that will Support Josh in the proper upright standing position while still allowing
54. le the product weight of the cords are 0 37 Ib it is unknown what weight one cord can withstand Therefore extensive testing will need to be executed The bungees will be extended past the point where Joshua would be able to reach to ensure that he will not snap the bungee cords One cord will be tested will all of the weight even though multiple cords are being used This will make sure that if something were to happen Joshua would be supported by less cords than will be present It may also be determined that more cords than the plan for one cord from each corner of the frame will be necessary The testing will also help determine the exact placement of the cords on Josh s harness and whether other configurations besides the planned two by two from the four corners will be more favorable If the hooks for the bungee cords are not able to close and deemed unsafe adjustments will be made with the use of additional carabineer clips If the bungees are found to have too much elasticity during testing climbing rope will be added to ensure Josh is not lifted too high in any direction 2 2 Prototype This section details the final components used in Joshua s Jumper Below is also the SolidWorks visual made to represent the device It does not contain the bottom coverings in order to show components on the lower platform of the device Following this picture is a photo of the completed project Figure 27 SolidWorks visual of Joshua s Jumper
55. n to an emergency kill switch which ensure that Josh can practice controlling the device while under parental supervision The budget for Joshua s Jumper was determined to be 2000 This is a reasonable cost considering there are multiple components to this project and the desire to have the device remotely controlled and motorized has increased the price dramatically While the project may be costly the effect it will have on Joshua s quality of life will be greatly beneficial to both Joshua and his family By including the motorized components into the design it will allow Joshua s family more freedom to move him about the house and other family outings Also by providing Joshua with his own set of controls he will be able to improve his fine motor skills with the goal of one day controlling his own motorized wheelchair Both the controls and the adjustable nature of the device will be incredibly beneficial to the client and well worth the time and effort required to manufacture it 1 Introduction 1 1 Background This project is for the client Joshua Bouchard a nine year old male with Cerebral Palsy His medical condition stemmed from a brain injury at birth and has therefore made him completely dependent on assistance from his parents and caregivers As is the case with many children with Cerebral Palsy Joshua has both mental and physical limitations He is unable to talk and therefore has a more difficult time expressing his thoughts
56. nc as well Frequent contacts are made with 80 20 customer service to ensure the best choice of materials is used to make up the frame for the device The 5 Hole 90 degrees joining plates compatible with the 15 series are used to hold together the frame at the lowest and highest corners Anchor fastener counterbores and assemblies are needed to bind each individual 1515 Lite Smooth Aluminum Extrusion to each other for added stability The fasteners require pre drilled holes on the 1515 Aluminum Extrusions in order for them to be incorporated as part of the frame T Hole YO Joining Plate atM Jy ee Qr bo S 3 3n x 2015 FEHSCS amp Econ ENa E ge For more 10 Senes mourteg hardware optors see able G on page T 15 Sore Recorrrended Mourtng Merdeere mC e 18 2 Ya FBMSCS amp Ecoe TNA A c eun Y t a tis tS a n En 9 See n a Bete Shu Figure 19 5 Hole 90 degree Joining Plate Anchor Fastener Counterbore Service Anchor fastener counterbores are required when using an anchor or butt fastener for a profile connection Acounterbore allows the anchor fastener face to be flush with the profile surface See below for counterbore T slot designations 23 Figure 20 Anchor Fastener preparation by 80 20 pre shipping The frame can be tested by attaching different amounts of weights with the harness to determine whether or not the frame is sufficient enough to support the client s body weig
57. ng Microsoft PowerPoint Each individual needed to know and understand everything related to the project in order to effectively present the current status Ultimately the team must have the ability to present about the completed project which is made easier by the previous presentations This project has also taught the team a great deal about working in a group setting and time management The deadlines for this project come quickly and often and it has been a challenge to remain organized and meet each deadline As the team has become more comfortable with each other and learned each member s strengths and weaknesses the group aspect of the project became much smoother and more beneficial for meeting the required deadlines By assigning tasks for each individual to complete and then scheduling time to compile each member s work into the finished project both time and work can be evenly distributed and thus lighten the workload on each member All of these lessons are extremely beneficial to future success particularly in the working world where teamwork and time management are essential for a successful career This project will present the team with numerous other challenges which must be handled By taking the lessons the team has learned thus far these challenges can be overcome and ultimately the project will be completed successfully 7 Budget The budget originally presented during the proposal was 2690 However after changes in the
58. ns the parts of the optimal design are explained thoroughly including specifications and how the components will function in the whole system Pictures are incorporated to show each of the parts some SolidWorks visuals were also produced for the frame Because changes have been made throughout the semester these depictions are not as detailed as they later will be 2 1 2 Subunits Control System Transmitter The controls that will be used in both the remote control for Josh s parents as well as the platform for Josh will be custom made by Miratron Inc The T 1 Standard Belly Pack Transmitter is a fully customizable control system and will be used to control the movement of the device Two sets of controls will be designed a simple version containing a joystick and power switch and a second version containing joystick controls power switch and emergency kill button to be used by Josh s parents The designs for the controls are pictured below in Figures 13 and 14 Josh s set of controls will be adapted for use in the removable control platform described above Each set of controls are powered by three standard D cell alkaline batteries and LED indicators will be placed on each control to inform the user of low batteries 18 This particular transmitter is unique in that is also contains a tether which can be used to learn the address of the receiver By momentarily attaching this tether to the receiver the transmitter will sync with
59. om platform A small slit was drilled through the top platform for the strap to go through This was made as small as possible to prevent Josh from having anything on the surface that could hurt his feet while jumping The safety strap is to be employed when Josh is moving the device around using the motorization This prevents him from being able to move too far in any direction while moving around the house The strap is shown attached to the bottom of the harness in the Figure 54 below Figure 54 Safety strap attached to harness through top platform 3 Realistic Constraints Economic constraints This project had obvious economic constraints in that the budget was fixed in order to allow for monetary support for all of the other projects The first issue that arose was having enough money for the motorization of the device However the team s budget of 2000 was accepted in order to accomplish this The team was fortunate enough to have parts donated otherwise the budget of 2000 would not have been met with the parts that were purchased Cheaper frame materials would have been purchased and only one deep cell marine battery would have been bought A cheaper harness was found than originally planned on because of lack of funds A better 46 harness could have been bought had there been enough money but the current harness functions perfectly and met the needs of the project Environmental constraints This device is designed for use pr
60. ords which are suspended from the top of the frame The harness will have padding for comfort 17 with long time use and it will be adjustable to account for Joshua s growth over the years It was decided that it would be ideal for him to have the ability to stay in this device while also being able to move from room to room which is why the team decided to make it motorized He enjoys following his family around the house and this device will allow him to do so while putting less stress on the bodies of his parents who must always support him The motorization aspect will also permit the practice of controls for Josh to become accustomed to using a motorized wheelchair inside and outside of his home Josh does not frequently use his upper body so the jumper will encourage his use of a joystick to get from place to place While some would think that a tall and large structure is not convenient for around the house Joshua s parents have ensured the team that they have wide hallways and doorways in their home and would rather him be able to be mobile than to have to remain stationary in one room in the house The 80 20 Erector set materials for the frame provide the ability for simple adjustments to be made because the components can be assembled and dismantled using common tools If the original design was used bulky poles would be welded into the platform making it much more difficult to transport the heavy mechanism In the following sectio
61. otor system and transmitter and receiver The risk of having a battery leak acid is very small but still a concern It is important that the batteries be changed as needed and that they remain in dry conditions at room temperature In this way any potential leakage or over heating can be avoided and any electrocution hazards can be avoided by covering the batteries and keeping them removed from any moisture 5 Impact of Engineering Solutions The design of this assisted jumping device could have some impact on the engineering world in a global economic and societal context If this device was able to become mass produced it could have a great effect upon many disabled individuals particularly those in a situation similar to Joshua If there are individuals that are restricted to remaining in a wheelchair and only intermittently experience the sensation of standing and having the freedom to jump they could benefit from this product This device along with multiple other devices being designed for clients with cerebral palsy are allowing these clients to more fully experience life and enjoy activities that most children take for granted By making this device available to the public children with disabilities will be able to have fun in a safe and controlled manner while also working to improve their leg strength and coordination This device can be used as a home therapy tool to provide those with disabilities a relatively inexpensive alternat
62. ploaded was in the correct file type as requested and follow the networking protocols Dreamweaver was used to maintain the contents of the web pages Nathan kept in contact with 80 20 Inc to make sure the most optimal parts from the erector set were ordered with the help of Ryan Zettle Nathan handled the frame and pre drilling the holes on the motor mounts before the group sought help from Serge for the welding of the motor mounts Nathan helped Elyssa and Mike when needed and took trips to Mansfield Supply when required as well 53 9 Conclusion Independence and freedom are very important in the development of a child Due to his cerebral palsy the client Joshua Bouchard has been limited in his ability to independently stand and jump Because of this in activity in stimulating the muscles of his lower body Joshua has been undergoing physical therapy to help aid in the development of his physical and cognitive abilities However when he is not in therapy there are a limited amount of times when he is able to experience the feeling of being able to stand and jump freely When these moments occur it puts a strain on his parents who need to be there to support him The development this device will give Josh the freedom to remain in and upright standing position for extended periods of time while his parents are alleviated from the physical stress of supporting his weight Current suspension systems on the market are too small and do not pro
63. r output from the speed controller and the indicator does NOT work Problem No mput power or possible internal damage Possible Solutions If the indicator on the Victor is not operatng properly and there is no output the Victor may be mtemally damaged This condition is typically caused by no input power or a reverse polarity on the input Check the following l Disconnect the output wires 2 Ensure the indicator on the Victor will not illuminate at any joystick position 3 Check the mput at the Victor BATTERY to GND with a voltmeter If the mdicator is not working properly and the input is good the speed controller is probably damaged The final test to determine if the Victor i damaged is to replace 1t with another Victor CAUTION Prior to replacme a potentially damaged speed controller ensure that the wire connected to the output are not shorted and the input i not reversed Also verify that neither of the motor output leads are shorted to the chassis of the motor and or the robot 68 69 NPC 41250 Motor CAD Drawing Sg18 4 OVO1ON Sd S s SJHLDROR L S 8 Ollv dvo D0 Act Wdy 86 88 0S LFDdN SOLLOYOU DdN NOLL LOW MO C38 MIA SNOT OG 9MY OL Dort VON RII T Se j aei ouo zeNOOE l o Xa L Bog a ous e RS E ET x m s 88 g88 amp EFL dn Lr DE b Gc BEEN d V 1 t ol DE UV il N NAK ero e n oor rp nm y EHE 9 SX n owe 0
64. rms will support around 150 pounds of weight which is more than enough strength for this application The bottom platform has L joining plates mounted to prevent the battery and other large components from moving around on the platform The platforms are made of hard plastic which allows for easy drilling of holes while maintaining structural integrity Figure 37 below shows the platform with its corner notches taken out The platform in system can be seen in Figure 36 above 36 Figure 37 Top platform by itself Motor Mount The motor mounts are welded parallel to the 31 inch 1501 Lite Smooth T Slotted Aluminum Extrusions one at each on the rear corners of the frame The plates sit on top of the bottom platform so careful welding was necessary Because the 80 20 15 Lite series are made of aluminum the plate material must also be aluminum in order for welding The mount plates dimensions are 0 25 inches thick 10 inches tall and 12 5 inches and 15 inches in length for the two mount plates It was necessary for one to be longer than the other due to the orientations of the motors The shafts of the motors must be concentric and since they are identical yet facing opposite directions the motor plates had to take this into account for adequate support The motors are laid down on their sides to allow for better overall clearance underneath the device when paired with the wheels This is not an ideal configuration for stability however the mo
65. s production of the device Elyssa participated in most aspects of fabrication Her main responsibility was the suspension system for which she researched and purchased the bungees harness and safety strap She did the main alterations for the harness using a grommet kit and also created the safety strap from scratch Elyssa assisted Mike with the electrical system once he put it together working to troubleshoot the device She helped in the fabrication of several parts including the couplers motor mounts and bottom covering Elyssa created the main SolidWorks visual representation including all aspects of the design Team Member Michael Ballintyn Throughout the course of the project Mike s primary responsibilities concerned the motorized portion of the device He was the primary contact with Miratron Inc and The Robot Marketplace and was responsible for researching all of the electronic components prior to purchasing Once the components arrived he completed all of the wiring testing troubleshooting and mounting of the entire system He also fabricated the two custom couplers that connect the wheels to the motor spindle along with the Plexiglas housing to enclose the motorized components He also assisted Elyssa and Nate in assembling the frame and making modifications to the harness Team Member Tianyi Nathan Xu Nathan was responsible for taking care of the team project pages on the BME website He had to make sure everything he u
66. s current the motor also produces approximately 1 30 horsepower which will allow the device to move a reasonably slow rate allowing Josh to be able to adjust to the controls and feeling of movement without causing the device to operate at high speeds Two of these motors will be used to create the differential steering of the device Each motor will be controlled by the signal processed by the receiver and will act independently of each other to cause the device to turn either left or right In addition the transmission will be modified to increase the pushing capacity of the motors Since a significant amount of weight will be placed upon the platform enough torque must be applied to propel the device forward A CAD drawing produced by The Robot Marketplace is attached in the Appendix Figure 24 NPC Geared Motor NPC 41250 Support System Harness A change in harness has been made since the original optimal design was chosen The ExoFit harness will be purchased because in addition to being cheaper than the Ergo blue harness it provides a no tangle design that slips on easily One the harness is adjusted once it will remain that way making it easier for Josh s parents to secure him in each time he uses the jumper It has Lycra edging which prevents rubbing and chafing to make it more comfortable for Josh The polyester webbing is described as soft and lightweight to provide strength without stiffness The harness itself weights abou
67. side D B 34 500 7010 17 EA Cut to Length 1 5 x 1 5 T Slot and Tube 1 950 33 15 7o40 dh EA Anchor Fastener Counterbore for L5 Serie 3 BbDD b EU T5 B EA Cut to Length Panel All Sides lt 444in 10 00 21 00 T5ll gu EA PRILL amp C SIMK FOR E Lb FHSCE 3 4 FROM 3 700 44 40 EPGE FOO A EA Overlay Motch For L1ELL 3 700 29 60 E 43E B EA 2 9k i5 HOLE 40 DEGREE JOINING PLATE 7 100 Ch a0 3355 B EA 0 80 E lb L DOUBLE ECONOMY T NUT x TWO 21 12 1 500 L2 00 FBHSCS 3357 B EA 1 12 E5 Llb Ll TRIPLE ECONOMY T HUT amp THREE 341 14 2 200 144 00 FBHECS 3360 Jb EA 2 60 35 ANCHOR FASTENER ASSEMBLY 3 150 41 50 3412 gu EA O 9b S b X L B FHsCS amp ECON T NUT 0 770 4 48 72 tron Inc Ira ided by Rod Seely of M iagram prov ircuit Di C Im MIRATRON RX4 17 RX4 17 CABLE HARNESS AIN7 OUT9 AIN6 OUT10 AINS OUT 11 AIN4 OUT12 AINS OUT13 AIN2 OUT14 AIN1 OUT15 OUT16 PWR TETHER DTM13 12PB MAIN DTM13 12PA PWR PWR GND OUTO OUT OUT2 OUTS OUT4 OUTS OUT6 OUT7 OUT8 DEUTSCH PLUG P N DTM06 12SA DEUTSCH PLUG P N DTM06 12SB DEUTSCH WEDGE P N WM12S DEUTSCH 20 SOCKET P N 0462 201 20141 C16 1 C16 1 C16 1 RED 18 4 SEOW 6 black t __ ____ N DONGLE TETHER TETHER Dau cr W U U 18 6 SEOW 15 TETHER l DTMO06 12SB sie E PAA a i E MAR m EE c A A up mE Eto oe 2 LL CUI d DTM C16 1 7 PIN 2100899 DT
68. t three pounds which when distributed over Josh s body should not create too much pressure There is padding in the shoulder hip and leg areas to also aid in Josh s comfort Josh s parents expressed a desire for a harness that has increased upper body support to make sure he remains in an upright position After viewing the alternative design plans they said that they think a device similar to the one pictured in design one would be best for Joshua While the harness that was chosen is different it is very similar and can be seen displayed below in Figure 25 The harness is adjustable 2 which the team hopes will be sufficient to conform to Josh s long and lean build It has been determined that a cheaper harness will be purchased and improved upon if the 80 20 frame exceeds the cost of what was anticipated Figure 25 ExoFit Harness from White Cap Construction Supply Testing will occur using the harness on either an individual or a testing apparatus that weighs more than Joshua When the team meets again with Joshua after the purchasing of the harness Joshua will be put into the harness to fit it correctly to him This will allow for the team to decide if any extra supports will be needed At this time it is determined that extra padding might be necessary in the pelvic back and shoulder areas to make the harness more comfortable for Joshua s petite frame This will also permit extensive use of the jumper while preventing surface injur
69. the receiver and prevent any cross communication between the receiver and other radio signals that may be present In this way Josh s controls can be synced with the receiver and prevent any accidental direction change while operating the device The parental controls will be tethered to the receiver at all times By having this direct connection these controls will be able to override any activity from Josh s transmitter In this way Josh can safely practice using his joystick under complete parental supervision In addition another safety feature will require that the parental controls be powered on and within range of the receiver for any activity to occur This will ensure that the parents are present and supervising the movement of the device In the event of a remote malfunction only the transmitter will have to be replaced while the same receiver can continue to be used The datasheet for the transmitters can be found in section 12 the Appendix section f N A N LED Battery Indicator Power Switch C D On Off Dual Axis Joystick Taak Joshua s Jumper Remote Control n Figure 13 Simple Remote Control Design 19 O O O LED Battery Indicator aro eS a uw On Off Emergency Kill Switch Button Dual Axis Joystick Controls O Y Joshua s Jumper Remote Control gt eee _ mm I
70. tor mounts provide the necessary immovability and strength to hold up the frame off the ground The motors have six points of connections via screws so the motor mount plates were pre drilled with this hole formation before the welding process The motor mount plates have the corners cut out to fit into the frame and sit on the bottom platform simultaneously L brackets were used to secure the motor mount plates to the middle beams holding the upper platform which provides the motor mount with three points of 37 connection to the frame to ensure maximum strength of stability Visualizations of these plates after welding and in system are shown in Figures 38 and 39 F Figure 39 Motor mount with motor inside and top platform lowered above Control Mount The control mount is a VideoSecu Articulating LCD TV Wall Mount which was modified to be attached to Joshua s controller The control mount allows for adjustable reach as well as tilting of the head to match Joshua s preference Whenever the device is not being moved electronically the mount can simply be pushed to the side outside of 38 the frame This will prevent Josh from coming into contact with the transmitter or mount The control mount is secured to the front right side of the frame via two 80 20 5 16 18 screws and nuts This is because Josh s mother has noted that when Josh does use his extremities he has better use of his right hand The height of the control mount
71. torized device which will allow for a child with cerebral palsy to be free to remain in a standing position and jump for an extended period of time The client Joshua Bouchard is a ten year old male with cerebral palsy who has difficulty maintaining his balance and standing under his own power The device is an adaptation of a popular baby bouncing apparatus and is motorized to allow for easy transportation of Joshua By allowing him to remain in a standing position for an extended amount of time Joshua will be able to strengthen the muscles in his legs while learning how to maintain his own balance The device was constructed out of lightweight yet stable aluminum allowing for ample support of Joshua without compromising the safety and structure of the device The harness provides support to Josh particularly in the torso and pelvic regions to promote a proper standing position and allow him to strengthen his legs without having to support his entire body weight The motorized portion of the device has two sets of controls One set will be used primarily by Joshua s parents where they will be able to remotely control the device The other set of controls will be available for Joshua to use These controls will ultimately help to adjust Joshua to those of a motorized wheelchair which his parents hope to have him using in the future There are safety features in place such as the ability for the parental controls to override all activity in additio
72. ve a hole designed for a 6 or 28 screw If the center hole is too large 10 or larger Inadequate mechanical contact may result in excessively high resistance and temperature mse ii Check all lug connection after cnmping and soldennz You should not be able to pull the luz off the wire with your hands 6 Once the input and output wires are fumlv nected tie the wires using tie straps within 2 of the Victor This will ensure the wires do not move and loosen the connections WARNING BEFORE APPLYING POWER l Ensure the input connection are not reversed Connecting 17V and GND backward will destroy the unit E Ensure that there is mot a short circuit on the output A short circuit will destroy the unit Ensure there is a circuit breaker either mline with the 12V power input to the speed controller or inline with the motor Use an appropriate circuit breaker for your application to ensure that long term exposure to a stalled motor hich currents will not overheat the Victor 66 IFIROBOTICS 12V Victor 88 25 Sept 06 www JFilrobotics com Users Manual Page 2 PWM Connection You will need 1 PWM extenzion cable or PWM Signal Dnver l Use a PWM Signal Diver to ensure the signal from your recerver is Victor compatible if you are not using an IFI Control System The male PWM cable connector connects to the speed controller The Victor housing is design to provide a firm
73. vide the required support that Josh would require if he were to be suspended Therefore Joshua s Jumper was designed to be a safe secure and fun environment for Josh to be suspended and be able to work the muscles of his lower body Using a modified construction safety harness and a secure bungee system Josh is now able to be suspended from an independent and movable frame The entire device is remotely controlled and can be maneuvered by Josh s parents or by Josh himself By providing Josh with his own set of controls he will be able to learn what it is like to use a joystick in the hopes of preparing him to use a motorized wheelchair in the future The ultimate goal of this project was to provide both Josh and his family a degree of freedom and independence and to improve Josh s overall quality of life By providing him with a device that will allow him to remain standing for long periods of time Josh now has the opportunity to do something that he has not been able to do without support from others The design team has learned many valuable lessons and has gained valuable knowledge and experience from completing this project The team is pleased to present the device to the Bouchard family and hopes that it will be used and enjoyed by Josh for years to come 54 10 References 1 THERASUIT Universal Exercise Unit EuroFitnessRehab com Accessed on December 1 2010 http www eurofitnessrehab com therasuit universal exercise unit
74. while he is standing in the device A removable tray intended for a high chair will be purchased for this purpose It will be affixed to a crossbar using 80 20 components so that it can be easily removed when Josh s family plan to keep the device in one place for a long time It is smooth plastic so it can be effortlessly cleaned yet it will provide the strength to support the controls and any other weight placed on it gt m de 2 a y 7 Figure 22 Plastic Platinum Gray High Chair Tray by Rubbermaid The table will be tested once fastened to make sure the weight of the controls plus the added weight of Josh s limbs and any other objects can be supported safely While it is presumed that the 80 20 components will be able to support the tray table additional attachments will be put on if it does not do so 25 opeed Controller opeed controllers are extremely important in regulating the speed and direction of the motors being used For this design the IFI VEX Pro Victor 884 model will be used This model as shown in Figure 23 below will be controlled by the modified signal coming from the R 4 receiver Speed controllers regulate the motors by varying the amount of voltage that is input to each motor After the transmitted signal is processed by the receiver and output to the speed controller the H bridge circuit of the controller determines which way the current is flowing through and thus which direction the motor should turn
75. xtended range 16 channel receiver RAP Programmable International 16 channel receiver RUMP Programmable Microlink compatible 16 channel receiver PAGE 32 MIRATRON 866 417 5008 503 352 0654 FEATURES Simple to Set Up and Use Pre wired cable harness with Deutsch DTM series connector Factory programmed for your application Ficld adjustable using optional R4P programming tool Wiring diagram included Compact Rugged Enclosure Compact size is ideal for mounting in tight spaces Environmentally sealed for harsh off highway applications P66 rated enclosure and connector Affordable Pully integrated receiver No external modules required Outputs factory installed for your application Pay only for the outputs and features you need License Free Pre certified FCC no license required External Antenna Option Flexible antenna can be installed away from obstructions to improve range APPLICATIONS Cane control Wood chippers and grinders Blower trucks Sawmill machines Conveyors Earth compactors Rock crushers Robotics Remote process control Winch systems Specialty off highway equipment www miratron c BAI n IF VEX Pro Vector 884 Speed Controller Users Manual IF IROBOTICS 12V Victor 884 25 Sept 06 www IFlrobotics com Users Manual Page 1 The Victor speed controller are specifically engmeered for robotic applhea
76. y stop Receiver The receiver used was also donated to the group by Miratron Inc and was compatible with both of the transmitters The R 4 Configurable Receiver was used to properly transmit the signals from the joysticks to the two motors of our differential motor system Using pulse width modulation the signal was split into two and was responsible for the power distribution to each motor The receiver was programmed to accommodate for gradual ramping of the voltage to each motor thus providing a gradual increase in the speed of the motors The receiver was also connected to the relay an added safety feature If the emergency stop button is pushed or if either of the transmitters are turned off or out of range the relay will cut all power to the motors This safety feature ensures that there is parental supervision when the device is in motion Figures 31 and 32 below show photos of the receiver and the relays respectively Figure 31 Miratron Inc R 4P Field Programmable Receiver 32 Figure 32 Relay Electrical Motor System Motors Two NPC 41250 12V DC motors were purchased from Robot MarketPlace Each motor operates at 93 RPM with a 34 1 gear ratio and can output a maximum torque of 260 in Ibs which is far more than the required 26 in Ibs of torque required to move this device This motor is ideal for middleweight robots and will produce the necessary horsepower and torque to power the device with minimal current
77. y to put on and adjust for his body type Seat belt like buckles are used to secure the harness around the person s legs and across the chest making it very easy to put on and remove The other beneficial feature is that there is only one strap connected to the harness This strap would be made of climbing grade tubular webbing and clipped onto the harness The other end of the webbing would be the central point from which four separate elastic straps would meet These straps will be attached to the external aluminum frame and will be spaced so as to evenly distribute the load of Joshua s body The elasticity of these straps will be extremely important in ensuring that Joshua is suspended at the proper height for optimal jumping and leg strengthening These straps will also be adjustable to correct any off center positioning of Joshua while he is in the device It is important that the harness be adjustable comfortable and secure and this harness will provide all three Finally both the frame and the suspended harness will be mounted on top of a motorized platform Ideally the frame and harness components will be able to detach from the motorized portion so that it can remain stationary in certain areas as well as allow for easier portability For this design the square motorized platform will have rear wheel drive with two supporting swivel wheels on the front of the device The motorized portion will attach to the rear of the device and t
78. zontal aluminum bars will also be welded in approximately halfway down the frame to both increase stability and provide a method with which to keep Joshua from bouncing too far in one direction These bars will be padded with durable foam to prevent any injury that may result from bumping into them One cross bar will be placed on a hinge so as to allow for easier access when placing and removing Joshua from the harness Another crossbar will also feature a removable control panel which will contain Joshua s joystick control In this way the device can remain Stationary and allow for movement only via the remote controls The joystick for Joshua can then be attached only when he is ready to begin practicing and training towards the use of a motorized wheelchair The frame will also be comprised of telescoping poles allowing for easy height adjustment as Joshua grows over the next few years The second major component is the harness and elastic straps used to support and suspend Joshua For this design a suspension trauma strap will be used to help keep Joshua in the upright standing position As see in Figure 7 this particular strap is quite similar to that of a full body climbing harness With adjustable support in both the pelvic region as well as shoulder harness connected across the chest this harness will be able to comfortably and safely support Joshua s weight Figure 7 Suspension Trauma Strap It is relatively inexpensive and eas

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