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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
MECHANISM DEVELOPMENT OF THREE LINK
MANIPULATOR APPLIED AS PROSTHETIC FOOT
This report submitted in accordance with the requirements of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours.
By
MUHAMAD RIZAL BIN NARI
FACULTY OF MANUFACTURING ENGINEERING
2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Mechanism Development of Three Link Manipulator Applied as Prosthetic Foot SESI PENGAJIAN: 2009/2010 Semester 2 Saya MUHAMAD RIZAL BIN NARI mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan Penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap: 03G, LINTANG 3, KG SEPARAP,
MUKIM 4, 83000, BATU PAHAT,
JOHOR DARUL TAKDZIM.
Tarikh:_________________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh:_________________________
** Jika laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai
SULIT atau TERHAD.
DECLARATION
I hereby, declared this report entitled “Mechanism Development of Three Tink
Manipulator Applied as Prosthetic Foot” is the results of my own research except as
cited in the references.
Signature : …………………………………
Author’s Name : …………………………………
Date : …………………………………
APPROVAL
This report submitted to the Faculty of Manufacturing Engineering of Universiti
Teknikal Malaysia Melaka as a partial fulfillment of the requirements for the degree
of Bachelor of Manufacturing Engineering (Robotics and Automation) with
Honours. The member of the supervisory committee is as follow:
……………………………………………….
Project Supervisor
(Official Stamp & Date)
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ABSTRACT
The title of the project is “Mechanism Development of a Compounded Three Link
Manipulator applied as Prosthetic Foot". This aim of the developing this project is to
help the people who are losing limbs from war or having health problems. Architecture
and the accurateness in a machining process are very important in order to enactive the
product are function in a proper ways. In this project, flow chart is used to show the
development from the beginning until the end of the project. The equipment was used to
develop this project is “Solid Work” software. It is used to design the architecture of the
product in detail from the smallest part until the architecture of the structure is complete.
This machine was used to develop this project are lathe machine and drilling machine.
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ABSTRAK
Projek sarjana muda merupakan subjek wajib yang perlu diambil oleh semua pelajar
tahun akhir ijazah Kejuruteraan Pembuatan.di Universiti Teknikal Malaysia Melaka.
Projek ini mendedahkan pelajar dengan pengetahuan dan pengalaman dalam membuat
satu pembangunan projek berkenaan proses pembuatan sebelum melangkah ke alam
pekerjaan. Tajuk projek ini adalah "Pembangunan Pergerakan Gabungan Tiga
Manipulasi Rangkaian yang Diapplikasikan dalam kaki Palsu”. Projek ini dibangunkan
bertujuan untuk membantu golongan yang mengalami cacat anggota kaki berpunca dari
peperangan ataupun penyakit. Rekebentuk dan ketepatan dalam proses pemesinan
dititikberatkan dalam projek ini bagi memastikan produk yang dihasilkan boleh
berfungsi dengan baik. Di dalam projek ini, carta alir digunakan untuk menunjukkan
pembangunan projek dari peringkat awal hingga akhir. Antara peralatan yang digunakan
bagi pembangunan projek ini adalah seperti perisian"solid work". Ianya digunakan untuk
membuat lukisan terperinci rekabentuk produk dari bahagian-bahagian yang kecil
hingga menjadi struktur rekabentuk yang dikehendaki. Antara mesin yang digunakan
untuk pembangunan projek ini adalah mesin larik dan mesin gerudi.
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DEDICATION
Specially dedicated to my beloved mother, family, and friends who provide a loving,
caring, encouraging and supportive atmosphere. These are characteristic that
contribute to the environment that is always needed to achieve the goals ahead.
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ACKNOWLEDGEMENTS
A work of this kind, drawing on our combined experiences over many years in
the manufacturing industry, owes a debt of gratitude to all people we have worked with.
The impossibility of acknowledging everyone in person does not mean that we fail to
value every contribution, suggestion or conversation that has helped us to refine these
ideas.
This project would not have been possible without the help of so many people. I
would like to take this opportunity to thank them for their effort in completing the
PROJEK SARJANA MUDA (PSM). Firstly to my God, Allah s.w.t who never fails me.
My deepest appreciation goes to my supervisor, En. Ahmad Yusairi bin Bani Hashim for
his extra ordinary level of support and patience. I always remember those countless
hours he spent time for this project. His expertise and advice have been a great
motivation for me and have a key role in making this unique and rewarding Degree
Project. And my special thanks go to my family, En.Nari and Pn. Khadijah, my beloved
friend that I cannot mention here because there are too many of them who always
provide moral support and encouragement throughout this project. I’m always able to
count on their support and advice. Without all of them that I had mentioned above, I
would not be able to undergo my PSM successfully.
Last but not least, I would like to thanks those who are not mentioned here but
have directly or indirectly helping and guiding me towards completing my PSM, your
help and time are much appreciated. All the experiences and knowledge that I have
gained from all are very valuable and thankful. Thank you for giving me better
perspective.
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TABLE OF CONTENT
Abstract i
Abstrak ii
Dedication iii
Acknowledgment iv
Table of contents v
List of Tables ix
List of Figures x
List of Abbreviation xi
1. INTRODUCTION 1
1.1 Project background 1
1.2 Objective 2
1.3 Project aims 2
1.4 Scope 3
1.5 Problem statement 4
2. LITERATURE REVIEWS 5
2.1 Introduction 5
2.2 History of Prosthetic foot 6
2.3 Existing Prosthetic foot 9
2.3.1 Niagara Foot 10
2.3.2 Power foot one 11
2.3.3 Low Profile LP Vary – flex 12
2.3.4 Seattle Voyager Foot 13
2.3.5 Tensegrity Foot 14
2.4 Normal Human Foot Analysis 15
2.4.1 Research about normal walking gait 17
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2.4.2 Result 18
3.0 METHODOLOGY 23
3.1 Introduction 23
3.2 Project Flow Planning
3.3 Project Selection 24
3.4 Literature Review 27
3.5 Data Collection 27
3.5.1 Data Collection 28
3.5.2 Internet 28
3.5.3 Journal Artical 29
3.6 Methodology 29
3.6.1 conceptual design 29
3.6.1.1 Solid Work Software 30
3.62 Material Selection 31
3.7 Fabrication and Assembly Pocess 31
3.8 testing and Analyzing 31
4.0 DESIGN AND DEVELOPMENT 34
4.1 Introduction 34
4.2 Mechanical Design 35
4.2.1 Conceptual design 40
4.2.2 Technical drawing 40
4.3 Development process 45
4.3.1 Base structure development 46
4.3.2 Ankle structure 47
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4.3.3 Shaft 46
4.3.4 Assembly process 47
4.4 Machining process 48
5.0 RESULT AND DISCUSSION 49
5.1 Introductions 49
5.2 Result 49
5.3 Discussion 50
5.3.1 Discussion about analysis 50
5.3.2 Design 50
5.3.3 Mechanical structure 51
5.3.4 Machining process 52
6.0 CONCLUSION 54
6.1 conclusions 54
6.2 recommendations 54
6.2.1 Conceptual design 55
6.2.2 Material selection5 5
6.2.3 Development method 55
REFERENCES 55
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APPENDIXES
A Gantt chart
B Technical drawing
C Solid modeling
D Product picture
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LIST OF TABLES
Table 3.1: Gantt Chart PSM 1 32
Table 3.2: Gantt Chart PSM 2 33
Table 4.1: Measurement at normal human foot point 36
Table 4.2: measurement at skeleton foot point 37
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LIST OF FIGURES
Figure 2.1: Niagara Foot 10
Figure 2.2: PowerFoot One 11
Figure 2.3: Low Profile LP Vary-Flex 12
Figure 2.4: Seattle Voyager Foot 13
Figure 2.5: Tensegrity Foot 14
Figure 2.6: Nine Segment of Human Body 16
Figure 2.7: Ankle Torque 18
Figure 2.8: Normal Foot timing 19
Figure 2.9: vertical Force Data 20
Figure 2.10: Force plate record of the ground reaction acting on the foot 21
Figure 2.11: Barograph record at the distribution of pressure at two
phase of the step 21
Figure 2.12: Load distribution on the human foot on step. 22
Figure 3.1: Flow chart project flow planning 25
Figure 4.1: Normal human foot point measurement 35
Figure 4.2: Normal human foot and skeleton structure 38
Figure 4.3: Normal human foot and skeleton foot structure graph 39
Figure 4.4: Prosthetis foot ankle design 41
Figure 4.5: Screw Shaft 42
Figure 4.6: Rubber drawing 43
Figure 4.7: Assembly drawing 44
Figure 4.8: Base structure 45
Figure 4.9: ankle structure 46
Figure 4.10: Base structure 46
Figure 4.11: Final product 47
Figure 5.1: Final product 50
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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
POM - Polyxymenthelenes
ISO - International Standard Organization
LP - low Profile
HC - Heel Contact
HO - Heel Off
TO - Toe Off
CAD - Computer Aided Design
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CHAPTER 1
INTRODUCTION
1.1 Project Background
This project is developing to design the structure of prosthetic foot and the aim of
developing this product is to assist the group of people who have physical disabilities to
gain normal life again. Nowadays, the improvement made to make sure the prosthetic
foot to be properly functional and comfortable to user takes lot of time. As known, the
soldier in the military sector is facing a very high risk in losing their limbs during
combat. The highest risk is losing their foot. The research of the prosthetic foot was
founded since World War 1 until World War 2 (Erin Strait, E 2006).
During that time, the equipment, material and the research of the prosthetic foot cannot
be done as nowadays because the technology have not been achieve yet and because of
that, the United States government made a deal with some military companies to
improve prosthetic body parts rather than weapons. In addition, the government
standardized prosthetic training, instead of the previous apprenticeships, as well as
increasing funding for engineering research in universities.
Nowadays, the risk of losing limbs does not only come from war, but from health
problems where this phenomenon is becoming worse. There are a lot of diseases that
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could cause the convict to lose their limbs and because of that, the need of prosthetic
foot is becoming more important to a society. The research of this prosthetic foot is
focusing in improving the function of the prosthetic limbs to be more efficient and this
project is to design and develop a compounded three-link manipulator applied as
prosthetic foot. It focuses on the mechanism design and the expectation on precise
mechanical on all parts when the mechanism high (M., Renfrow, 2005).
1.2 Objective
This project is carried out with the following objectives.
a) To design the structure for the prosthetic foot that will be assembled at the actual
foot frame.
b) To make mechanism development of a compounded three link manipulator applied
as prosthetic foot.
1.3 Project aims
The aim of this project are designing and developing a compounded three-link
manipulator applied as prosthetic foot with precise mechanical machining on all parts
where the design is expected can function properly.
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1.4 Scopes
The scopes for this project are as below:
a) This project will focus on the mechanism development of a compounded three-link
manipulator with precise mechanical machining.
b) To fabricate and assemble the prosthetic foot with precise mechanical machining.
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1.5 Problem statement
Nowadays, the existing prosthetic foot is expensive and not comfortable with the
average class users. It is because the cost of developing material is so expensive. In
addition, the function of existing prosthetic foot does not function properly and just
refers the basic concept of important point of human foot. Because of that, the users do
not feel comfortable when using them. The suitable design and material must be eminent
and considered when developing the high quality prosthetic foot.
As known, users always choose to posses the best product at the lowest price for their
prosthetic limbs. Originally prosthetic were simply replacement for missing limbs, but
now they can help people who have extremely active lifestyles. Such improvements
have been made possible because of the new surgical techniques, the advancement of
components for making prosthetics, and creative engineering ideas. Many researches
about the material and concept must be considered to get the high quality design. The
cost factor is one of important thing that must be considered to make the new prosthetic
foot suitable with all class because not all of the users who lost their limbs are from rich
background.
Besides that, the shape and the conceptual design of existing products are not suitable
with all users. This is because, certain products have a design that can cause injuries to
user like blister to the skin. Other than that, the materials used are also heavy in their
weights that make the users feel uncomfortable.
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
Literature review is showing the research that related to the project topic. The meaning
of literature review is a critical look of existing research that significant to the work that
we are carrying out. Literature review is important because it show the target of the
project.
This chapter describes about the surveys scholarly articles, books and other sources for
example dissertations, conference proceedings and so on that relevant to a particular
issue that is on how to determine the error. Besides that, this chapter also describe about
area of research or theory. The compilation of the information is to ensure that the
process of referring the sources of information collected are well organized and can be
easily referred.
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2.2 History of prosthetic foot
The history of prosthetics and amputation surgery began at the very dawning of human
medical thought. Its historical twists and turns paralleled the development of medical
science, culture, and civilization itself. Prostheses were developed for function, cosmetic
appearance, and to provide a psychological sense of wholeness. These patients needs
have existed from the dawn of time to the present. The earliest evidence of humankind's
recognition of deformity and concern for rehabilitation is difficult to determine. Many
ancient civilizations had no written records and history was recorded orally in poems,
sagas, and songs. The prosthesis of ancient cultures began as simple crutches or wooden
and leather cups as depicted in some of the earliest recovered pottery. This grew into a
type of modified crutch or peg to free the hands for functioning. An open socket peg leg
had cloth rags to soften the distal tibia and fibula and allow a wide range of motion (Erin
Strait. E, 2006).
These prostheses were very functional and incorporated many basic prosthetic
principles. Prosthetic limbs made of fiber have been found in the wrappings of Egyptian
mummies which were probably the creation of the burial priests rather than a functional
device. In fact, a drawing dating back to 500 BC was found in France showing a man
working in a field with a wooden support under his knee (International Rehabilitation
News, 2000). This information shows that not unlike the countries of today, the ability to
be mobile were a necessity, and not an option. In the three great western civilizations of
Egypt, Greece, and Rome, the first true rehabilitation aids recognized as prostheses were
made. With the birth of these three great civilizations, came the development of the
scientific approach toward medicine and subsequently prosthetic science. The Dark
Ages produced prostheses for battle and hiding deformity (Q. Choi.C, 2007).
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The industrial revolution brought about prosthetic advancement fueled by money
available to amputees following the American Civil War. After WWII, many soldiers
returned with missing limbs and people became more aware of the problems these
soldiers faced while trying to return to a normal lifestyle. With an escalated number of
amputees and increased awareness, this forced the development of functional prosthetics
for the masses. These functional prostheses were still by no means comfortable to wear,
but the user was much more mobile and independent with the use of such a device. From
heavy, immovable limbs to lighter, more functional limbs, prosthetics has come a long
way. Today, modern materials such as plastics, carbon fiber, and strong but lightweight
metals like titanium and aluminum, are water resistant and better able to withstand harsh
environments. These materials are now widely used along with advanced designs, both
of which allow the patient to expend less energy. Fundamental proven prosthetic
principles are never outdated, only the methods to accomplish them are refined. Ideas
are endlessly being recycled from the past. Concepts that may have been impractical at
the time of their inception, become possible with developments in materials and
technology (M.Renfrow, 2005).
Prosthetic devices have existed for centuries. Originally prosthetics were simply
replacements for missing limbs, but now they help people have extremely active lives.
Such improvements have been made possible because of new surgical techniques, the
advancement of components for making prosthetics, and creative engineering ideas
(4/08/2009, http://www.unc.edu).
An artificial big toe found on the foot of an Egyptian mummy could prove to be the
world's earliest functioning prosthetic body part, it was announced today. Volunteers
who have lost their right big toe are now being recruited to see how effective replicas of
the prosthesis are. The fake toe from the Cairo museum in Egypt was found in 2000 in a
tomb near the ancient city of Thebes. Archaeologists speculated the 50- to 60-year-old
woman the prosthesis came from might have lost her toe due to complications from
diabetes (Q. Choi.C, 2007).
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Nowadays, current prosthetics designs do not replicate the exact characteristics of a
normal human foot. A human foot is multi functional device that can be used to perform
a wide range of activities; however, a prosthetics foot is limited to only a few. More
recently, manufactures of prosthetics feet are looking into the characteristics of a
prosthetics that may be adjustable. The amputee may then be able to perform a number
of activities without requiring a different prosthesis (rihs.D, 2007).
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2.3 Existing prosthetic foot
Usually, to develop the new prosthetic foot is take a very long time and effort because
it’s very complex development. Nowadays, many prosthetic feet are existing in the
market at the world. Various type of prosthetic foot with different appearance we can see
in the market. Provided that, no one of the function existing prosthetic foot similar with
the normal human foot function. It just takes a few of important point at the foot system.
Because of that, the functional of current prosthetic foot have much weaknesses that can
be improved to make the new prosthetic foot is more efficient and comfortable. Below is
the example existing prosthetic foot in the market.