ppt - BlueSky Designs
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DESIGN AND DEVELOPMENT PROCESS
ACCESSIBLE, AFFORDABLE, AND
MODULAR ROBOTICS
Dianne Goodwin, MEBME
President/Rehab Engineer
Nicholas Lee, BSME
Partner/Design Engineer
Minneapolis, MN
RESNA 2014
Indianapolis, IN
Design and Development Process
Need: Problem needs solving
Identify the Need
Involve real people and end users
Design and Development Process
Design Goals and Specifications
Prototype Development (electronics/mechanical)
Design for Manufacturing (DFM)
Best materials and methods of Manufacture
Cost of Production (NRE and Piece parts)
RESNA 2014
Indianapolis, IN
The 3 areas impact each other
DFM
Design
Needs
and
Usability
RESNA 2014
Indianapolis, IN
Needs: end users and teams
End user preferences
Ease of use/Accessibility
Product Cost
Compatibility with equipment
Look and feel
Preferences
Manufacturability
Ease of assembly
Manufac. costs (parts, tooling)
Material options
Safety
RESNA 2014
Indianapolis, IN
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Manufacturing
Product
Design
Needs &
Usability
Figure 2. Interdependence of
Development Considerations
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Need: Independent
access and positioning
People with significant disabilities (no UE)
Independent access
reliant on others
devices, electronics, speech, water, controls
AND to move/position things independently
move it where they need it
when they want it
easily, safely and efficiently
Across environments—bed, w/c, table
RESNA 2014
Indianapolis, IN
Review Existing Technology
Static mounts
Daessy, Rehadapt, CJT
Movable with some extremity use
Mount’n Mover
Daessy SwingAway
Wheelchair-mounted Robotic Arms
Focus on reaching and grasping
Move by alternate means (ie, joystick, switch)
Load capacity is <3.5 pounds
RESNA 2014
Indianapolis, IN
Wheelchair-mounted Robotic Arm
JACO
Holds 1 kg (2.2 pounds )
Reach 70 cm (27.5 in)
Speed: 20 cm/s (8 in/s)
Weight: 5 Kg (6 pounds)
$38-50,000
RESNA 2014
Indianapolis, IN
iArm (formerly Manus)
iArm
Holds 1.5 kg (3.3 lbs)
Reach 90 cm (35.4 in)
Speed: 15 cm/s (6 in/s)
Weight: 9 Kg (20 lbs)
$34,000-??
RESNA 2014
Indianapolis, IN
Product concept:
Modular Power Mount
Power mount
Support and
reposition devices
NOT grasping and
reaching
Accessible controls
Single or Multi-joints
Simple and functional
RESNA 2014
Indianapolis, IN
Design goals:
Accessible, Modular, Affordable and Safe
Support up to 15 lbs, extended 15 inches
Accessible and easy to operate
A wide range of control options
Memory positions (easy to program)
Fine adjustments also accessible
Modular (hybrid/system/build your own)
Single Joint—Tilt or Rotation
Multi-jointed
Height Adjustment module
RESNA 2014
Indianapolis, IN
Sometimes Less is More
Single Joint/Actuator
Tilt (Hybrid)
SMART Joint
Rotation
Lift
Operated by
Single switch
Two switches
Joystick (via ECU)
RESNA 2014
Indianapolis, IN
SMART joint
Sometimes More is More
Multi-joint Systems
Programmable
Up to 12 Sweet Spots
Levels (devices,
environments, people)
Individual joint
adjustments
Many input options
Joystick, switches,
smart devices
RESNA 2014
Indianapolis, IN
Original concept: one arm length
Big new idea: SMART Joint
SMART Joint = Building block
Joint + Extrusion opens up options
Single Joint version to create hybrids
Joint in different orientations
Horizontal, creates Rotation
On its side, creates a Tilt
Joint + Extrusions (of different lengths)
= different arm lengths
RESNA 2014
Indianapolis, IN
Lego-land: so many options…
RESNA 2014
Indianapolis, IN
So many details to decide
Implications: Design, Usability, Manufacturing
Length of arm
How many options?
Joint Housing
Joint Cap
Joint Release
Connections
Inputs
Wiring harnesses
Power and data
RESNA 2014
Indianapolis, IN
Locks w/o power
How it Works
Programming
Feedback
Worm Gear
Control
Input options
Display
Graphics
Dizzy Di and the Wonder Guy
I wonder
how long
the arm
should be?
I wonder
What kind
of people
will use it?
RESNA 2014
Indianapolis, IN
How will it
attach to a
wheelchair?
How fast
should it
move?
How will
people
control it?
How
should it
work?
I wonder
what forces
it needs to
withstand?
What material
should we
use?
Usability considerations
User Interfaces, Input and feedback
End Cap
Input jack(s)
Touch control
Control Pad/Display
Touch, input jacks, wireless
Feedback
Movement
Visual (joints glow)
Auditory
RESNA 2014
Indianapolis, IN
What it Does and How it’s Done
End Cap and Control/Display
RESNA 2014
Indianapolis, IN
Development Methods
Mechanical and Electronics vary
3D CAD and Printing
Simulation Software to demo
Cannot look at things in isolation
Concurrent focus on:
Technical design and feasibility
Accessibility and Usability
Manufacturability
Areas overlap and influence one another
RESNA 2014
Indianapolis, IN
End User and their Team
Needs
End User preferences
Ease of Use
Accessibility
Product Cost
Compatibility with other equipment
Look and feel
Safety
RESNA 2014
Indianapolis, IN
Questions we’re asking
What will they use this for? What controls do they
want to use?
Who might use it?
How would they access it? What kind of user
interface makes sense?
What are they doing now?
How will the UI operate?
How do they want it to
How big can it be?
work?
How much would they pay? How long is the “arm”?
Do they want a Single
Who (person, voc rehab,
joint, or Multiple joints?
insurance) would pay?
RESNA 2014
Indianapolis, IN
Product design considerations
Functionality
Utility
Ease of Use
Durability
Safety
Aesthetics
Size and weight
Compatibility
RESNA 2014
Indianapolis, IN
Tech support
Assembly
Electronics
Loads
Impact
Failure modes
Environments
Manufacturability
Simplify
Product
Limit choices
Interface
Easy to use
Intuitive (relate to familiar products)
Manufacturing
Reduce parts (Unibody and worm carriage)
Easier to assemble
Use one part in multiple ways
RESNA 2014
Indianapolis, IN
One part, Multi-purpose
Extrusion
Plate
Arms
Battery pack
Mounting Plate
Bottom Plate
Hole pattern
Existing MM parts
Extrusion
Compatibility increases flexibility
RESNA 2014
Indianapolis, IN
Manufacturing influences Design
Ex: Joint Housing
Idea: from tour of an Investment Cast facility
Clam shell (2 part) evolved into UniBody
Part reduction 2>1; no screws needed
Fewer seams for water
Minimize part count
Combine parts
Less assembly
Have each part “do more”
RESNA 2014
Indianapolis, IN
Worm’s turn: Investment Casting
Carriage: 6 parts to 1
Multi-functional
No assembly required
Easy assembly of motor/worm
More rigid
Motor attachment
Release feature/gear mesh adjustment
Investment casting
Tooling cost <die cast
0 degree Draft
2nd Ops: Machine for precision
RESNA 2014
Indianapolis, IN
Joint Release Mechanism
RESNA 2014
Indianapolis, IN
Iterative Design Process
RESNA 2014
Indianapolis, IN
Joint Release—Multi-functional
Release for
Safely and easily move the mount
Without power
Release for
Ease of programming
Perhaps for
Training the arm to follow a path
RESNA 2014
Indianapolis, IN
Ideal Design Evolution
Key features—design and evaluate for:
DFM
Manufacturing/design
Usability
Manufacturability
Consider alternatives
Cost implications (tooling/parts)
End result
Design
Needs
and
Usability
Affordable product
That meets their needs
People can do what they want—independently!
RESNA 2014
Indianapolis, IN
Questions?
Thank you!
Your opinions and ideas are Welcome
Keep in touch
[email protected]
[email protected]
http://blueskydesigns.us/projects/powered-mount/
Thank YOU! To NIH/NICHD!!!
Research supported by NIH/NICHHD
SBIR Award Number R44HD072469
RESNA 2014
Indianapolis, IN