Vibratory Conveyor - Vibrations Class Project, USF 2004
While in Vibrations class my classmates and I were tasked with designing and fabricating a vibratory conveyor. The device had to move a quarter 1 inch vertical over a distance of 12 inches. To add to the difficulty, it had to do so in 15 seconds. This device below is what I came up with.
Backpack Relocator - Senior Capstone Project U.S. Patent 20,080,069,678, USF 2006
During the final semester of my bachelors I worked in a group to create a capstone project. Myself and four of my classmates were asked to design a device that would mount onto a power wheel chair to allow easy access to a person's belongings while minimizing the amount side space needed to do so. We patented this device and sold the rights to Rehab Ideas, a start up company created by Stephen Sundarrao, the Associate Director of the Rehabilitation Engineering and Technology Program at USF. This was a great project because it forced us to work as a team and it taught how the patent process works. The video and photos below illustrate the product that we designed and fabricated. The first video is of the actual device that went to market, created by Rehab Ideas.
Robotic Gripper - Research Experience For Undergrads, USF 2006
During the summer between my bachelors and masters degree I enrolled in a program called an REU (Research Experience for Undergrads), where I assisted a fellow Phd student with his thesis. Together we designed and fabricated an electro-mechanical gripper. The gripper was to be attached to a wheelchair mounted robotic arm to assist handicapped individuals with everyday tasks.
Prosthetic Kayak Hand - Coop w/ Physical Therapy & Rehabilitation Sciences, USF 2007
In addition to my masters research with compliant pediatric knees, I worked with the Rehab Department to redesign a prosthetic hand specifically used for kayaking. The original Revision 1.0 design, shown below, suited the main requirement of holding the kayak paddle but needed improvement.
Issues to address with the 1.0 design:
Issues to address with the 1.0 design:
- It was made of steel and unnecessarily heavy.
- The straps used to secure the device onto the paddle made it difficult to remove from kayak paddle in the event of emergency.
- The fixed attachment bolt prevented articulation needed for proper paddling motion.
Rehab Department's Revision 1.0
Kayak Hand
In attempts to improve the function and safety of the original 1.0 Revision, I designed 2 carbon fiber/kevlar prototypes, Revision 2.0 and 3.0. These models were both function tested on water as well as pull tested for tensile load capacity.
In attempts to improve the function and safety of the original 1.0 Revision, I designed 2 carbon fiber/kevlar prototypes, Revision 2.0 and 3.0. These models were both function tested on water as well as pull tested for tensile load capacity.
Revision 2.0 - Ball-Joint Attachment Kayak Hand
To make Revision 2.0, epoxy soaked kevlar was first wrapped onto a piece of pipe, layers of carbon fiber were placed over the kevlar, then they were cured in a vacuum bag. A spherical joint was then attached to the clamshell body with an additional layer of carbon fiber and epoxy. The inner kevlar layer acted as a wear surface as well as a hinge. Once cured, an axial cut was made on either side of the cured part to remove the pipe inside. One side was fully cut to the depth of the pipe, the opposite was partially cut leaving the inner kevlar layer intact. The remaining layer of kevlar was flexible and acted as hinge. This allowed the two halves to open like a clam shell so that the paddle could be inserted. A kevlar strap with a snap closure was used to keep the two halves secured on the paddle and allowed for easy opening in the event of an emergency. The pictures below illustrate the manufacturing process described above.
It was originally thought that the spherical joint would be beneficial because it provides freedom of rotation in all directions. Unfortunately during testing we realized that it's lack of vertical support was not a benefit and forced the user's non-prosthetic wrist to work harder than necessary to stabilize and support the paddle during use. A Revision 3.0 was needed...
Revision 3.0, shown below, utilized a hinged bolt rather than a ball joint. The new design allowed for the required range of motion while paddling and provided the vertical support lacking from the 2.0 design. On-water testing with the new 3.0 design was a huge success.
Evolution of the Design - Revision 3.0 Next To The Original 1.0 Revision
To validate the strength and safety of the new prototypes both designs were load tested to destruction. Load testing proved to be very helpful in pinpointing the weakness of the two designs. The picture below illustrates how the testing was conducted.
Revision 3.0 - Pull Test Setup
Pull Test Results - Load vs. Displacement
The new kayak hand design successfully accomplished the goals of the project. The carbon fiber/kevlar design was a fraction of the weight, easy to open, durable and provided the range of motion that was lacking in the 1.0 Revision. My greatest achievement was realized when the 3.0 Revision was provided at the O&P Extremity Games later that year. I couldn't have been happier.