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Material: Riccardo Karim Khamaisi
Material: Riccardo Karim Khamaisi
Material
I. Frame
The existing solutions which the market offers are pursuing the idea of an increasing reduction of
the weight-strength ratio, adopting a precise policy in the choice of frames materials, such as
titanium, carbon fibre, alloys like chrome-moly or advanced materials which cause the companies
to raise in price. Appearance, durability, manufacturing processes and cost are influenced too,
transforming the frame definition in an intricated topic. On the top of all this, the mechanical
performance represents the fundamental parameter with which coming to a definitive decision.
The first step was to consider the strength (and so the safety) of the framework as well as the
durability: the fatigue strength of the material is affected not only by the tubing dimensions and
shape but by the other assembly-related aspects (as welding characteristics and manufacturing in
general). Initially, different ideas were considered:
a) Carbon fibre;
b) Titanium;
c) Aluminium;
In order to match the key points of the Product Design Specification, the first two solutions were
discarded after an accurate selection based on:
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Cost: Carbon fibre and Titanium are two of the most expensive products available in the
market and involve a great manufacturing expenditure;
Vibration transmissibility (VT) and the weight-normalized work-per-meter (WN-WPM):
many studies have been done with the aim of trying to understand the connections between
these properties (Chnier and Aissaoui, 2017). The risk of shoulder injuries as well as the
whole-body vibration could be reduced improving these features: since no evident
difference was found apart from the value related to the Carbon fiber, the Aluminum was
believed to be the most efficient and profitable in term of cost-VT or cost-WN-WPM ratio
(see the Appendix for more details).
Weight: one of the most important breakthroughs for the wheelchairs technology is the
introduction of lightweight material which could maintain at the same time good physical
properties. Aluminum represents an excellent compromise in terms of strength-weight ratio,
being the best choice for such applications; moreover, the weight strongly influences the
mechanical work to be done to travel to given distance (WN-WPM) too, increasing the
efforts of the person if the overall design turns out to be heavy. In order to minimize the
weight of the frame, round hollow bars will be used.
At the end, the Aluminium 6061 T6 (solution heat-treated and then artificially aged) was
selected as final solution (Comparative Matrix in the Appendix). This alloy is commonly
known for its corrosion resistance and weldability, being used in high pressure applications:
both features were thought to be fundamental during the lifecycle of the product, seeing that the
framework should be easily manufactured and designed to give the customer the possibility to
use the wheelchair outside too (considering every weather conditions).
Considering the average weight of manual wheelchairs attested on the market, 22 kg (Karman
Healthcare, 2017) and the supplementary devices necessary for the general functionality of the
product (such as the battery, the engine and in general all the components of the bar
mechanism), the targeted weight for the only frame (including the extendable handles) is set up
to 5 kg. As for the expected cost, instead, tubes 2.4 meters long will be purchased for 44 from
external suppliers (Metals, 2017) and then finished.
III. Cushions/Seating
The seating is essential to gain the customers satisfaction and to the cost; in fact, wheelchair
users most of the time suffer of pressure sores connected to some uncomfortable positions.
Moreover, it should fit the person need even if a change with clothing, age or physique occurs
and be durable to withstand daily use with different climate and weather conditions. Other two
aspects were considered, such as the possibility to be laundered easily whenever it is needed
(hygienic and aesthetic reasons are also important) and the air circulation required to guarantee
the comfort. Specific needs of precise groups are to be considered: the material provided should
not ignite too easily (fire retardance is important too) to face everyday situations and especially
for smokers. On these basis, Polyurethane viscoelastic foam was chosen as final answer thanks
to its durability, optimal contouring, pressure relief (medical instances like reduction of
subcutaneous stress inferior to the ischial tuberosity were taken into consideration) and
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resistance to mildews, mites and bacteria. A simple plastic frame will be furnished as support
for the overall section too.
In terms of price and weight, the raw material will be supplied in large foam sheet for 23
(Foamorder.com, 2017) and then cut: regarding the structure of the seating, it was decided to go
on with the A.B.S. (Acrylonitrile Butadiene-Styrene), a thermoplastic material known for its
strength, resistance to abrasion and heat, and low absorption of moisture and odours: it is
currently sold for 2/kg (Alibaba.com, 2017). The total section weights around 2 kg.
IV. The bar mechanism
The ascent or descent of the Trailblazer Wheelchair is ensured
by this mechanism (Figure 4) which is continuously under
stresses during its service: the main requirement for this part is to
stand the forces aging on the three bars in the mutual rotation.
Combining the FEA analysis (images and values are given in the
Appendix) and the forces study in the previous chapters, it was
seen that the three elements can perfectly sustain the loads
without any particular consequence: the ultimate tensile strength
for the elected material, or the Stainless Steel, is 860 MPa against
5.2341x e8 Pa outlined by the test. The principles followed were
based on the necessity of setting a safety factor to avoid
malfunctioning: to strengthen the steel, first the bars will be
quenched and then tempered. On the market, quenched and
tempered square steel bars are sold for 330/ton (Alibaba.com,
2017): a subsequent metal working will provide the final shape
(the weight is about 2 kg). As for the case of the motor, Figure 4
Aluminium 6061 sheets will be used to ensure a correct covering
for the potential risky part (Cost: 20, weight: 1.2 kg)
Conclusion
In conclusion, the selection was marked by several evaluations aimed to reach the key points of the
material section of the Product design specification (for the complete list of the requirements see in
the Appendix): the general weight for all the materials is approximately 18 kg, exceeding the
targeted value of 15 kg. As concerns the budgeted cost, the final value is attested to 466 (see
complete calculations, including the ones regarding the weight, in the Appendix) which is not in
line with the expectations: generally, the decisions were made trying to reach a compromise
between cost and performance, without losing in the overall quality of the product.
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Appendix
The vibrations recorded during the test are shown in Figure 5: the triaxial distribution of the phenomenon is
clearly evident, underlying various behavior in the three directions. As for the mechanical work per meter
(J(kgm)1), instead, the performance is exhibited in Figure 6.
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Cost 4 1 5 1
Weight 4 5 4 5
Vibration 4 5 4 4
transmissibility
(VT)
Workability 3 4 5 2
Durability 3 4 4 4
Appearance 1 5 4 4
Total 73 83 62
As it could be seen here, a comparative matrix is provided with a weight system to select the final
material for the wheelchairs frame. The comparison was carried out between the three main elements
considered during the brainstorming sessions, because of their properties: the most important criteria
were cost, weight and VT, since the market analysis conducted highlighted the importance reserved by
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the customer to these three factors. Appearance, at the opposite, is the last characteristic to be valued
whereas functionality and ease of use are supposed to be the guidelines. During these sessions,
workability was inserted as a specific requirement too, taking into account the necessity of a simple
but effective manufacturing process.
Triboelectrification
During the analysis carried on the wheeled section, the triboelectric effect had a fundamental part, believing
it to be relevant for the functionality of the product. The triboelectrification is based on the frictional contact
between two or more surfaces of different materials which become electrically charged: the phenomenon is
related to the adhesion, or the attraction between molecules of various nature. Considering that this is not a
chemical bond, electrons are transferred between molecules, holding them together; at the moment of getting
separate, materials develop a positive or negative charge (depending on the excess or on the deficit of
electrons in the surface), since the movement of elementary charges in distinct elements is not immediately
reversible.
As concerns the Trailblazer Wheelchair, it was necessary to protect all the electronic components which
the mechanism is made of, avoiding dangerous malfunctioning: polyurethane wheels are supposed to
minimize this fastidious occurrence, creating an insulating barrier between the framework of the collapsible
wheels (assembled in Aluminium and so electrically conductor) and the ground.
Compound elements
As for the carbon black, it is the result of the incomplete combustion
of heavy petroleum products, being usually inserted as reinforcing
filler in many compound following its high-volume use.
Natural and synthetic
rubber As listed in the table, these tyres are also made up with vulcanizing
aids and vulcanization accelerator: vulcanization is the
chemical process through which the natural rubber is transformed in
Fillers, e.g. carbon black,
chalk, silica a more durable material with sulphurs insertions: these additives
create cross-link between polymer chains which enhance the
Softeners, e.g. oils and mechanical properties of the material and convert them in less sticky
lubricants elements.
This type of tyre offers many interesting features such as
Anti-aging agents (aromatic
extensibility, fatigue resistance, abrasion resistance and strength
amines)
(given by the Carbon Black): physical properties (tensile strength,
rebound resilience etc..) are generally determined by the Carbon
Vulcanizing aids, e.g. sulfur
Black percentage (Scialert.net, 2017).
Vulcanization accelerators;
e.g. zinc oxide
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Figure 8
FEA Analysis
Below, the images and related stress values of the Ansys analysis for the bar mechanisms parts have been
shown: as it is visible, the most stressed elements are the connection pins between the components which
undergo shear stress during the mutual rotation (explainable through a dynamic study of the forces) and the
bar in contact with the ground on which all the weight of the wheelchair is aging. Considering the critical
situation, or the moment in which the motor pushes up the entire wheelchair, the stress are not so relevant to
cause the bars to be damaged.
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