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)

i

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.

ii

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.

iii

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.

iv

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.

v

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

vi

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

vii

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

viii

APPENDIXES

A Gantt chart

B Technical drawing

C Solid modeling

D Product picture

ix

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

x

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

xi

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

1

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

2

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.

3

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.

4

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.

5

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.

6

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).

7

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).

8

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).

9

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.