A Robot for Hand Rehabilitation
by
Kristin Anne Jugenheimer
B.S. Mechanical Engineering
Massachusetts Institute of Technology, 1999
Submitted to the Department of Mechanical Engineering
in partial fulfillment of the requirements for the degree of
Master of Science
at the
MASSACHUSETTS INSTITUTE OF TECHNOLOGY
February 2001
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OF TECH$NOLOGY
@Kristin Anne Jugenheimer, 2000
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Department of Mechanical Engineering
January 19, 2001
Certified by ................
.............
Neville Hogan
Professor
Thesis Supervisor
Accepted by........................
.............
Ain A. Sonin
Graduate Officer
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A Robot for Hand Rehabilitation
by
Kristin Anne Jugenheimer
Submitted to the Department of Mechanical Engineering
on January 19, 2001, in partial fulfillment of the
requirements for the degree of
Master of Science
Abstract
This thesis describes the design of a robot for hand rehabilitation and is based on earlier
work done in the MIT Newman Lab for Biomechanics and Human Rehabilitation. The
goal of the new robot described here is to provide rehabilitative therapy to the hand.
MIT MANUS is an active therapy device previously designed and built in the Newman
Lab. It has been used with success to improve strength and control of the upper extremity and promote recovery in stroke patients. However, research showed that only joints
directly involved in robot therapy demonstrated greater improvement than the control
group. This data was an impetus to design robotic therapy for other parts of the body.
Another factor in the development of this robot was that there is a need for functional
therapy. A robot which can provide active therapy using the functional tasks of the hand
would be very novel. The robot design described in this thesis fulfills the requirements of
such an idea. The robot will later be combined with controls software and video games
to allow for active therapy of the hand.
Included in this thesis is the background information on rehabilitative hand therapy,
as well as on the anatomy and function of the hand, used for the design. Design options
and choices are discussed. Finally the overall design and current status of the robot are
presented.
Thesis Supervisor: Neville Hogan
Title: Professor
2
Acknowledgments
First off I would like to thank everyone in the Newman Lab for their help and support. In
particular I owe thanks to Prof. Neville Hogan and Dr. Hermano Igo Krebs for advice and
supervision. A big thank you goes to Lori Humphrey for helping out with my day-to-day
questions. Particular thanks also to Rainuka Gupta and Dustin Williams for being an ear
and a sanity check for the design. Thanks also to Jerry Palazzolo for help with my data
acquisition questions.
Thanks also goes to the numerous people who have helped me outside of lab. Special
thanks to Fred Cote and the Edgerton Student Shop. Thanks also to Matt Page for
help with the ZCorp machine. Appreciation to Edmund Golaski for bearing and machine
design questions and to Byron Stanley for help with the cable drive system.
A huge
thanks to Ebbe Bamberg for his valuable advice during the design review of the robot
and for his help trying to convert Pro/Engineer files for machining. Finally, thanks to my
family and friends for tons of support and many gallons of therapeutic ice cream.
The material in the thesis is based upon work supported under a National Science
Foundation Graduate Fellowship.
3
Contents
1
2
Introduction
13
1.1
P urpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
1.2
Outline of Chapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Background
2.1
15
Stroke . . . . . . . . . . . . . . . . . . . . . .
15
2.1.1
Terminology . . . . . . . . . . . . . . .
16
2.1.2
Stages of Recovery
. . . . . . . . . . .
17
2.1.3
Edema . . . . . . . . . . . . . . . . . .
18
2.1.4
Grasp Reflex
. . . . . . . . . . . . . .
18
2.2
Synergy
. . . . . . . . . . . . . . . . . . . . .
19
2.3
Rehabilitation . . . . . . . . . . . . . . . . . .
19
2.3.1
Continuous Passive Motion . . . . . . .
19
2.3.2
Functional Electrical Stimulation . . .
21
2.3.3
Active Motion for Neuro-Rehabilitation
23
3 Hand Anatomy and Function
3.1
Joints
26
. . . . . . . . . . . . . . . . . . .
26
3.1.1
Anatomy . . . . . . . . . . . . . .
26
3.1.2
Degrees of Freedom . . . . . . . .
27
3.1.3
Ranges of Motion . . . . . . . . .
31
4
3.1.4
3.2
4
33
Anthropometric Data .....
Function . . . . . . . . . . . . . . . .
36
3.2.1
Types of Grip . . . . . . . . .
36
3.2.2
Motor Assessment
. . . . . .
41
3.2.3
Functional Tasks . . . . . . .
42
3.2.4
Forces . . . . . . . . . . . . .
43
47
Functional Requirements
4.1
Degrees of Freedom (DOF) . . . . . .
47
4.1.1
Individual Joint DOF . . . . .
47
4.1.2
Number of Actuated Joints
48
4.2
Ranges of Motion (ROM)
. . . . . .
49
4.3
Patient Interaction . . . . . . . . . .
49
4.4
4.3.1
Safety
. . . . . . . . . . . . .
49
4.3.2
Comfort . . . . . . . . . . . .
50
4.3.3
Ease of Use . . . . . . . . . .
50
4.3.4
Aesthetics . . . . . . . . . . .
50
Summary of Functional Requirements
51
52
5 Design
5.1
General Design .......
5.2
Design Parameters
. . . .
54
Forces . . . . . . .
54
Mechanism of Rotation . .
55
5.2.1
5.3
5.4
52
5.3.1
Options
. . . . . .
55
5.3.2
Flexure Details . .
59
5.3.3
Slider Details . . .
64
. . . . . . .
67
. . . . . .
67
Transmission
5.4.1
Options
5
5.4.2
5.5
5.6
5.7
Cable Drive Details
73
A ctuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.5.1
Linear Options
5.5.2
Rotary Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.5.3
Rotary DC Motor Design
. . . . . . . . . . . . . . . . . . . . . . . 81
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.6.1
Joint A ngle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.6.2
Motor Angle of Rotation . . . . . . . . . . . . . . . . . . . . . . . . 90
5.6.3
Force Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Other Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.7.1
M otor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.7.2
Patient Interaction....... . . . . . . . .
. . . . . . . . . . . . 93
96
6 Hardware
7
6.1
First Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.2
Second Prototype ....
6.3
Final Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
..
..... .............
.
..........
.. 98
110
Conclusion
7.1
Current Status
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2
D esign Process
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.3
Proposed Design Improvements . . . . . . . . . . . . . . . . . . . . . . . .111
7.4
7.3.1
Hardware Improvements . . . . . . . . . . . . . . . . . . . . . . . .111
7.3.2
Material and Manufacture Improvements . . . . . . . . . . . . . . . 112
Future Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A Appendix A - Anthropomorphic Data
113
B Appendix B - Spreadsheets and Calculations
116
B.1 Flexure Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6
B.2 M otor Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
C Appendix C - Component List and Specification Sheets
C.1 Component List .......
.................................
122
122
C.2 Specification Sheets ..............................
. 122
D Appendix D - Pro/Engineer Drawings
145
7
List of Figures
2-1
H3 Hand by Orthologic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2-2
Kinetec 8080 by Smith and Nephew . . . . . . . . . . . . . . . . . . . . . .
2-3
Bionic G love . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-4
A stroke patient working with MANUS . . . . . . . . . . . . . . . . . . . .
24
3-1
The bones and joints of the hand (Adapted from [22]) . . . . . . . . . . . .
27
3-2
A Hinge Joint (Adapted from [25])
. . . . . . . . . . . . . . . . . . . . . .
28
3-3
Rotation of phalanges in joints (Adapted from [32])
3-4
Axes of rotation for the thumb joints (Adapted from [4])
. . . . . . . . . .
29
3-5
Thumb axes with respect to the anatomy (Adapted from [4]) . . . . . . . .
30
3-6
A Saddle Joint (Adapted from [25]) . . . . . . . . . . . . . . . . . . . . . . 30
3-7
Location of thumb in neutral position (Adapted from [30])
3-8
Motions of the MCP joint (Adapted from [32]) . . . . . . . . . . . . . . . .
3-9
Motions of the CMC joint (Adapted from [32]) . . . . . . . . . . . . . . . . 34
21
. . . . . . . . . . . . . 29
. . . . . . . . 31
3-10 Motions of the MP and IP joints (Adapted from [32]) . . . . . . . . . . . .
32
35
3-11 An example of hook grasp [39] . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-12 An example of lateral prehension [13] . . . . . . . . . . . . . . . . . . . . .
37
3-13 An example of palmar prehension [13] . . . . . . . . . . . . . . . . . . . . . 37
3-14 An example of cylindrical grasp [39] . . . . . . . . . . . . . . . . . . . . . . 38
3-15 An example of spherical grasp [39] . . . . . . . . . . . . . . . . .
. . . . . 38
3-16 An example of precision pinch [39] . . . . . . . . . . . . . . . . . . . . . . . 39
3-17 An example of key pinch [39] . . . . . . . . . . . . . . . . . . . . . . . . . .
8
39
3-18 An example of chuck grip [39] . . . . . . .
40
3-19 An example of power grasp [39] . . . . . .
. . . . . . . . . . . . . . . . 40
5-1
General Top View of Robot
. . . . . . . . . . . . . . . . . . . .
53
5-2
A Simple Pin Joint . . . . . . . . . . . . . . . . . . . . . . . . .
56
5-3
Schematic of Composite Flexion . . . . . . . . . . . . . . . . . .
57
5-4
A Pin and Slider Joint . . . . . . . . . . . . . . . . . . . . . . .
57
5-5
Example of a Clamped Flexure [38] . . . . . . . . . . . . . . . .
58
5-6
Forces and Resulting Rotations on Generic Flexure
. . . . . . .
59
5-7
Proof of Flexure Concept . . . . . . . . . . . . . . . . . . . . . .
60
5-8
Beaded Flexure . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
5-9
Location of CMC Abduction/Adduction and Flexion/Extension Axes on
R ob ot
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
5-10 Effective Width for Resistance to Moments for Back-to-Back and Face-toFace Configurations [38]
. . . . . . . . . . . . . . . . . . . . . . . . ..
. . 66
5-11 Slider Cross-Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5-12 Example of a Push Rod Causing Rotation . . . . . . . . . . . . . . . . . . 68
5-13 Double Bellows for Transmission of Force . . . . . . . . . . . . . . . . . . . 69
5-14 Flexure Rotation Using Hydraulic Bellows . . . . . . . . . . . . . . . . . . 69
5-15 Rolling Diaphragm Actuator Technology, adapted from [7]
. . . . . . . . . 70
5-16 Schematic of the Cable Drive Transmission . . . . . . . . . . . . . . . . . . 73
5-17 Cable Stretch Data from Sava Industries . . . . . . . . . . . . . . . . . . . 74
5-18 Stress and Deflection of Narrow Flexure
. . . . . . . . . . . . . . . . . . . 77
5-19 Stress and Deflection of Slotted Flexure . . . . . . . . . . . . . . . . . . . . 78
5-20 An Amplified Piezo Actuator (Cedrat Recherche)
. . . . . . . . . . . . . . 78
5-21 A Moving Magnet Actuator (Moving Magnet Technologies) . . . . . . . . . 80
5-22 The RBE motor from Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . 83
5-23 Frameless Motor Mounting from Kollmorgen . . . . . . . . . . . . . . . . . 85
5-24 Miniature Shape Sensor by Measurand
9
. . . . . . . . . . . . . . . . . . . . 87
5-25 Shape Sensor Testing Jig
87
5-26 Close-Up of Testing Jig . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 89
5-27 Sensor Testing Data
5-28 Hollow Shaft Encoder by Gurley Precision Instruments
. . . . . . . . . . 90
5-29 A Standard Flexible Force Sensor by Tekscan
. . . . .
. . . . . . . . . . 92
6-1
Finger Module of First Prototype . . . . . . . . . . . .
. . . . . . . . . . 97
6-2
Thumb Module of First Prototype . . . . . . . . . . . .
. . . . . . . . . . 99
6-3
Second Prototype ...............
6-4
Finger Module of Second Prototype . . . . . . . . . . . . . . . . . . . . . . 10 2
6-5
Side View of the Finger Module of Seco nd Prototype
6-6
CMC Rotation in Second Prototype
. . . . . . . . . . . . . . . . . . . . 104
6-7
Solid Model of Entire Robot . . . .
. . . . . . . . . . . . . . . . . . . . 106
6-8
Close-Up of the Hand-Robot Interfaces . . . . . . . . . . . . . . . . . . . . 10 7
6-9
Robot Finger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
. . . . . . . . . . . . . . . . . . . . 10 1
. . . . . . . . . . . . 103
6-10 Robot Thumb Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 9
. . .
. . . . . . . . . . . . . . . . . . . . 124
C-2 Large Pinion Gear Drawing . . .
. . . . . . . . . . . . . . . . . . . . 125
C-3 Motor Spec Sheet 1 . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 126
C-4 Motor Spec Sheet 2 . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 127
C-5 Motor Spec Sheet 3..........
. . . . . . . . . . . . . . . . . . . . 128
C-6 Motor Spec Sheet 4..........
. . . . . . . . . . . . . . . . . . . . 129
C-7 Servoamplifier Spec Sheet 1 . . .
. . . . . . . . . . . . . . . . . . . . 130
C-8 Servoamplifier Spec Sheet 2
. . .
. . . . . . . . . . . . . . . . . . . . 13 1
C-9 Servoamplifier Spec Sheet 3
. . .
. . . . . . . . . . . . . . . . . . . . 13 2
C-10 Servoamplifier Spec Sheet 4
. . .
. . . . . . . . . . . . . . . . . . . . 133
C-11 Servoamplifier Power Supply Spec
t I . . . . . . . . . . . . . . . . . . 134
C-12 Servoamplifier Power Supply Spec
t 2 . . . . . . . . . . . . . . . . . . 135
C-1 Small Pinion Gear Drawing
10
C-13 Encoder Spec Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
C-14 Encoder Spec Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
C-15 Encoder Spec Sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
C-16 Encoder Spec Sheet 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
C-17 Encoder Spec Sheet 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
C-18 Joint Angle Sensor Spec Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . 141
C-19 Joint Angle Sensor Spec Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . 142
C-20 Sensor Power Supply Spec Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . 143
C-21 Sensor Power Supply Spec Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . 144
11
List of Tables
. . . 33
3.1
Joint Ranges of Motion .
3.2
Force Table 1 . . . . . . . .
3.3
Force Table 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5
3.4
Experimental Force Results
4.1
Individual Joint ROM
. . .
49
5.1
Chosen Design Forces . . . .
55
5.2
Necessary Motor Torques .
82
A.1
Digit Anthropometric Data
. . . . . . . . . ... . . . . . . . . . . . . . . . 114
.
44
. . . . . . . . . . . . . . . . . . . . . . . . . . 45
A.2 Hand Anthropometric Data . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 5
B.1
Finger Flexure Calculations
. . . . . . . . . . 117
B.2 Thumb Flexure Calculations
. . . . . . . . . . 118
B.3 Flexion/Extension Necessary Force Calculations
. . . . . . . . . . 119
B.4 Flexion/Extension Motor Torque Calculations . . . . . . . . . . . . . . . . 120
B.5 CMC Abduction/Adduction Motor Torque Calculations.
C.1
. . . . . . . . . . 121
Components List . . . . . . . . . . . . . . . . . . . . . .
123
. . . . . . . . .
123
C.2 Bearing Specs (all dimensions in inches)
12
Chapter 1
Introduction
1.1
Purpose
This thesis describes the design of a robot for hand rehabilitation done in the MIT Newman Lab for Biomechanics and Human Rehabilitation. The goal of the robot is to provide
rehabilitative therapy to the hand of stroke and other patients.
After stroke, "hand function seems to be the most difficult motor function to restore
even with intensive therapy" [43]. It is also arguably one of the most important motor
functions used during everyday life. For these reasons, developing a robot to help stroke
patients recover hand function is both a difficult and a valuable task. The robot was
designed as my Master's thesis during the year of 2000.
1.2
Outline of Chapters
In order to understand the robot design, some background is needed. Therefore, Chapter 2
describes stroke and the stages of recovery after a stroke, while Chapter 3 is a summary
of hand anatomy and function relevant to the design. Chapter 4 describes the functional
requirements for the robot design. Chapter 5 describes the design choices and decisions in
detail, while Chapter 6 discusses the prototypes which were produced. Finally, Chapter 7
13
tells where the robot is today and where it is going.
included in the appendices.
14
Drawings and calculations are
Chapter 2
Background
2.1
Stroke
Stroke is a general term which refers to any acute brain disorder that is caused by a
disturbance of the vascular system in the brain. There are many types and causes of
stroke, though cerebral infarction due to blockage of a blood vessel in the brain is the
most common [24]. Strokes, or cerebrovascular accidents (CVAS), are the third leading
cause of death in the U.S. and are the most common cause of chronic neurologic disability
[43]. At any one time, there are approximately two million stroke survivors in the United
States alone [43].
The most common results of a stroke is weakness (hemiparesis) or paralysis (hemiplegia) on the side of the body opposite the CVA [43]. These can cause abnormal patterns of
posture and movement. If left untreated, many patients recover little or no functionality
in paralyzed limbs. This non-functionality can propagate chronic motor problems as the
patients modify their normal side actions to compensate for the loss [14].
Physical therapy and neuro-rehabilitation treatment can reduce or eliminate these
patterns and can allow patients to regain movement and control. Various studies suggest
that motor recovery and re-learning to use the affected limb can be maximized by active
repetitive use of that limb [15].
15
2.1.1
Terminology
Terms describing the muscles of a stroke victim:
Flaccidity Lack of normal muscle tone. The limb feels limp and will fall into place if
not supported.
Spasticity Excess tone and hyperactive response to stretch. In moderate to severe spasticity, the limb feels tight and is difficult to move into position.
Tone Resistance of muscle to passive elongation or stretching.
Contracture Tightening of the muscles.
Synergy Patterned movements of the entire limb in response to a stimulus or voluntary
effort. The patient has difficulty separating out individual muscle movements.
Terms describing the planes of the hand:
Dorsal Plane The plane through the back of the hand.
Palmar Plane The plane through the palm of the hand.
Terms describing the motion of the fingers:
Flexion In the fingers, bending towards the palmar side of the hand. In the thumb,
bending across the palm towards the base of the little finger.
Extension In the fingers, bending away from the palm, towards the dorsal side of the
hand. In the thumb, bending away from the palm as in a hitch-hiker's thumb.
Abduction Motion away from the center line of the hand, in a direction perpendicular
to the palm.
Adduction Motion towards the center line of the hand, in a direction perpendicular to
the palm.
16
Pronation From neutral position, rotation inwards (i.e. clockwise for the left hand and
counter clockwise for the right hand).
Supination From neutral position, rotation outwards (i.e. counter clockwise for the left
hand and clockwise for the right hand).
2.1.2
Stages of Recovery
In general, recovery from paralysis progresses from "proximal to distal movement and
from mass, patterned, undifferentiated movement to fine, isolated movement" [43]. In
the case of the arm, gross trunk and shoulder movements will occur first. Movement will
continue down the arm, progressing to the elbow, wrist and finally to the fingers. Mass
flexion and extension of the hand is followed by flexion and extension of individual fingers
and then by abduction and adduction of the thumb [10]. More specifically, the observable
stages of recovery of the hand are flaccidity, followed by little or no active movement, then
mass grasping (all the fingers grasping at once), lateral prehension (holding between the
side of the index finger and thumb), palmar prehension (holding between the thumb and
the first two fingers) and then, finally, individual finger movements [8].
The following scale describes hand function as tested shortly after a stroke [17]:
1. No active motion in digits.
2. Active flexion of all fingers in synergy only.
3. Active flexion and extension of all fingers in synergy.
4. Ability to extend index finger with all others in flexion.
5. Ability to bring thumb in opposition to the tip of the index finger.
6. Ability to oppose thumb to all fingers.
It can generally be assumed that a patient will not be undergoing hand therapy until
they have recovered at least some functionality in the muscles of their upper arm and
17
wrist. This is not always true, however, as there are cases where stroke victims will show
no movement in the upper arm but will have full control and dexterity of their fingers
[19]. The robot therefore needs to be able to support itself and the wrist of the patient in
case they are not able to do it themselves. Ideally the robot would also allow for passive
movement of the wrist (motion initiated by the patient) for practicing functional tasks
[10].
2.1.3
Edema
Edema, or accumulation of fluid in the tissue, is seen in approximately 16% of hemiplegic
patients [8]. During the clinical trial work previously done in the Newman Lab, almost
all patients have had significant hand edema [29]. In many cases, edema occurs due to
loss of muscle action and reduced circulation [43). Often, in the case of arm paralysis, the
fingers and wrists of the patient will be extremely swollen, reducing the range of passive
joint motion. This condition needs to be considered in the design of the robot; many
patients with edema will fall outside of the normal anthropometric ranges for hand and
finger size and will not be able to reach the ranges of motion of a normal person.
2.1.4
Grasp Reflex
Along with paralysis, a stroke victim may also demonstrate other motor disturbances. One
of these can be the reappearance of the "grasp reflex", such as is seen in young infants. It
is usually seen when pressure moves over certain areas of the palmar region of the hand
[37, 31]. Grasping is seen in about 8% of brain damaged patients, predominantly in those
with hemispheric lesions . It is also generally associated with frontal lobe pathology . For
this reason, as well as for increasing functional ability, the robot design avoids contact
with the palm.
Separate, but similar to, the grasp reflex is the instinctive grasping reaction. In this
case, the response is elicited with a stationary pressure. The patient is compelled to close
his or her hand over whatever object is touching it [37]. This reaction is also seen in
18
patients suffering from stroke.
2.2
Synergy
Another motor impairment that a stroke patient often demonstrates is abnormal synergy.
As described above, synergy is a patterned movement that the patient has trouble breaking
down into individual muscle movements.
The most prevalent synergies in the upper
extremity are the flexion and extension synergies. These occur when the patient tries to
accomplish a general flexion or extension movement.
The most common flexion synergy consists of having the arm in abduction, extension
and external rotation of the shoulder, elbow flexion, forearm supination and flexion of
the wrist and fingers. Extension synergy, on the other hand, consists of forward flexion,
adduction and internal rotation of the shoulder, extension of the elbow, pronation of the
forearm and finger and thumb extension [35]. These synergies affect the robot design in
that the patient's fingers are difficult to move individually and may be affected by how
else the patient is moving his or her arm.
2.3
Rehabilitation
There are several schools of thought on what type of rehabilitative therapy is most beneficial to a person suffering from hemiplegia. The most common types of therapy associated
with hand rehabilitation are discussed below.
2.3.1
Continuous Passive Motion
Continuous Passive Motion (CPM) uses a therapist or machine to move a patient's limb
for hours at a time. There is evidence that this method of therapy reduces edema [8, 1, 21]
and is beneficial in the treatment of spastic flexion [5]. However, it requires eight hours
of therapy a day to be beneficial [1], and the effect of reducing edema may only last 24
19
Figure 2-1: H3 Hand by Orthologic
hours [21]. CPM can help a patient with movement control, but has no effect on force
control [5]. Also, since the patient is simply being moved, there is no connection between
what the patient wants to do and what he or she actually does. Therefore it is helpful
but cannot replace active motion of the limbs [1].
Several products on the market today are available to provide CPM for the hand.
There are both portable and non-portable devices, though all of them achieve basic flexion
and extension without focusing on the individual joints [1].
Portable Devices
Orthologic has two portable CPM devices for the hand. The first, the WaveFlex hand,
provides composite flexion to the individual fingers. H3 hand, their second device, uses
at
adjustable rods attached to the fingertips to provide composite flexion of all fingers
once (see Figure 2-1) [33).
The Kinetec 8091 by Smith and Nephew has finger pieces which slide onto an anatomically shaped drive bar and provide motion into a full composite fist [41]. These portable
devices concentrate on the fingers and only apply composite flexion. There is no individual
joint angle control and little or no interaction with the thumb.
20
Figure 2-2: Kinetec 8080 by Smith and Nephew
Non-Portable Devices
Some of the non-portable devices do have the ability to move the thumb. For example,
the Kinetic 8080 by Smith and Nephew provides composite flexion and extension of the
fingers, as well as thumb flexion and extension (see Figure 2-2). However, the device does
not have the ability to actuate individual joints.
2.3.2
Functional Electrical Stimulation
Another method of physical rehabilitation is Functional Electrical Stimulation (FES).
FES is a technique that applies electrical pulses the peripheral nerve fiber members of
disabled limb, causing the muscles to contract [43]. Studies have suggested that electrical
stimulation reduces spasticity and enhances the muscle strength of the affected limb [15].
Less a type of therapy and more a way of achieving functionality, FES has been
21
A
adhesive electrodes over
muscles. nerves
contr I/stimulator
wrist position
box
sensor
panels inside glove automatically
connect control box to electrodes
Figure 2-3: Bionic Glove
integrated into devices which the therapist or patient can use to activate otherwise inactive
muscles. One such device is the Bionic Glove, designed at the University of Alberta,
Canada (see Figure 2-3). In this device electrodes are placed on the skin, with the glove
over them. Tightening the glove makes contact between the electrodes and metal panels in
the glove itself. Stimulation is sent to these panels and into the patient via the electrodes
[44].
A subset of FES is electromyography (EMG) triggered neuromuscular stimulation.
The basis for this assistance is that "alternative motor pathways can be recruited and
activated to assist the stroke-damaged efferent pathways."
This theory is based on a
sensorimotor integration theory that says that sensory input from the affected limb during
movement will affect subsequent movement [14]. In other words, as a patient attempts
to accomplish a movement, EMG activity in the limb is measured and when it reaches a
threshold level, the limb is electrically stimulated, completing the movement. Over the
22
span of a treatment regimen, this method is reported to help the patient gain control.
However, results using the Motor Assessment Scale and Fugl-Meyer test did not show
any significant improvement [14]. Also, some studies show that although the stimulation
can cause function, spasticity is not reduced and voluntary action can actually reduce the
effectiveness of the stimulation [27].
2.3.3
Active Motion for Neuro-Rehabilitation
A newer type of therapy, active motion therapy, has two goals. One is movement of the
paralyzed limbs, to reduce edema and improve muscle strength. Along with this, active
motion therapy seeks to achieve the neuro-rehabilitation necessary to control these limbs.
Brunnstrom's method states that "during the early recovery stages the hemiplegic
patient should be aided and encouraged to gain control of the basic limb synergies" and
for this, stimuli of proprioceptive and exteroceptive origin are justified and advantageous
[37]. In layman's terms this means that giving patients external physical and visual stimuli
to encourage rehabilitation can be very helpful in their recovery.
It has also been suggested that full neurological rehabilitation is possible after a stroke
and that the environment in which rehabilitation occurs can play a role in this [16]. To
these ends the rehabilitative robot MIT MANUS was created.
MIT MANUS
MIT MANUS combines an impedance-controlled robot with a series of video games to
achieve neuro-rehabilitation. The stroke patient holds, or is attached to, the end effector
of the robot while he or she attempts to play various target oriented games shown on a
screen above the robot. The goals of the games vary to provide a wide range of muscle
therapy. One game has the patient resist the robot as it tries to move him or her, while
in another the patient tries to follow a star shaped path to several targets. In the latter
game, if the patient can not accomplish the task and reach the target, the robot will help
the patient do so. Figure 2-4 shows a stroke patient working with MANUS.
23
Figure 2-4: A stroke patient working with MANUS
24
The movements accomplished by the patient are in the plane of the robot table and
use mostly the shoulder and elbow muscles. Clinical results show that patients undergoing
this type of therapy "improved further and faster, outranking the control group in all the
clinical assessments of the motor impairment involving shoulder and elbow" [26].
An additional degree of freedom in the vertical direction was designed for MANUS
in the Spring of 2000. The movements aided by this new design should increase the
usefulness of MANUS for the re-learning of functional tasks. The robot can now be used
to simulate lifting something from the table to the patient's mouth, placing something on
a shelf and other such common tasks.
Hand Robot
The clinical research done on MANUS also showed that only joints directly involved with
the robot therapy demonstrated greater improvement than the control group [26]. This
data was an impetus to design robotic therapy for other parts of the body. Along with
this data, there was a desire to achieve more functional rehabilitation. It is unusual for a
hemiplegic patient to use the affected hand for any type of activity until finger and thumb
extension can be accomplished without synergy [35]. Therefore, helping the patients reach
that point is very important.
For these reasons, among others, a design for a robot to provide active motion therapy
for the hand was desired. The robot design described in this thesis fulfills the requirements
of such an idea. The robot will later be combined with controls software and video games
to allow for active therapy of the hand.
25
Chapter 3
Hand Anatomy and Function
3.1
Joints
In order to understand the design of the robot, it is necessary to know a little about the
anatomy and function of the hand. Of particular interest are the joints of the hand and
their ranges of motion since this is what the robot must actuate. Anthropometric data,
or human factors data, is useful for the sizing of the device. Finally, the functional grips
used in everyday activities are of interest if the robot is going to provide such function.
3.1.1
Anatomy
The fingers contain 12 joints. Four, the metacarpophalangeal (MCP) joints, are located
at the base of the fingers at the first knuckle. Another four, the proximal interphalangeal
(PIP) joints, are between the first two phalanges of the fingers at the second knuckle.
The distal interphalangeal (DIP) joints are the last knuckle on the fingers, between the
second and third phalanges. Figure 3-1 shows the various bones and joints of the hand.
The thumb has three joints. The carpometacarpal (CMC) joint is located at the base
of the thumb, near the wrist. The metacarpophalangeal (MCP or MP) joint is located at
the crook between the index finger and thumb. Finally, the interphalangeal (IP) joint is
between the two phalanges of the thumb at the knuckle.
26
Phalarges
Middh
.--MCP-
MP
TrapeZd
CarpEia (Trapezium
CMC
Figure 3-1: The bones and joints of the hand (Adapted from [22])
All the joints are actuated by the pulling of various tendons at attachment points
along the bones of the hand. There are generally two opposing tendons for each degree of
freedom of a joint. Large scale motions, such as flexion and extension of the fingers, are
also accomplished by the extrinsic muscles of the hand. Fine motor control and smaller
motions of the hand are accomplished by the intrinsic muscles. Generally speaking, the
extrinsic muscles are much stronger and more important functionally than the intrinsic
muscles.
3.1.2
Degrees of Freedom
The joints in the fingers and thumb all have either one or two actuated degrees of freedom.
The first degree of freedom is flexion and extension, while abduction and adduction provide
the second degree of freedom. For some joints, when these two degrees of freedom are
actuated at the same time, pronation or supination occurs as well. In joints with only
27
Figure 3-2: A Hinge Joint (Adapted from [25])
flexion and extension, such as the DIP joints, the PIP joints and the IP joint, the joint
itself can be modeled as a pin or hinge joint [11, 13] (see Figure 3-2). In actuality, the
distal phalange rotates inside a cup-like shape on the proximal phalange (see Figure 3-3).
For the DIP and PIP joints of the fingers, the axis of rotation is almost perpendicular
to the finger itself. In the case of the IP joint, the axis is not perpendicular to the bone
and the result is some pronation as the joint flexes to aid in opposition. As the joint flexes,
the distal phalange goes through 5 to 10 degrees of pronation [6]. Figures 3-4and 3-5 show
the joints and axes of rotation for the thumb.
The joints with both flexion/extension and abduction/adduction, which are the MCP
joints and the CMC joint, can be modeled as a saddle or universal joint [11, 13]. In this
case, the proximal bone provides a "saddle" over which the distal bone can rotate in two
directions (see Figure 3-6). Both degrees of freedom can be actuated simultaneously as
in a universal joint. The CMC can also be modeled as two hinge joints twisted with
respect to one another [4]. Since these pivots are not perpendicular to each other, the
combination of flexion/extension and abduction/adduction also creates rotation.
28
Metacarpal
Figure 3-3: Rotation of phalanges in joints (Adapted from [32])
-LFEX-EXT
AA&s
FLEX-EXT
Axis
I
ABD-ADD
~Axis
& ASD-AD
Axis
FLEx-EXT
Axis
Figure 3-4: Axes of rotation for the thumb
29
joints
(Adapted from [4])
Axis
Axis
Axis
FLEX-EXT
Axis
Figure 3-5: Thumb axes with respect to the anatomy (Adapted from [4])
Figure 3-6: A Saddle Joint (Adapted from [25])
30
Dortal Piane of Hand
60d40g
FlsAcOn
Adurct
ti
Line:
Trapeziurm
Figure 3-7: Location of thumb in neutral position (Adapted from [30])
When the CMC joint is abducted, it also rotates laterally, while when the joint is
adducted, it also rotates medially [6]. This conjunct rotation is what allows the thumb to
oppose the fingers. In the neutral position, the finger joints are more or less in the plane
of the fingers. The thumb however is rotated about 60 degrees in the palmar direction
from the dorsal plane of the hand [30] (see Figure 3-7).
3.1.3
Ranges of Motion
The two main ranges of motion (ROM) are flexion/extension and abduction/adduction.
As mentioned above, all the finger joints (MCP, PIP and DIP) are able to achieve flexion
and extension. Only the MCP joints have abduction and adduction however. Figure 3-8
shows the movements of the MCP.
In the case of the MCP joints, abduction and adduction are the responsibility of the
intrinsic muscles of the hand. Also, as the MCP joint flexes or extends, abduction and
adduction become much more difficult due to the geometry of the joints. Abduction and
adduction take the longest to come back to a patient after a stroke [10]. In addition, these
movements are not necessary for a majority of functional tasks. For these reasons, the
robot does not have actuation in these degrees of freedom.
31
Extension
Flexion
Abduction
Adduction
Figure 3-8: Motions of the MCP joint (Adapted from [323)
32
Author
MCP
PIP
DIP
CMC
MP
Chao
85.5
89.5
50.36
50.4 aa
Becker
85.58
107.15
73.64
Smutz
20/25
60/10
60/20
20/20 aa
15/15 aa
Eaton
90/45
100/0
80/0
60 f
55/10
Hume
100/0
105/0
85/0
56/0
73/5
Arbuckle
65/6
100/5
91/0
Palastanga
90/50
90+/2
80/5
40-50, 0/80 aa
45/0
Merck
90/30
120/0
80/0
70/0, 0/25 aa
90/0
IP
80/15
90/10
Table 3.1: Joint Ranges of Motion
The motions of the joints of the thumb are more complex. At the CMC there is
flexion/extension and abduction/adduction, as well as some rotation when opposition is
achieved (see Figure 3-9). At the MP and IP joints, however, there is mostly flexion and
extension. Some rotation occurs depending on the grasp but it is passive and is a function
of the shape of the joint interface (see Figure 3-10).
Extensive research has been done on the ranges of motion of the human hand and
there is general consensus about what those ranges are.
of several range of motion studies.
Table 3.1 gives the results
The following abbreviations are used: f=flexion,
fe=flexion/extension, ad=adduction, aa=abduction/adduction. If no designation is given,
flexion/extension is implied. In the table, one value signifies the entire ROM of that joint,
with no regard for the neutral position. Two values signify the range from neutral in
flexion/extension or abduction/adduction, in that order. All values are in degrees.
3.1.4
Anthropometric Data
There has also been extensive work done to obtain anthropometric data on the human
hand. Done mostly through military projects, this data, also known as human factors
data, can be used to size the robot. Ideally, the robot should be able to fit anyone from
33
I
Extension
Flexion
Adduction
Abduction
/
Opposition
Figure 3-9: Motions of the CMC joint (Adapted from [32])
34
Flexion
xtensian
d31
I!
t
ft//
P Joini
~% ~
pk
Flexion
Extension
I.10
I PJoint
Figure 3-10: Motions of the MP and IP joints (Adapted from [32])
35
the 5th percentile woman to the 95th percentile man. As mentioned in Section 2.1.3, some
patients may be even larger than this 95th percentile. Appendix A contains the various
anthropometric measurements and their values.
The range of sizes is quite large and therefore the robot needs to either be highly
adjustable or there need to be several sizes to accommodate all types of patients. Also,
there are some measurements that are not well known, such as the exact location of the
joints inside the fingers. For this reason, the robot design should have a some compliance
built into it so as to avoid poor kinematics resulting from not co-locating the robot joint
with the patient joint.
3.2
Function
Types of Grip
3.2.1
There is varied thinking on what movements are most necessary and should be relearned
first. The following is a review of the most common types of grips tested and used in
rehabilitation of hemiplegic patients. Ideally, the robot should be able to help the patient
accomplish all of these tasks.
One established rehabilitative therapy strategy for stroke is Brunnstrom's movement
therapy [37]. This therapy consists of eight tasks which follow the order of returning
movement and control. The therapy tasks are:
Hook grasp This is the type of grasp used to hold the handles of a bag. It requires
flexion of all the fingers at once but not to their full range of motion (Figure 3-11).
Lateral prehension This type of grip is used to pick up an item such as a card between
the thumb and the side of the index finger (Figure 3-12).
Palmar prehension This type of grip is used to hold an item such as a pencil between
the thumb and the first one or two fingers. Also known as pincer grasp (Figure 3-13).
36
Figure 3-11: An example of hook grasp [39]
Figure 3-12: An example of lateral prehension [13]
Figure 3-13: An example of palmar prehension [13]
37
Figure 3-14: An example of cylindrical grasp [39]
Figure 3-15: An example of spherical grasp [39]
Cylindrical grasp This grasp is used to pick up medium sized cylindrical objects, such
as a small jar, in the palm using the fingers and thumb (Figure 3-14).
Spherical grasp Similarly, this grasp uses the fingers and thumb to hold a round object,
like a ball, in the palm (Figure 3-15).
Opposition This grip places the thumb to the tip of the index finger (Figure 3-16).
Thumb This task is general movement of the thumb by itself up and down, as well as
side to side.
38
Figure 3-16: An example of precision pinch [39}
Figure 3-17: An example of key pinch [39]
Fingers This task is flexion and extension of individual fingers by themselves.
Other functional tasks which are used for rehabilitation include [13]:
Key pinch This pinch is used as its name implies, to hold a key. The thumb is pressed
to the side of the index finger as the finger is in flexion (Figure 3-17).
Chuck grip This grip is similar to Brunnstrom's palmar prehension, using the thumb
and first two fingers to hold a slender cylindrical item as in a drill chuck (Figure 318).
Power grasp This grasp is used to hold a hammer or such object. The fingers are
in flexion around the object and the thumb is along the object for stabilization
(Figure 3-19).
39
Figure 3-18: An example of chuck grip [39]
Figure 3-19: An example of power grasp [39]
40
3.2.2
Motor Assessment
There are several tests which are used to determine the status of a stroke patient. Of the
most interest for the design of this robot are the tests of upper extremity function. In
particular, prior work in the Newman Lab has focused on using the Fugl-Meyer Assessment, the Motor Status Score, and Motor Power to assess impairment. Recently the FIM
and the Chedoke Arm and Hand Activity Inventory (CAHAI) are being investigated as
ways to assess functional competencies [18].
The Fugl-Meyer is based heavily on the functional grasps described by Brunnstrom
and consists of seven tests:
1. Fingers, mass flexion
2. Fingers, mass extension
3. PIP-DIP hook grasp
4. MCP joints extended, PIP and DIP joints flexed
5. Thumb adduction with paper, all other joints at zero
6. Pincer grasp with pencil
7. Cylinder grasp with small can
8. Spherical grasp with tennis ball
The Motor Status Score is more specific, focusing on individual motions and opposition. It includes most of the Fugl-Meyer tests as well as several tests for pad pinch and
tip pinch to the various fingers.
Finally, the CAHAI is the most functional of the three tests. It consists of several
everyday tasks which the patient must complete, either by him or herself or with the aid
of a therapist. Representative tasks include opening a jar of coffee, calling 911, doing up
buttons and putting toothpaste on a toothbrush. These tasks, although they do not focus
41
on specific "functional" grips, are very similar to the activities that a patient may have
to do on their own after they leave a rehabilitation setting. These are the tasks that are
most difficult to practice with existing therapeutic devices.
3.2.3
Functional Tasks
According to occupational therapist Lisa Edelstein at Burke Rehabilitation Hospital in
White Plains, NY, the most useful generic functional tasks are thumb opposition to the
little finger, prehension between the thumb and index finger as well as between the thumb
and first two fingers, and mass grasping [10].
As mentioned above, one of the most
important functional movements is bending all of the fingers around an object. In this
movement, also known as a composite fist, all of the joints of the fingers are used. The
order of motion is as follows [2]:
1. The MCP flexes
2. The PIP begins to flex with the MCP, with the PIP flexing slightly more than the
MCP. From about 20 to 90 degrees, the DIP also flexes with the PIP.
3. At flexion of about 100 or 110 degrees, the PIP stops movement and the MCP
continues to flex
4. At the end of the movement, the PIP flexes a bit more.
With opposition of the thumb to one of the fingers, motion of the CMC and the thumb
MCP are coupled together [12]. Three elementary movements make up opposition. The
first is flexion and abduction simultaneously at the CMC. During this movement, the MP
joint also flexes and abducts. Next there is active rotation of the metacarpal. Finally
there is adduction at the CMC joint [40]. At the completion of the movement, there is
about 20 degrees of abduction at the thumb MCP joint and 40 to 50 degrees of abduction
at the CMC. Flexion varies on which finger the thumb is opposing and what, if anything,
is being grasped, and pronation is about 70 degrees at the CMC joint [40].
42
Another concern for the robot design is the position of the wrist during functional
tasks. If the robot is stabilizing and supporting the wrist, it must be in an orientation
that allows for easy movement of the fingers. Generally the functional position of the
wrist is 20 to 25 degrees extended, with 0 to 10 degrees of radial deviation [34, 10
3.2.4
Forces
It is well established that different types of grip result in varying forces provided by
different fingers.
The goal was to determine what was the maximum force the robot
needed to provide. A survey of prior research showed a wide variability in the published
data.
The main cause of this variability is that no two researchers have done exactly the
same experiment. The experiments also have mostly been done on cadavers or normal
subjects.
Only the work done by Mayo was on stroke patients. Therefore I assumed
that the maximum force necessary would be one half to three quarters of what a normal
patient would be able to exert.
Because of the variability and difficulty in understanding what a grip force of 52 N
really is, hands-on experimentation was also used to get a better feeling for the maximum
and normal forces exerted. Using a Chatilon device capable of measuring the force used
to displace two sides of a frame, I tested my grip force. I found my maximum grip force to
be approximately 60 lbf (266.9 N) and my "normal" grip force to be about 20 lbf (88.96
N). "Normal" grip force was defined by the amount of force that would be necessary to
firmly hold a can of soda or other similar object.
Using a spring scale, I was also able to measure the flexion force of my index finger,
the rest of my fingers and my thumb at various joints. The data collected is shown in
Table 3.4. My results were within the range of the published results.
Another source of force information was previous devices. By looking at the force
provided by various existing products it was possible to get a better feel for what forces
were needed and appropriate to apply to a patient. The chosen provided forces will be
43
Strength Measure (N)
Chao
Kroemer
NASA
Boatright
Mayo
Tip Pinch (Men)
Index
63.06
50
Middle
63.35
53
Tip Pinch (Women)
Index
47.27
Middle
45.7
Palmar Pinch (Men)
Index
64.53
63
Middle
62.37
61
Palmar Pinch (Women)
Index
44.62
Middle
44.82
Grip Strength (Men)
367.85
Grip Strength (Women)
218.69
318
500.78
336.73
318.72
296.01
209.07
191.23
Table 3.2: Force Table 1
44
Strength Measure (N)
Chao
Radwin
Index MCP Flex/Ext
35.1
Index PIP Flex/Ext
33.75
Index DIP Flex/Ext
34.96
Richards
52.67
58.84
52
Middle MCP Flex/Ext
Ring MCP FLex/Ext
34.67
Little MCP Flex/Ext
26
32.36
Thumb CMC Flex/Ext
Table 3.3: Force Table 2
Experiment
Max Force
Index alone
10 lbf (44.48 N)
Middle through little
10 lbf (44.48) N
Thumb CMC
15 lbf (66.72 N)
Thumb MP
10 lbf (44.48 N)
Thumb IP
10 lbf (44.48 N)
Table 3.4: Experimental Force Results
45
discussed later in Section 5.2.1.
46
Chapter 4
Functional Requirements
The first task in any design is to determine what the design needs to do. In the case
of this robot, the two major classes of requirements were the kinematics and the patient
interaction. Kinematics include the degrees of freedom (DOF) of the robot as well as the
ranges of motion through which it will move the patient. Patient interaction requirements
define how the robot will work with the patient and how the patient will interact with
the robot.
4.1
4.1.1
Degrees of Freedom (DOF)
Individual Joint DOF
It was determined early on that to accomplish the robot in a timely manner, not every
function of the hand would be simulated. To this end, not all the fingers are individually
actuated. The middle, ring and little fingers are actuated together while the index finger
and thumb are done separately. This allows for mass grasping action of all fingers and
thumb, as well as more delicate grasping using only the index finger and thumb.
Also, abduction/adduction in the fingers and distal thumb joints was eliminated for
a couple of reasons. For one, these movements do not have a large impact on the basic
functionality of the hand; they are more instrumental in fine motor control. Also, these
47
movements are controlled by small intrinsic muscles in the hand. These muscles are
difficult to actuate and not usually controllable by the patients who would use the robot.
Therefore the design only actuates flexion/extension of the finger and distal thumb joints.
In the thumb, however, abduction/adduction of the CMC joint is necessary for the
vital movement of opposition. Flexion/extension is also necessary in this joint and so
both degrees of freedom are actuated in this joint.
4.1.2
Number of Actuated Joints
Another simplification that was made was the number of joints actuated on the individual
fingers. Although the fingers have three joints each (see Chapter 3), most functions do
not require specific movement of each individual joint. In fact, it is impossible to bend
the PIP and DIP joints on the finger independently. The kinematics of the patient hand
will determine the exact path of the finger tips as the hand opens and closes. For these
reasons only two actuated finger joints were designed into the robot. The MCP is actuated
to separate it from the PIP and DIP for movements such as hook grasp and flat hand
grasp. The DIP and PIP are actuated together for actions such as a composite fist. This
convention reduces the clutter on the back of the hand, simplifies the power transmission
and leaves more room for anthropomorphic variability.
The thumb however has all its joints actuated since it plays a vital part in almost
all functional tasks.
Therefore, as mentioned earlier, the CMC is actuated in flex-
ion/extension as well as abduction/adduction, while the MP and IP joints are actuated
only in flexion/extension.
The total number of DOF in the robot is eight: two for the middle, ring, little finger
group, two for the index finger and four for the thumb.
48
Finger MCP
450 extension
900 flexion
Finger PIP
00 extension
110' flexion
Thumb CMC
200 abduction
450 adduction
Thumb CMC
200 extension
600 flexion
Thumb MP
100 extension
600 flexion
Thumb IP
200 extension
900 flexion
Table 4.1: Individual Joint ROM
4.2
Ranges of Motion (ROM)
In addition to determining which joints needed to be actuated, it was necessary to determine their ranges of motion. Most stroke patients will not have full mobility in their hands,
especially at the start of therapy, but it was deemed important for the robot to be able
to span the entire range. Based on clinical research and measurements (see Chapter 3),
the ranges of motion shown in Table 4.1 were chosen as functional requirements.
4.3
Patient Interaction
The most important functional requirements of the robot center on how the patient and
the robot interact.
Many of the patients the robot will interact with are elderly and
have never used a computer, let alone a robot, before. To that end, these general patient
interaction requirements were made: safety, comfort, ease of use and aesthetics.
4.3.1
Safety
Since we are dealing with human subjects, keeping the robot safe is our paramount concern. This includes not applying excessive force, including software and hardware stops
if necessary and avoiding shapes and mechanisms which could pinch or otherwise injure
the patient. Also included in this is the ability to back-drive the robot. The patient or
49
the therapist should be able to do this when the robot is not powered for both therapy
and safety reasons.
4.3.2
Comfort
Early in the design process, it was obvious that the robot would have to have direct
physical contact with the patient. This contact is in the form of a simplified exoskeletal
frame which applies force to the patient's hand to move his or her fingers and thumb.
It is very important that neither this force nor the connection where it is applied is
uncomfortable.
Some possible methods of accomplishing this are using flexible, ergonomic connections
to the patient, incorporating padding into the robot structure and limiting the pressure
applied to the patient. The actual implementation of these designs is described in Chapter 5.
Adjustability is another aspect of comfort. The robot, either as a single model or several sizes, needs to accommodate almost any size patient. As mentioned in section 2.1.3,
patients can have severe swelling in their hands. This needs to not affect the comfort or
functionality of the robot.
4.3.3
Ease of Use
Another important requirement is the robot's ease of use. In this case ease of use refers to
the therapist's ability to get the patient in and out of the robot in a short amount of time.
Therapy time is very limited (about 1 hour) for our patients so it is highly undesirable to
have it take 15 minutes to get a patient in and out of the robot.
4.3.4
Aesthetics
As mentioned earlier, the robot is a foreign object to many of our subjects. Some patients
even named our previous robot in order to make it seem less scary and strange. It is
50
therefore important for the robot to seem non-threatening. Especially since the robot will
be surrounding and touching the patient's hand, we want them to feel comfortable with
it. Some possible ways of achieving this feeling is using small, streamlined parts, using
plastics and colors instead of metallics and keeping the overall machine simple.
4.4
Summary of Functional Requirements
Below is a summarized list of the robot functional requirements just discussed.
1. Must be adjustable (ideally 5th percentile woman to 95th percentile man). Must
be adjustable enough to deal with edema in the patient's hand.
2. Must be easy to put on and take off the patient (less than 2 minutes each way)
3. Must be back-drivable by patient
4. Must not cause pain or injury to the patient
5. Must actuate the fingers and thumb with the DOF and ROM discussed above
6. Must be compact and aesthetically pleasing to the patient
7. Must have accurate measurement and control of the actuated joints
51
Chapter 5
Design
This chapter describes the design choices that were made, including the actuators, transmission, sensors and general hardware. There were several choices for almost all of the
design components. These choices are discussed briefly, then the chosen component is
described in detail. Also included are some of the basic design equations and criteria that
were used. For complete equations see Appendix B.
5.1
General Design
The general design for the robot consists of a main cradle piece in which the patient's wrist
is held. Attached to this piece are several cantilevered pieces that reach out over the hand
to transmit force to the fingers or thumb. This configuration allows the robot to move
the patient's digits without significant exoskeletal connections. The main advantages of
this design are that the robot is not bulky or intimidating and is easier to get on and off
the patient. See Figure 5-1 for a top view of the device.
The human hand is very complex kinematically; if the joint movements are not
matched to a good degree by the robot, (1) the robot will not accomplish the necessary therapeutic movements and (2) the robot will hurt the patient. Neither of these are
acceptable.
52
Figure 5-1: General Top View of Robot
53
Therefore, the axes of rotation in the joints of the robot need to be aligned with the
axes of rotation in the hand. The above design allows the axes of the finger and thumb
joints to be aligned closely with the corresponding joints in the hand. The MCP, CMC,
MP and IP joints on the robot can line up directly with the corresponding joints on the
patient. Since the PIP and DIP joints are combined on the robot, they can be closely
aligned with the patient's PIP joint while the force is transmitted distally, moving both
the PIP and DIP joints.
This design utilizes a cable drive transmission system to actuate the rotation out near
the fingers with low endpoint inertia. A direct drive system would require having motors
directly mounted at the joints and would be heavy and cumbersome.
5.2
Design Parameters
Most of the design parameters that the design needs to fulfill were discussed in Chapter 4.
However, there are a few more that should be mentioned before the design details are
discussed.
5.2.1
Forces
Using a variety of information from published research, personal experimentation and
specifications of other devices, it was possible to choose what forces the robot should be
able to provide to the patient. The forces listed in Table 5.1 are maximum forces. They
would allow the patient to accomplish almost any functional task and could counteract
the tone and spasticity commonly found in stroke patients. These force values are not
necessarily maximum values for a normal person, since there is a concern that such high
forces might injure the patient. In addition, most of the time the force provided will be
lower than the listed values.
Once the transmission and other subsystems were designed, these forces were converted to necessary torques so that the motor specifications could be determined (see
54
Joint
Max Force
Fingers MCP
50 N
Fingers PIP
25 N
Index MCP
30 N
Index PIP
15 N
Thumb CMC
45 N
Thumb MP
30 N
Thumb IP
30 N
Table 5.1: Chosen Design Forces
Section 5.5.3).
5.3
Mechanism of Rotation
The first design decision that needed to be made was just how to rotate the joints of the
robot. The rotations needed to be aligned with the patient's hand as mentioned above.
They also needed to provide the desired ranges of motion. There were three main options
for the axial rotation, each with a different amount of precision and kinematic constraint.
5.3.1
Options
A pin joint has a very specific axis of rotation, though as a result it is very confining
kinematically. Adding a slider to a pin joint allows the axes of rotation to traverse along
a specified direction as external forces act on the axis, giving it a degree of freedom the
simple pin joint does not have. Finally, a flexure joint bends at an axis anywhere along a
specified plane.
55
Pin Johnt
Figure 5-2: A Simple Pin Joint
Pin Joints
is conA pin joint, also known as a revolute joint, is where the rotation of two bodies
strained to move only around one axis. Figure 5-2 shows an example.
As shown in Section 6.1, pin joints were used in the first prototype of the robot design.
fingers if
These did allow for the desired range of rotation and aligned with the axes of the
the patient was the correct size. The problem with the pin joints was that if the patient's
not line
digit lengths were different than those prescribed for the robot, the joints would
at
up and moving the patient was uncomfortable. Also, pin joints keep the axes of rotation
a fixed distance to one another. Since the PIP and DIP joints are combined in this design,
the second fingers axis of rotation actually moves relative to the first during movements
such as composite flexion (see Figure 5-3).
Pin and Slider
(see
Adding a slider to the pin joint allows the joint to move along a line as it rotates
and the
Figure 5-4). This can be used to add adjustability to the location of the joints
a slider
distance between them. However, it also adds complexity to the design. Having
at every pin joint would make the robot quite bulky and would be difficult to implement
well.
56
M'CP
DIP
PIP
Figure 5-3: Schematic of Composite Flexion
Figure 5-4: A Pin and Slider Joint
57
-
--
- -
i--
-
--
--
I----
--
--
-
-
--
-
-
-
Figure 5-5: Example of a Clamped Flexure [38]
Flexure Joints
The final option for rotating the joints is to use a flexure joint. In this case, a clamped
flexure provides stiffness in two of the three translational directions. In the third direction
bending can happen and therefore there is rotation about an axis across the flexure and
perpendicular to the bending. See Figure 5-5 for an example.
The main advantage of a flexure joint is that it can bend anywhere along its length,
providing adjustability in the location of the axis of rotation. Therefore, when placed
next to the patient's finger, the kinematics of the finger will determine the kinematics of
the robot joint. This prevents patient discomfort or mechanical damage due to misaligned
axes of rotation. Also, the flexure is very simple to design and implement. There are no
bearings or moving parts to cause friction. If the flexure should fail, the clamps simply
have to be removed and a new flexure put in place.
Another advantage of the flexures is that they allow use of a differential transmission
system. The specifics of the transmission choice will be described below. The basic idea,
however, is that by pushing or pulling on the top or bottom of the clamp section, rotation
of the flexure can be achieved. This allows for rotation in both directions with only a
58
Clockwise Rotation
F
Counter-Clockwise Rotation
Figure 5-6: Forces and Resulting Rotations on Generic Flexure
force on the clamp as shown in Figure 5-6.
5.3.2
Flexure Details
Proof of Concept
to
A simple flexure prototype, shown in Figure 5-7, was constructed using 0.030" Teflon
that
prove the concept of using flexures to provide joint rotation. This mock-up proved
rotation of the flexure could be achieved by holding one clamp stationary and pushing
or pulling above the flexure on the second clamp. It also showed that the Teflon had
some shape memory, and the flexure did not always return all the way back to its original
position. This particular flexure had little torsional stiffness although the bending stiffness
in the non-desired directions was good.
This original type of flexure was incorporated into the second prototype of the robot
out of 0.030" thick Delrin to
(see Section 6.2). In this version, the flexures were made
the
try and eliminate the shape memory of the Teflon. The Delrin did do this, however
formulation of Delrin used was found to be rather brittle and not as easy to bend as the
Teflon.
In order to increase the torsional stiffness of the flexure, a "beaded" flexure was manthin
ufactured (see Figure 5-8). This flexure had alternating thick and thin sections. The
59
Figure 5-7: Proof of Flexure Concept
thick regions provide torsional
sections allowed for bending at several locations, while the
stiffness.
the original prototypes.
The beaded flexure was significantly stiffer in torsion than
final design, it was deterHowever it was also more difficult to bend. Therefore, for the
mined that the thin section would be made thinner to allow for easier bending. Also,
of bend between the
the thick section would be made thinner to allow for more angle
individual thick sections.
are discussed
The calculations used to determine the material and various stiffnesses
below.
Bending
various equations are
The stiffness of a normal flexure is direction dependent, and the
is the bending direction
given below. The x direction is in compression, the y direction
and the z direction is the sideways direction (see Figure 5-5).
K =
wtE
21
60
(5.1)
Figure 5-8: Beaded Flexure
2EIzz
=v 12[ZI + L] + 21t 2(1+v)
2EIyy
2
+ L] +
21W2(1+v)
(5.2)
(5.3)
where w is the width of the flexure, t is the thickness of the flexure, 1 is the length
of the flexure, L is the length of the clamp, v is the Poisson's ratio and E is the Young's
modulus of the flexure and
Izz
=
Wt 3
tw3
-Iy =
12
(5.4)
(5.5)
The beaded flexure in Figure 5-8 can be likened to s series of clamps and flexures as
in Figure 5-5, where 1 is the length of the thin section and L is the length of the thick
section.
61
Torsion
In general, the torsional stiffness of a beam is given by
K =
GIp
L
(5.6)
where G is the shear modulus of the material,
4p is the
polar moment of inertia of the
beam cross-section and L is the length of the beam [20]. The compliance is given by the
reciprocal, or
C
1
K1
L
L
KiGIP
(5.7)
In the case of a beam of multiple cross-sections, the torsional stiffness is given by [20].
1
L
- =E G
(58)
(5.8
In the case of the beaded flexure, Kt for each section was computed and then the
above equation was used to obtain Kt for the total beam.
Buckling
Another strength concern was the buckling of the flexure. In the case of a cable or belt
drive, often the drive element is pre-tensioned to avoid slippage. This pre-tension would
put a resulting force on the flexure, possibly causing it to buckle. Modeling the flexure as
a column clamped at both ends, the maximum force the flexure can take without buckling,
Pcit, is given by
7r 2 EI
Pcrit =
2
(5.9)
eff
Leff = 0.5L
(5.10)
where I is the moment of inertia, L is the length of the beam and E is the Young's
modulus . In the case of the finger flexure the buckling force is about 33 N and for the
62
thumb flexure it is approximately 22 N. Therefore, although a pre-tensioned system could
be used, the tension, T, would have to be relatively low.
Pcrit
(5.11)
2
2
One alternative in such a system is to rigidly connect the drive element to the pulley
and then eliminate any slack so that any rotation of the pulley moves the drive element
but the system is not in significant tension when in its neutral position.
Material and Fatigue
Although many plastics will allow for the bending required by the flexure, there are few
that will not fatigue rapidly. Nylon is a common material used for living hinges and
similar applications. In bending, the stress at the extreme fiber of the material, is given
by
o- = -Et
(5.12)
2R
where t is the thickness of the flexure or hinge, R is the radius to which it is being
bent and E is the Young's modulus [3]. In the case of a 900 bend,
R
-
7r
(5.13)
where L is the length of the flexure.
Chosen Dimensions
Using the above equations in a spreadsheet format (see Appendix B) it was possible to
optimize the flexure dimensions to obtain a low bending stiffness in the desired direction
and a high torsional stiffness.
The elastic bending stress which results is 5176.49 psi. The yield strength of the Nylon
6/6 used is 12,400 psi so the material is not at the risk of yield. Fatigue data predicts
that the flexure will have a life of approximately 10,000 cycles [42].
63
Clamping
The clamping of the flexure is pretty straightforward. There is a top and bottom section
to each clamp. A bolt between the halves and through the flexure squeezes the clamp
down on the flexure, preventing movement. The constraint in this design was the size of
the clamp.
The bottom half clamp needed to have enough room for the transmission system but
if it was too high, the rotation of the joint in flexion would be limited. The equation
7rh = L
(5.14)
360
gives the maximum height of the clamp h given the angle of rotation
e
in degrees and
the length of the flexure L.
For extension the height constraint was on the top half of the clamp. However, since
for most joints extension is less than flexion, it was less of a concern. The index finger
pieces were an exception since they needed to be tall enough to clear all the other fingers
when only the index finger was actuated in flexion.
In order to decrease the height,
thereby allowing more extension and reducing the inertia of the hardware, the piece was
angled back at 45 degrees. This angle was chosen because it is very difficult to rotate the
MCP joint of the index finger more than 45 degrees without moving the other fingers.
5.3.3
Slider Details
Although the flexures allow for most of the joint rotations needed for the robot, abduction/adduction of the thumb CMC joint can not easily be accomplished by this mechanism. As mentioned earlier (Section 3.1.2), the CMC has two degrees of freedom: flexion/extension and abduction/adduction. Although the two axes of rotation are not coincident, they are close, and it would be difficult to put two flexures in the same space.
Also, abduction/adduction is a rotation about an axis almost in the middle of the hand,
which is not accessible. Therefore, in order to accomplish the second degree of freedom,
64
2==
Axes on
Figure 5-9: Location of CMC Abduction/Adduction and Flexion/Extension
Robot
a slider mechanism was devised.
around
In this mechanism, the first clamp of the CMC flexion/extension flexure rotates
axes of
the axis of the wrist along a curved linear guide. Figure 5-9 shows the resulting
chosen over a
rotation for the CMC. Due to the size constraints, a sliding bearing was
stiffness (see
roller design. The bearing has a back-to-back configuration to obtain higher
the slider in
Figure 5-10). The geometry, shown in Figure 5-11, is designed to constrain
of the bearing
all necessary directions while keeping contact forces low. Also, the length
is more than twice the width of the bearing in order to prevent jamming.
65
Face to Face
Back4oF-Back
Figure 5-10: Effective Width for Resistance to Moments for Back-to-Back and Face-toFace Configurations [38]
Figure 5-11: Slider Cross-Section
66
Materials
The materials chosen for the sliding bearing were 303 Stainless steel for the external
"rails" and Delrin for the internal carriage. The coefficient of friction of Delrin on steel is
0.20 for static friction and 0.35 for dynamic friction [9]. The rails mount to the aluminum
wrist cradle, while the carriage mounts to the aluminum clamp for the CMC flexure.
This design allows the hardware to stay relatively lightweight while addressing tribology
concerns about the bearing surface materials. Also, the modularity allows individual
elements to be replaced relatively cheaply if necessary.
5.4
Transmission
As mentioned earlier, in order to prevent the robot from being very bulky, a transmission system was deemed necessary early on in the design. There are several methods of
transmitting power, however, and this was the most thought-provoking design decision.
5.4.1
Options
The decision to use flexures constrained the transmission either (1) to push and pull at one
point above the flexure or (2) to push/pull above and below the flexure alternatively. The
options that were considered included using push/pull rods, integrating a type of hydraulic
actuator (spring return, bellows or rolling diaphragm actuator) or implementing a drive
system (belt, tape or cable).
Push/Pull Rods
One of the stiffest methods of transmitting force is to use push or pull rods. These rods
are usually attached to a rotary or linear actuator at one end and to a lever arm on the
other (see Figure 5-12).
The major disadvantages of this design are that it is bulky and complex. Also, it
is difficult to have the actuator movement match the movement of the other end of the
67
Pushrod
Force
Figure 5-12: Example of a Push Rod Causing Rotation
rod. The mechanism must be carefully constrained to provide the correct magnitude and
direction of forces.
Hydraulic Bellows
The first option for hydraulic actuation was the use of bellows. In this design, a bellows
is located above and below the flexure. Remote from the robot, at the originating end of
the hydraulic line, are two more bellows. When one of these remote bellows is compressed
by a linear actuator or similar device, the displaced fluid travels through the line and the
same volume is displaced in the second bellows next to the flexure, as shown in Figure 513. This displacement provides a pushing force on the clamp, bending the flexure and
rotating the joint. The rotation of the joint compresses the bellows on the other side
of the flexure (see Figure 5-14). The resulting displaced fluid travels backwards through
the second hydraulic line, extending the remote bellows on that line and back-driving the
actuator attached to that bellows.
One of the major advantages of this design is that there is no significant mechanical
friction; the fluid speeds are low enough to not result in significant losses. Also, like all
the hydraulic options, large forces can be transmitted in small cross-sectional area tubes.
Finally since the bellows can compress to very small lengths they can fit between the two
68
ActMaOr Bellows
Jc'rnt 1Belkwvs
Figure 5-13: Double Bellows for Transmission of Force
Hykraidic_________________
Lines
Belon's
Figure 5-14: Flexure Rotation Using Hydraulic Bellows
flexure clamps even with a large angle of rotation (and therefore a small space between
the two interior clamp edges).
This design does have some disadvantages however.
First, there is compliance in
the fluid and the bellows which can have a destabilizing effect on the system dynamics.
More importantly, the system is slow overall. The transmission of force from the remote
actuator to the clamp is only as fast as the fluid transmission speed. Finally, the major
concern was constraining the bellows such that (1) it only expands in the longitudinal
direction and (2) it does not "squirm".
The first concern, that of limiting the direction of the bellows displacement, can be
solved relatively easily. Having convolutions in the bellows encourages it to expand longitudinally more than radially. The second problem is more difficult to get around. Squirm
is the case where the pressure inside the bellows causes a sort of buckling and the bellows takes on a "S" shape. Although the bellows may be physically able to take a large
69
Cyhtrer Wall
RolI[ Diaphir~qm,
Figure 5-15: Rolling Diaphragm Actuator Technology, adapted from [7]
pressure without expanding radially and/or failing, squirm can happen at relatively low
pressures.
Using data from a miniature bellows manufacturer (Miniflex Corporation), a stainless
steel bellows of the desired size has a squirm pressure of only 330psi. A plastic or rubber
bellows, which would be necessary to get sufficient compression during bending, would
have an even lower squirm pressure. The pressure necessary to provide the specified
force would almost definitely be higher than the squirm pressure. Therefore, other linear
hydraulic actuators were researched.
Hydraulic Rolling Diaphragms Actuators
Linear hydraulic actuators as a whole have several disadvantages. First of all, position
control is non-trivial. They are usually on or off. Secondly, they have a tendency to leak.
Lastly, friction is generally high since the piston seal rubs on the wall of the cylinder.
Rolling diaphragm actuators (RDA) resolve this last problem. In RDA's, the piston
seal is replaced by a flexible diaphragm. This diaphragm is rigidly attached to both the
piston and the cylinder and moves with the piston, rolling along the wall, practically
eliminating friction (see Figure 5-15).
70
In order to replace the bellows with RDA's, the actuators would have to be attached
to the flexure clamps with pin joints in order for them to rotate with the flexure. However,
since the actuators have a significant length even when compressed, there is not room for
an actuator above and below the flexure.
Spring Return
A method of getting around the space constraint is to eliminate one of the actuators. The
spring return actuator is a way to do this and is the simplest of the hydraulic actuator
systems considered.
In this design scheme, a hydraulic actuator pushes the second clamp of the flexure
in order to provide one direction of rotation. This push is against a spring force that
returns the flexure to a pre-determined position when the hydraulic force is released. If
the actuated rotation is flexion (clockwise in Figure 5-6), the actuator can be above the
flexure. Extension is a smaller range of motion; therefore, the clamp edges are not all the
way together and there is space for the compressed actuator . The fact that only one of
the directions of rotation is actuated is a major disadvantage of the design.
Eventually, it was determined that none of the hydraulic actuation schemes were really
feasible without great complexity and many custom-made parts. Therefore other, more
conventional, methods of transmission were considered.
Belt Drive
One of the oldest transmission systems is that of using belts to transmit torque. The
belt is wrapped around a drive pulley at one end, which is connected to a rotary motor,
and is attached to another driven pulley at the other end. There are several incarnations
of the belt drive including v-belts, timing belts, metal tapes and timing chains. The
advantage of the system is that it allows torque to be transmitted over long distances
between otherwise decoupled shafts.
One disadvantage is that there is usually compliance in the belt which can cause a loss
71
of efficiency or create unexpected natural frequencies in the system. Also, as mentioned
earlier, most belt drives need to be pre-tensioned to allow the torque to be transmitted.
Finally, the main disadvantage in the case of a betl drive is that the path from the drive
pulley to the driven pulley needs to be straight and unobstructed.
Cable Drive
Although cables can be used in push/pull systems such as in bicycle brake lines, they are
most often used in rotary systems. Such a system is similar to a belt drive, but wire rope
or cable is used as the driven element. The main advantage of the cable over the belt is
that a cable can be routed through and around obstacles. The more interfaces the cable
has with its surroundings, the greater the friction in the system. Even with this friction,
however, the cable can still transmit force. Like the belt drive, the cable drive has an
inherent compliance which can be detrimental to the system dynamics. In the case of this
design, that worry is outweighed by the advantage of being able to transmit force through
a complicated path. Wire rope is extremely strong for its size, so the cable drive can be
very compact.
In the robot design the cable is rigidly connected to the drive pulley to avoid having
to highly pre-tension the system. The cable end passes into the drive pulley where it is
secured using a stop. The distance to the stop can be adjusted using a screw, thereby
allowing slack in the system to be eliminated. The cable also must be mounted carefully
to avoid unwinding during load.
As the drive pulley rotates, the cable pulls either above or below the flexure, depending
on the direction of rotation. This rotation also provides slack to the opposite side of the
flexure. Thus the flexure bends and the torque from the motor is transmitted out to the
patient's finger (see Figure 5-16). Each clamp has two cables above and two cables below
the flexure so that the tension force is even and twist of the flexure does not occur.
72
Ist Clamp
Clamp
2nd
2nd Clamp
Flexure
r tion of
d
Hardware
Rotation
Direction of
Drive Pulley
Rotation
Cable
Direction of
Resulting Force
on Flexure Clamp
Figure 5-16: Schematic of the Cable Drive Transmission
5.4.2
Cable Drive Details
Material and Strength
One of the big advantages to using a cable drive is that a lot of force can be transmitted
by a small cable. For that reason a stainless steel cable was desired. A 7x19 construction
was chosen to maximize the cross-sectional area of the cable for a given diameter. In this
construction, seven wires of 19 strands each are wound to create the cable.
The 1050SN cable from Sava Industries has a minimum breaking strength of 270 lbf
which is greater than four times the expected force on the cable at maximum torque. This
safety factor is consistent with cable use in industry [23]. Stress strain curve data from
the manufacturer gives a measured Young's modulus equal to 5.537e6 psi.
Even though in tension the cable is more than strong enough, there is also the concern
of the stress on the cable as it passes over the pulley and the edges of the housing holes.
When the flexure joint is fully bent, the cable will be pressed up against the edge of the exit
hole with significant force over a small area. Therefore all holes through which the cable
passes have funneled openings to increase the area over which the force is distributed.
General pulley design information recommends that to maximize life for a 7x19 construction, the pulley diameter should be greater than 16 times and ideally should be 25
73
LOW-STRETCH vs STANDARD MINIATURE STEEL CABLE
LU
Standard Cable
I
7J~
D 0
-_07
kLr,4
..
~~
2
Low-Stretch Cable
.....
Low...
A
Is
14
A
16
1.
20.
MWLOUS OF CYCLES
Figure 5-17: Cable Stretch Data from Sava Industries
times the uncoated cable diameter. For the chosen cable the uncoated diameter is 0.048",
giving a minimum pulley diameter of 0.768" and an ideal pulley diameter of 1.2". Due
to size constraints on the motor boxes, four of the eight drive pulleys are 0.875" in diameter. The rest are 1.125" in diameter. The pulley diameter also affects the effective
strength of the cable. The ratio of the pulley diameter to the cable diameter determines
the percentage of catalog strength the cable will have. For the small pulleys this ratio
is 18.23, giving an effective strength of 90% the catalog strength, or 243 lbf. The large
pulleys have a ratio of 23.44, resulting in an effective strength of 91.5%, or 247 lbf [36].
Both values are acceptable for this design. All of the fittings for the cable are also rated
to at least 200 lbf in tension.
Stretch
As mentioned above, one of the biggest problems with a cable drive system is the compliance in the cable. For that reason, a low stretch cable from Sava Industries was chosen.
Figure 5-17 shows the difference between the low stretch cable and a normal miniature
steel cable.
74
Routing
Another problem inherent to the cable drive system designed is friction. Since the robot
is serially actuated, the cable for the PIP joint must pass through the MCP joint and the
base before reaching its end connection. Thus, the further out the joint is on the robot,
the more obstructions the cable has to pass through and the higher the friction. For
this reason, although the necessary actuation force is lower at the outer joints since less
inertia is being moved, the additional friction may eliminate this advantage. The chosen
motors can provide more than the required torque for all joints in case there is additional
or unexpected friction.
Other design choices were also made in an attempt to reduce friction. Choosing a
nylon coated cable running through aluminum housings provides a good bearing surface
for the cable. Also, the housing holes are a little oversized to allow some freedom of
movement for the cable, while still providing support for the cable. Finally, as mentioned
above, the edges of the holes are countersunk. This not only reduces the stress on the
cable but also the friction since the normal force is reduced.
The other significant problem with routing for the cable was that when the flexure
bends in flexion, the top cable will have to extend more than the bottom cable is pulled
back. To eliminate this the cables are crossed from top to bottom in the middle of the
joint. This causes the deflection of both cables to be the same. However it presents a
new problem since there is a flexure between the two cables. Either the flexure needed
to be made narrower, with the cables passing on either side, or slots had to be cut in the
flexure to allow the cables to pass.
Using Pro/Mechanica's finite element analysis (FEA) ability, it was possible to determine the difference in bending and torsional strength between the two designs. Figures 518 and 5-19 show the resulting stresses and deflections for the bending case. The slotted
flexure was stronger than the narrow flexure in both bending and torsion. Since there is a
concern that the weight of the hardware might bend the flexures if they are too weak and
torsional stiffness is vital, the slotted flexure design was used. The slots were rounded at
75
each end to avoid stress concentrations present at corners.
5.5
Actuation
The method of actuation for the robot is highly dependent on the method of transmission, but since several transmission systems were considered, so were several methods of
actuation. With the cable drive system either a linear actuator or a rotary actuator could
be used. The linear actuator would pull directly on the cable and thus on the flexure.
Conversely, the rotary actuator rotates the drive pulley, thus pulling on the flexure. The
main constraints were the amount of displacement that was necessary in the cable and the
force that needed to be provided. Actuation also needed to be back-drivable in accordance
with the functional requirements of the robot.
5.5.1
Linear Options
Linear actuators are becoming more prevalent in machine design, and there are several
technologies that can now provide accurate linear positioning. The options considered
were piezoelectric actuators, DC linear motors, solenoids, moving magnet actuators and
rotary to linear systems such as a rack and pinion or lead screw and stepper motor.
Piezoelectric Actuators
The biggest drawback to piezoelectric actuators is their limited stroke length. Cedrat
Recherche has overcome that problem by manufacturing amplified piezoelectric actuators
(see Figure 5-20). In these actuators a specially designed external cage amplifies the motion of the piezo to obtain strokes up to 500pm. When the hydraulic bellows transmission
was being considered this would have been sufficient, however with the cable drive it is
not. The actuators can be stacked serially to provide greater displacements but this is
very cost prohibitive.
76
Figure 5-18: Stress and Deflection of Narrow Flexure
77
Figure 5-19: Stress and Deflection of Slotted Flexure
Figure 5-20: An Amplified Piezo Actuator (Cedrat Recherche)
78
DC Linear Motors
A more standard linear technology is the DC linear motor. Similar to a rotary motor, an
iron core moves in relation to an electromagnetic field. In the case of a linear motor, the
core is the carriage and the electromagnetic field is created in the track. The positioning
can be very accurate when used with a linear encoder. DC linear motors come in a wide
range of strokes and forces. However, the relative size of the motor to the stroke length
is high. Therefore it was determined that linear motors would be too bulky for a design
focused on being small and unobtrusive.
Solenoids
Another long-standing linear technology is the solenoid. Like the piezoelectric actuator,
solenoids are limited in stroke. They also do not provide a constant force along their
stroke. The push/pull force is proportional to how much of the core is inside the housing.
For these reasons, solenoids were not desirable for this design.
Moving Magnet Actuators
With a moving magnet actuator, a permanent magnet is fixed to the center yoke and
the stator contains an electromagnet. The yoke moves up and down inside the stator
as it is energized (see Figure 5-21). The advantages of the moving magnet actuator are
that the force is constant regardless of position and is proportional to the input current.
Unfortunately, the strokes and forces are too small for this application.
Rotary to Linear Actuators
Finally, using a rotary to linear conversion was considered. Two options were a rack and
pinion or a miniature lead screw on a stepper motor. Both systems can provide significant
stroke lengths in a small package. With the stepper motor system, force is a concern since
most small stepper motors do not have high torque. Unfortunately, both systems have a
good deal of backlash which was undesirable.
79
Figure 5-21: A Moving Magnet Actuator (Moving Magnet Technologies)
80
5.5.2
Rotary Options
Using the cable drive transmission system encouraged the use of rotary acutators. Once
the limitations of the linear actuation options were determined, rotary options became
even more important.
Two main rotary options were considered:
solenoids and DC
motors.
Solenoids
The rotary solenoids have similar concerns as the linear ones. Rotation is fixed, and
usually limited. It is possible to get solenoids with various positions or stops but usually
there are only two or three. This would limit the number of joint angles the robot could
achieve. Therefore the idea of using a rotary solenoid was discarded.
DC Motors
Inside the category of DC rotary motors, there is the further breakdown of brushed versus
brushless motors. Both can provide large torques in a relatively small package. Also, since
the technology is very established, there are many feedback devices which can be used to
provide precise position control. With brush motors, the largest concern is the friction of
the brushes. The decision was made to use a Kollmorgen brushless motor.
5.5.3
Rotary DC Motor Design
Requirements
As mentioned earier, the transmission system and required forces had both already been
chosen. Therefore, in order to determine the motor requirements, the necessary forces
needed to be converted into necessary torques. These calculations can be found in Appendix B. The resulting required torques are shown in Table 5.2.
Since the torques are all in the same range, it was desirable to find one motor that
could be used for all joints. This would not only standardize the mounting hardware but
81
Joint
Torque (in-lbs)
Torque (N-m)
Fingers MCP
20.686
2.337
Fingers PIP
27.196
3.071
Index MCP
15.666
1.770
Index PIP
20.742
2.343
Thumb CMC Flex/Ext
27.341
3.089
Thumb CMC Ab/Ad
26.051
2.943
Thumb MP
27.267
3.081
Thumb IP
27.267
3.081
Table 5.2: Necessary Motor Torques
would also keep the actuator characteristics consistent across the system. In practical
terms, such a specialized motor is not usually a high volume item; ordering several can
decrease the price and/or the lead time.
The other main requirement for the motor was that it be small in size.
Using a
transmission system allows the motors to be set away from the endpoints but they still
need to be relatively close in order to avoid cable dynamics. Therefore compactness was
a key issue.
Gear Ratio
As Table 5.2 shows, the torques the motors needed to provide were significant. Therefore
a gear ratio was necessary to reduce motor size. Using a gear ratio necessarily decreases
the back-drivability of the system. However, it was determined that using a ratio of 10:1
was a good compromise between necessary torque and back-drivability.
Adding a standard gearbox to the chosen motor generally increases the size of the
package significantly. Therefore a single gear reduction was designed such that the small
drive gear mounted on the motor shaft and the large gear mounted directly to the cable
drive pulley. Hardened spur gears were used for the sake of simplicity and robustness.
82
Figure 5-22: The RBE motor from Kollmorgen
The result was that the motor needed to provide 0.31 Nm of torque for the maximum
provided force.
Specifications
The motor chosen was the frameless brushless Kollmorgen RBE DC motor model number
1213 (see Figure 5-22). A frameless motor allowed for close integration between the motor
and the housing and therefore a smaller package size. The RBE 1213 provides a continuous
torque of 0.387 Nm. Slanted windings were specified to reduce cogging. Also, although
the motor comes with Hall effect sensors, it was specified to interface with an encoder for
more precise position control. See Appendix C for specifications.
Kollmorgen also makes servoamplifiers to interface with its RBE motors. The Servostar CD servoamplifier includes a integrated power supply and can directly interface
with the encoder output from the motor. The 6 Amp model was chosen since at the
maximum force the motor may draw up to 5 Amps of current. Details can be found in
Appendix C.
83
Housing and Shaft Design
Kollmorgen provides a design guide for working with their frameless motors (see Figure 523). From this, the housings for the motor box were designed. The motors sit in a stepped
housing and are held in place by a mounting ring. Manufacturing the housings out of
aluminum allows them to act as heat sinks for the motors, thus lowering motor and box
temperatures.
Since the motors are frameless they come without a shaft. The shaft design was also
specified by Kollmorgen and was modified to allow the attachment of the drive gear using
a pin hub. The torsional shear,
Tmax,
on the shaft can be calculated from
(5.15)
- Tmax
I,
where T is the torque applied to the shaft, r is the shaft radius and
4,
is the polar
moment of inertia. From this calculation, it was possible to make sure the maximum
stress on the shaft was less than the yield stress of the material. For the motor shaft
the shear stress is about 9,000 psi and for the pulley shaft it is about 11,250 psi. The
motor and pulley shafts were manufactured out of 303 Stainless steel which has a yield
strength of 34,810 psi. Therefore both shafts are well outside the range of material yield.
See Appendix D for full drawings of the housings and shafts.
5.6
Sensors
In order for the robot to be controlled and for patient data to be collected, various sensors
were necessary. In terms of the patient, the most important piece of information is the
angle of their joints. However, since this is not co-located with the motor, which is the
system input, this information is non-ideal for control. Ideally, the angle of rotation of
the motors, and therefore the drive pulleys, should also be measured. Finally, although it
is not currently implemented in this prototype design, it would be desirable to know the
force at the robot/human interface.
84
AiM040iii
s&A
/
ww
/
Figure 5-23: Frameless Motor Mounting from Kollmorgen
85
5.6.1
Joint Angle
Sensor Specifications
Finding a compact and simple way of measuring the joint angles was a challenge. Strain
gages have been used in similar applications but they are difficult to mount and calibrate.
Another option was the use of a fiberoptic device.
Measurand Inc. makes such a device. Their Miniature Shape Sensor (model number
S720) can be mounted along the side of a rotating joint and measures the angle through
which the joint travels (see Figure 5-24). A LED at the base of the sensor sends light
down the fiber. The light bounces off the end of the measuring region and back to a light
sensor. A decrease in light is proportional to the angle through which the sensor has bent
and is output as a voltage. It is necessary to rigidly mount the sensor to the joint on
both sides of the measuring region, equi-distant from the region. Putty is provided by
the manufacturer for this use. The fiber can be made to any length; the measuring region
is a constant distance from the end however. For the final prototype seven sensors were
ordered. Three had 12" long leads for the thumb joints and the other four had 20" leads
for the finger and index joints.
Testing and Calibration
Although the product information claims that the output voltage from the sensor is linear
with angular deflection, it was desirable to actually test a sensor and find out. For this
reason a test sensor of standard length was ordered and tested.
A simple jig was constructed to allow me to mount the sensor to a pin joint then rotate
the joint through various angles (see Figures 5-25 and 5-26). The output was then read
by a standard analog-to-digital (A/D) card and then analyzed. The sensor takes a 5 V
input power supply and outputs a signal between 0 and 5 V.
Seven tests were run with the sensor jig. Before the testing began, samples of the
output were taken at zero degrees; the gain and offset on the sensor were adjusted so
86
Figure 5-24: Miniature Shape Sensor by Measurand
Figure 5-25: Shape Sensor Testing Jig
87
Figure 5-26: Close-Up of Testing Jig
that the zero position gave a reading of 2.5V. The first test was very encouraging due to
the good linearity of the data. However, during the test the sensor came loose from the
putty used to attach it to the jig. The sensor was re-attached using tape and the test was
re-run. Linearity was similar but there was a significant offset from the first curve. After
this run the sensor seemed to be saturating (tests three and four). The gain and offset
were re-calibrated and tests five through seven were done. Between tests six and seven
a wait of several minutes and a power down were performed to see if the sensor stayed
consistent. The results of tests five through seven are shown in Figure 5-27.
As Figure 5-27 shows, the sensor output was fairly linear over the range of angles
tested. The linear fit line follows the expression:
V = 0.03099 + 2.3158
(5.16)
with a R 2 value of 0.98. It is interesting to note that the non-linearities are centered
around zero degrees. The section before zero is nicely linear. Then, after a small flat
section, the output is again linear. This is possibly due to the sensitivity of the light
sensor. When the angular deviation from zero is small, the difference in light the sensor
88
Wow
--
*(
(A
-
F
I
I
a a
BIN
a
ftO M
a
a
a
V
III
a
Figure 5-28: Hollow Shaft Encoder by Gurley Precision Instruments
receives is also small. Therefore, the light sensor may have difficulty resolving the change
in light and outputs a zero reading for a few degrees before returning to a linear output.
The most encouraging thing about this data was that although there are distinct nonlinearities in the output, they are consistent across the tests and therefore can be predicted
and compensation can be made.
5.6.2
Motor Angle of Rotation
A more established technology was used to determine the angle of motor rotation. An
optical incremental encoder from Gurley Precision Instruments provides an index pulse
and angular measurement (see Figure 5-28).
Sensor Specifications
Due to the 10:1 gear ratio, a 1 degree rotation of the motor shaft is equivalent to 0.1
degrees of rotation of the cable drive pulley. The rotation of the drive pulley is then
converted to the deflection of the cable, s, by the equation
s =
7r
180
&Orpsule
90
(5.17)
where
E
is the rotation and
rpuuey
is the radius of the drive pulley. From geometry,
it takes 0.009 inches of cable deflection to cause one degree of flexure joint rotation.
Therefore a single degree of rotation of the motor shaft gives 0.085 degrees of joint rotation
for the small drive pulley and 0.110 degrees for the large drive pulley.
The encoder resolution is also constrained by the servoamplifier. The maximum allowable frequency for the encoder input to the servoamplifier is 3 MHz. Therefore the
maximum angular velocity the servoamplifier can handle is given by
Wmax =
frequency
reouin(5.18)
resolution
and
resolution = 4(linecount)(interpolation)
(5.19)
The frequency used is 2 MHz to be safe, the line count is 1024 and the interpolation
is 5. Therefore, Wmax equals 97.65 rev/s at the motor or 9.765 rev/s at the drive pulley.
Assuming that the maximum frequency of human movement is 10 Hz over 2 cm, the
minimum jerk profile gives a maximum velocity of 0.752 m/s. The maximum radius of
rotation for the joint is equal to the length of the flexure plus half the width of the
hardware, or 1.18" (3 cm). This gives a maximum joint angular velocity of 25.07 rad/s
or 3.99 rev/s [29]. Therefore the servoamplifier will be able to easily handle any input
the human patient gives the robot. The resulting resolution on the motor angle is 0.018
degrees, which is more than adequate.
5.6.3
Force Sensing
Finally, as mentioned above, in later versions of this robot force sensing will be necessary.
This will most likely be in the form of a thin flexible force sensor which can be applied to
the finger interfaces of the robot. Forces between the robot and the patient could then be
measured. Steadlands International and Tekscan are two of the manufacturers that make
91
Figure 5-29: A Standard Flexible Force Sensor by Tekscan
such devices (see Figure 5-29). Since there are so many other aspects to this prototype
and the force sensors are not integral to the robot, it did not make sense to also add force
sensing until the system has been built and characterized.
5.7
Other Hardware
5.7.1
Motor Box
The motor boxes do just as the name suggests; they contain the motors. Their main
function is to locate and provide housings for the eight Kollmorgen motors. One box
contains the four motors for the fingers and index modules. Another contains the motors
for the thumb CMC flexion/extension and MP joint. The last box has the motors for the
thumb CMC abduction/adduction and the IP joint. Using the frameless motors allowed
the boxes to be relatively compact. Also, since they are mounted underneath the robot
they can be sunk into the therapy table and will not seem imposing to the patient. See
Appendix D for complete drawings.
Thermal
The other main concern with the motor boxes besides size was temperature. Safety is
the main concern in the design of the robot, and the risk of burn from the motor box is
92
something to be considered. The maximum contact temperature a human can withstand
for one minute is 60'C on uncoated metal and 85'C for plastic. For ten minutes, the
limits are 50'C for metal and 60'C for plastic [28]. Using data from Kollmorgen and heat
transfer theory the worst case temperature at the outer surface of the motor box, which is
constructed of aluminum with a plastic face over it, is 56.240. This is below the maximum
temperature for one minute of contact. Since the patient should never be in contact with
the boxes at all this was considered sufficient. This does not include the fact that all the
motor boxes have vents on the non-patient facing sides to provide more air circulation
and cooling.
5.7.2
Patient Interaction
How the robot interacts with the patient is just as important as the function of the robot.
If the robot is not comfortable, patients and therapists will not want to use it, regardless
of its potential benefits. There are two main areas where patient interaction occurs on
the robot. The first is the wrist cradle and arm support. The second is the actual finger
and thumb interfaces. The final concern regarding patient interaction is the adjustability
of the robot.
Wrist/Arm Support
The wrist cradle and arm support are not actuated but they play a crucial role in keeping
the patient comfortably in position during therapy. The arm rest at the back of the robot
simply acts as a support for the forearm of the patient. It is padded and somewhat curved
to provide a comfortable resting place. Straps could be added to immobilize the patient's
arm if desired. The wrist cradle has a 200 degree curve in which the patient's wrist can
rest. It also contains the base for the abduction/adduction slider.
The robot actuates the patient's hand in a sideways position. In order for the patient
to get in and out of this position, the therapist simply has to pull the finger hardware out
of the way and then angle the patient into the wrist cradle. Later versions may incorporate
93
a lock to keep the hardware out of the way during patient entry and exit. The thumb
module can simply be rotated down out of the way and then put up into position once
the patient is in place.
The current prototype has padding in the cradle but no restraints. In actual use many
patients will use a splint since extending the wrist to about 25 degrees improves the ability
to move the fingers [101. This splint can fit between the patient's wrist and the cradle.
However it is also important to have the option for passive motion of the wrist especially
during some functional tasks. In that case the patient would not have a splint, and the
wrist cradle would act as the only constraint. For both these cases it would be desirable
to have velcro straps across the cradle which could hold the patient's wrist in place with
varying rigidity. These are easy to implement and can simply be mounted to the wrist
cradle after manufacture.
Finger/Thumb Interfaces
The interfaces between the patient's digits and the robot are one of the most difficult
things to design. The digits must be restrained such that forces from the robot can be
transmitted to the patient without discomfort. Since every person is different, a generic
but comfortable shape was necessary. Also, the size of the interfaces had to be such that
the pressure on the patient's skin was not too high. A pressure of less than one psi is
recommended for short term splinting applications [4].
The final result for the fingers was a flexible plastic interface with a gentle ergonomic
curve. Mounting the interface on a pin through the hardware gives rotation to the interface, reducing overconstraint. The edges of the interface piece are curved and the whole
piece is padded to eliminate discomfort as the robot rotates and helps the patient's digit
rotate. Again, adjustable straps will be mounted to the interface to attach it to the patient. For the thumb, the pin mounted system was not feasible so ergonomic curves were
added to the cantilever pieces. The CMC flexion/extension hardware acts like a clamshell
shape gripping the patient's thenar prominence for motion. See Appendix D for drawings
94
of the pieces.
Adjustability
As mentioned in the Section 3.1.4, patients are many different sizes and shapes. Making
a robot that could adjust to all patients would add signifiacnt complexity to the robot.
So it was decided that the first prototype would be for an average-size patient, and that
once the robot design was characterized and critiqued, more sizes could eventually be
produced. The design is scalable, with the main adjustability being in the length of the
flexures but also in the length and height of the cantilever sections.
Finally, although the robot was designed for the left hand, it could easily be redesigned
for the right hand. For the finger and thumb hardware, it is simply a matter of drilling
the holes for the cable stops in the other side of the pieces. The motor boxes also do not
need to change. The only significant change would be that the wrist cradle would have
to be made with the features on the opposite side from where they currently are.
95
Chapter 6
Hardware
As the design of the robot progressed, various prototypes were made. They tested different
methods of attachment to the patient, force transmission and rotation. Especially when
dealing with ergonomic issues, nothing is better than being able to feel what the robot will
be like on the patient. Design flaws and advantages were immediately apparent without
the cost of time and money required for machining. Below is a discussion of the various
prototypes and what problems they helped make apparent and solve.
6.1
First Prototype
The first prototype was made very early in the design process using a ZCorp threedimensional printer. This printer uses a cornstarch based material which was then hardened using marine epoxy.
This prototype was the first test of putting the robot to the side of the hand and
using cantilevers to reach the fingers. It also tested the idea of attaching to the end of the
patient's fingers, much like many of the CPM devices (see Section 2.3.1). The prototype
used pin joints for rotation. Figure 6-1 shows the finger module of the first prototype.
The PIP actuation occurs at the end of the fingers (the actual mounting to the fingers
was not prototyped), while the MCP actuation is cantilevered out over the fingers. This
96
Figure 6-1: Finger Module of First Prototype
97
prototype proved that the end location for the PIP actuation got in the way of many
functional tasks. The MCP actuation worked well except that the index MCP could not
rotate very far without the fingers due to the low height of the cantilever. Also, this
prototype proved that unless the patient's joints matched up very well with the pin joints
of the robot, the mechanism was uncomfortable.
The thumb module is shown in Figure 6-2. Like the finger module it was designed
to attach to a pre-existing splint at the wrist. This module was a test of using a slider
around the wrist to provide thumb abduction/adduction. The principle was good but this
implementation of two pins in slots did not work well. Therefore the slider was redesigned.
The odd shapes of the thumb interfaces were an attempt to push on the thumb without
encumbering movement. Unlike the finger module, the thumb joints of the robot are above
the joints of the patient, rather than next to them. This method worked reasonably well
so it was used in the next prototype as well.
6.2
Second Prototype
The second prototype came later in the design process after several modifications and
improvements had been made to the design. It was used at a design review in the early Fall
of 2000 as a tool to discuss remaining redesign issues. This prototype was manufactured
using stereo-lithography technology, where a resin is hardened by a laser layer-by-layer to
create the part. The parts are somewhat brittle but are fairly robust and could be drilled
and sanded for assembly if necessary.
Figure 6-3 shows an overall view of the second prototype. This prototype implemented
flexure joints for all flexion/extension DOF, and the wrist cradle has become integral
with the finger and thumb modules. The height of the index finger cantilevers has been
increased to allow them to pass over the other fingers. This time the finger interfaces were
prototyped, and velcro straps were used to hold the interfaces to the fingers and thumb.
As in the first prototype, the thumb features are located on the outer side of the
98
Figure 6-2: Thumb Module of First Prototype
99
thumb knuckles. This prototype proved that aligning the axes of rotation (as in the finger
module) worked much better than locating them outward from the joints. This required
redesign of the thumb module such that the axes of rotation were next to the anatomical
ones, yet the hardware did not get in the way of functional tasks. The final prototype
implements this new design.
Figure 6-4 is a close-up of the finger module. The holes in the hardware above and
below the features were sized for a hydraulic transmission system (see Section 5.4.1). In
this view it is possible to see how high the cantilevers are. It was later decided that this
height could be reduced by angling the pieces. The finger interfaces with their ergonomic
shape can also be seen in this view. These pieces turned out to be very comfortable for
several people, except on the edges when the joints were at a large angle of rotation. Edge
rounds and padding were added to the design as a result. The finger flexures worked quite
well, providing a comfortable rotation of the finger joints without too much resistance. It
became obvious the torsional stiffness needed to be increased however by using a beaded
flexure.
Another view of the finger module from the side can be seen in Figure 6-5. This view
shows that the hardware was heavy for the flexure design used, causing sag in the neutral
position. Using the beaded flexure design should eliminate this problem.
Finally, Figure 6-6 shows a close-up of the thumb slider for the second prototype.
A T-slot was used and worked well. The tolerance on the prototype made sanding and
shaping necessary, but the rotation was possible, and the slider provided good abduction/adduction. Occasionally the slider would jam due to a poor length to width ratio; a
flaw that was fixed in the final prototype.
6.3
Final Prototype
The final prototype is in the process of being manufactured and assembled. It will include
all of the actuation, transmission and sensor elements described in Chapter 5. All parts
100
Figure 6-3: Second Prototype
101
Figure 6-4: Finger Module of Second Prototype
102
Figure 6-5: Side View of the Finger Module of Second Prototype
103
Figure 6-6: CMC Rotation in Second Prototype
are being manufactured from aluminum, except for the motor and pulley shafts and the
finger interfaces. Aluminum is relatively cheap and is easy to machine. Also, it can be
anodized or powder coated to create a colorful robot. Eventually many aluminum pieces
could be replaced by injection molded plastic parts. The shafts are being made out of
303 Stainless steel for strength and the interfaces will be rapid prototyped using a flexible
material. It may also be possible to experiment with integrating straps into the interfaces
by using the prototyped pieces for urethane molding.
The flexures were manufactured in-house from Nylon 6/6 so that they could be tweaked
if necessary to get just the right feel and performance. As designed, the flexures were
easily bent in the desired direction but were torsionally stiff. The machining of the
flexures, however, was a very time consuming process involving a CNC mill and milling
saw. The nylon was fairly brittle in machining; once milled to the flexure thickness, it was
impossible to cut the material without a very small-toothed saw. Also, the machining left
104
numerous burrs where the nylon strands were cut. For these reasons, it is suggested that
either Delrin or a flexible rapid prototyping material is used for the flexures in the next
prototype.
Since the final prototype was not complete in time to be included in this thesis, solid
models of the robot and the various assemblies will be used to describe the final design.
The colors are not necessarily representative of how the final robot will look but are
used to identify the modules.
The hand in the model was constructed from average
anthropometric data and can be placed in almost any possible configuration to simulate
various grips and tasks.
Figure 6-7 shows an overall view of the robot. The motor boxes are mounted below
the robot so they can be sunk into the table and not interfere with the patient. Bolting
the arm rest into the table provides additional support for the patient. The finger and
thumb modules are described in more detail below.
Figure 6-8 shows a close up of the hand-robot interfaces. The flexures are not included
in the thumb module so that the rotation of the hardware can be seen. As mentioned
above, the axes of rotation are now aligned with the joints of the patient.
The finger module assembly is shown in Figure 6-9. As mentioned in the discussion
of the second prototype, the index hardware has been angled backwards to decrease
the cantilever height. Each piece of index hardware consists of three pieces, which are
assembled to create the cantilever. This simplifies the machining and reduces the material
cost significantly.
The finger interfaces are very similar to those used in the second
prototype. Beaded flexures with slots cut into them for the cables are shown in between
the hardware. The base piece is mounted to the motor boxes.
Finally, Figure 6-10 shows the thumb assembly, again without the flexures in place.
The CMC abduction/adduction hardware is three pieces assembled together to simplify
machining. The V-section of the slider is part of this hardware. The clamshell shape of
the CMC flexion/extension hardware holds and moves the patient without straps since
it is awkward and difficult to hold onto the first metacarpal of the thumb. The MP and
105
Figure 6-7: Solid Model of Entire Robot
106
Figure 6-8: Close-Up of the Hand-Robot Interfaces
107
Figure 6-9: Robot Finger Assembly
108
-~
____________
______________
-
717
7~~-
-----
Figure 6-10: Robot Thumb Assembly
IP pieces of hardware will have straps mounted to them to help transmit forces to the
patient.
Appendix C contains component specifications, and Appendix D contains part and
assembly drawings for all of the components of the final prototype.
109
-
----
_____
-
Chapter 7
Conclusion
7.1
Current Status
As mentioned in Section 6.3, the hardware for the final prototype is being manufactured
and assembled at the time of writing. All of the parts have been designed and all components have been ordered.
Many cosmetic details, such as coating the hardware for
aesthetic reasons, are being left out since there is much testing that needs to be done
before the aesthetics are a concern.
7.2
Design Process
Much of what was learned during the design of the hand robot was in the design process
itself. The decision to simplify the degrees of freedom of the robot made the design much
more feasible and opened up more options for actuation. As a result, significant time
was spent investigating possible methods of actuation. The resulting knowledge about
the limitations of hydraulic systems should be considered during future designs. Also,
the actual implementation of the cable drive system should be carefully studied to see if
improvements on established technology can be made.
The use of prototypes, particularly those manufactured using rapid prototyping tech-
110
nology, provided valuable information about how various design ideas would actually
work. It was possible to quickly assess design feasibility and to determine improvements.
Earlier and more frequent design reviews might have prevented some of the time spent
investigating novel yet somewhat impractical design ideas. Overall, however, the design
process was thorough and produced what promises to be a novel robot design.
7.3
Proposed Design Improvements
During the design process, several possible improvements to the design did became apparent. There are two main types of improvements that could be implemented. The first
is in the design of the actual hardware. The second is in the materials used or the method
of manufacture.
7.3.1
Hardware Improvements
The major change that should be implemented is a very practical one. The original design
for the flexure clamps called for 4-40 bolts. When the parts were manufactured it was
discovered that the resulting walls surrounding the bolt holes were very thin. Therefore,
the clamp bolts should all be changed to 2-56. This change is reflected in the drawings
included in Appendix D.
It would also be beneficial to have a version of the wrist cradle which has an integral
splint. This would prevent having to somehow attach the cradle to whatever splint is on
the patient. Integrating straps into the finger and thumb interfaces would also allow for
a smoother looking final product.
Other possible changes to the hardware include creating separate finger and thumb
modules. This would allow the therapist to target therapy to specific digits without having
to have the patient in the complete robot. In an attempt to provide more general upper
extremity therapy, the hand robot alternatively could be implemented in tandem with a
variation of the MANUS robot or other active therapy devices.
111
7.3.2
Material and Manufacture Improvements
As mentioned in Chapter 5, the current prototype hardware is constructed of aluminum.
In the final implementation, the finger and thumb interfaces could be manufactured out
of a stiff plastic. Plastic molding would allow various colors for aesthetic purposes and in
the long run would reduce manufacturing costs. Also, there is a possibility of molding the
interfaces and the flexures together, significantly reducing part count. The disadvantage
of this is that if the flexure fails, the entire module would have to be replaced. Finally,
molding or rapid prototyping the flexures themselves would greatly reduce manufacture
time.
7.4
Future Work
Over the next few months, the robot will be assembled and will reach the point where
it can be actuated and tested. Once the hardware is assembled it will be connected to a
computer for data collection and control. The electronics panel which will contain all of
the servoamplifiers and power supplies still needs to be designed and produced. Finally,
once all of those aspects are up and working, the robot needs to be characterized.
In order to successfully control the robot, the system needs to be well understood.
This will involve trying various controller schemes and obtaining a system frequency
response, among other things. Once the robot has been thoroughly characterized and
the controller has been proven stable, therapeutic games and a visual interface will be
designed and implemented. Finally, the prototype, or an improved version of it, will go
out for preliminary clinical testing with stroke patients in a rehabilitation hospital.
112
Appendix A
Appendix A
-
Anthropomorphic
Data
The first table gives anthropometric data for the individual digits of the hand. The second
table is data for the hand itself. All values are in inches. In Table A.1, the total length is
defined as the length from the crotch of the finger to the tip, not the total length of the
phalanges.
113
Biryukova
Tilley
Index Finger
Length - 1st Phalange
1.792
Length - 2nd Phalange
1.134
Length - 3rd Phalange
0.915
3.0 (M) 2.7 (F)
Total Length
Middle Finger
Length - 1st Phalange
1.920
Length - 2nd Phalange
1.308
Length - 3rd Phalange
0.915
3.4 (M) 3.1 (F)
Total Length
Ring Finger
Length - 1st Phalange
1.837
Length - 2nd Phalange
1.270
Length - 3rd Phalange
0.915
3.2 (M) 2.9 (F)
Total Length
Little Finger
Length - 1st Phalange
1.482
Length - 2nd Phalange
0.915
Length - 3rd Phalange
0.877
2.4 (M) 2.2 (F)
Total Length
Thumb
Length - 1st Phalange
1.966
Length - 2nd Phalange
1.308
Length - 3rd Phalange
1.134
2.3 (M) 2.1 (F)
Total Length
Table A.1: Digit Anthropometric Data
114
NASA
Airforce
Buchholz
Hand
Breadth (M)
3.44
Breadth (F)
2.99
Length (M)
7.59
Length (F)
7.25
Palm Length (M)
4.3
Palm Length (F)
3.78
3.47
3.48
3.22
7.68
7.42
6.76
Wrist Breadth (M)
2.59
Wrist Breadth (F)
2.4
Table A.2: Hand Anthropometric Data
115
Appendix B
Appendix B
-
Spreadsheets and
Calculations
B.1
Flexure Calculations
Tables B.1 and B.2.
B.2
Motor Calculations
Tables B.3, B.4 and B.5.
116
metric
inches
Variables
thickness of thin section
t
0.02
5.08e-04
thickness of thick section
h
0.2
5.08e-03
width
w
0.75
1.90e-02
length of thin section
1
0.125
3.17e-03
length of thick section
L
0.125
3.17e-03
4.00
number of thin sections
0.88
total length
2.22e-02
Young's modulus
E
7.00e+07
Poisson's ratio
n
0.4
9.40e+07
yield stress
1.75e-01
max allowable angle
shear modulus
2.50e+07
G
Izz thin section
2.08e-13
Izz thick section
2.08e-10
Ip thin section
2.93e-10
Ip thick section
3.13e-09
4.40
Ky per thin section
deflection needed
delta
bending force needed
Fbend
max stress in thin section
sigma
0.002
0.35
1.56
8.80e+06
3.52e+07
4
max stress with safety factor of
770.82
Kt thin section
2.31
Kt thick section
24.68
0.54
Kt total
max torsion force
Ftorsion
0.02
Table B.1: Finger Flexure Calculations
117
0.09
inches
Variables
metric
thickness of thin section
t
0.02
5.08e-04
thickness of thick section
h
0.2
5.08e-03
width
w
0.5
1.27e-02
length of thin section
1
0.125
3.17e-03
length of thick section
L
0.125
3.17e-03
4.00
number of thin sections
0.88
total length
2.22e-02
Young's modulus
E
7.00e+07
Poisson's ratio
n
0.4
9.40e+07
yield stress
1.75e-01
max allowable angle
shear modulus
2.50e+07
G
Izz thin section
1.39e-13
Izz thick section
1.39e-10
Ip thin section
8.69e-11
Ip thick section
1.Ole-09
513.88
Ky per thin section
deflection needed
delta
bending force needed
Fbend
max stress in thin section
sigma
0.002
0.23
8.80e+06
2.64e+07
3
max stress with safety factor of
1.04
Kt thin section
0.68
Kt thick section
7.92
Kt total
0.16
max torsion force
Ftorsion
0.006
Table B.2: Thumb Flexure Calculations
118
0.028
THUMB
INDEX
FINGERS
inches
metric
inches
metric
inches
metric
Maximum MCP Force
11.241
50.000
6.745
30.000
10.117
45.000
Maximum PIP Force
5.621
25.000
3.372
15.000
6.745
30.000
Distance to MCP Force
0.627
0.016
0.627
0.016
0.440
0.011
Distance to PIP Force
1.883
0.048
1.883
0.048
1.320
0.034
Maximum MCP Moment
7.054
0.797
4.232
0.478
4.451
0.503
Maximum PIP Moment
10.581
1.195
6.348
0.717
8.903
1.006
Provided MCP Moment
11.479
1.297
8.658
0.978
8.877
1.003
Provided PIP Moment
15.006
1.695
10.774
1.217
13.328
1.506
Distance MCP Flexure to Belt
0.375
0.010
0.375
0.010
0.250
0.006
Distance PIP Flexure to Belt
0.500
0.013
0.500
0.013
0.375
0.010
Necessary MCP Force
30.611
136.160
23.088
102.693
35.508
157.940
Necessary PIP Force
30.012
133.495
21.548
95.845
35.543
158.093
Tension of MCP Belt
45.917
204.240
34.631
154.040
53.262
236.910
Tension of PIP Belt
45.018
200.243
32.322
143.768
53.314
237.140
MCP Inertia (Index)
1.200e-03
1.356e-04
1.200e-03
1.356e-04
4.720e-03
5.333e-04
PIP Inertia (Index)
0.257
1.356e-04
0.257
1.356e-04
2.320e-03
2.621e-04
Acceleration
15.708
15.708
15.708
15.708
15.708
15.708
MCP Necessary Torque
0.019
0.002
0.019
0.002
0.074
0.008
PIP Necessary Torque
4.037
0.456
4.037
0.456
0.036
0.004
MCP Necessary Force
0.050
0.224
0.050
0.224
0.297
1.319
PIP Necessary Force
8.074
35.913
8.074
35.913
0.097
0.432
Table B.3: Flexion/Extension Necessary Force Calculations
119
FINGERS
INDEX
THUMB
inches
metric
inches
metric
inches
metric
Force to Bend Flexure
0.468
2.080
0.468
2.080
0.187
0.830
Flexure Length
0.880
0.022
0.880
0.022
0.630
0.016
Moment to Bend Flexure
0.206
0.023
0.206
0.023
0.059
0.007
Necessary Provided Force
0.549
2.441
0.549
2.441
0.235
1.046
Coefficient of Friction
0.350
0.350
0.350
0.350
0.350
0.350
Friction Force at MCP
16.071
71.484
12.121
53.914
18.642
82.919
Friction Force at PIP
15.756
70.085
11.313
50.319
18.660
82.999
Total Necessary MCP Force
47.281
210.308
35.807
159.272
54.681
243.224
Total Necessary PIP Force
54.391
241.933
41.483
184.517
54.535
242.571
MCP Pulley Diameter
0.875
0.022
0.875
0.022
PIP Pulley Diameter
1.000
0.025
1.000
0.025
1.000
0.025
Total Necessary MCP Torque
20.686
2.337
15.666
1.770
27.341
3.089
Total Necessary PIP Torque
27.196
3.073
20.742
2.343
27.267
3.081
Motor Output
3.319
0.375
3.319
0.375
3.319
0.375
Gear Ratio
10.000
10.000
10.000
10.000
10.000
10.000
Estimated Efficiency
0.850
0.850
0.850
0.850
0.850
0.850
Torque to Pulley
28.213
3.188
28.213
3.188
28.213
3.188
Table B.4: Flexion/Extension Motor Torque Calculations
120
inches
metric
Inertia
0.429
0.048
Acceleration
6.981
6.981
Necessary Torque
2.995
0.338
Output Force to Patient
10.117
45.000
Output Torque to Patient
20.234
2.286
Slider Friction Coefficient
0.350
0.350
Friction Force
1.411
6.277
Slider Radius
2.000
0.051
Friction Torque
2.822
0.319
Total Necessary Torque
26.051
2.943
Motor Output
3.319
0.375
Gear Ratio
10.000
10.000
Estimated Efficiency
0.850
0.850
Torque to Slider
28.213
3.188
For CMC Abduction/Adduction
Table B.5: CMC Abduction/Adduction Motor Torque Calculations
121
Appendix C
Appendix C
-
Component List and
Specification Sheets
C.1
Component List
C.2
Specification Sheets
122
Component
Supplier
Model
Price
Quantity
Small Bearing
Motion Industries
Consolidated Bearing FR3ZZ
$7.21 each
16
Large Bearing
Motion Industries
Torrington FS1KDD7
$19.71 each
16
Small Gear
General Product & Gear
Custom
$53.50 each
8
Large Gear
General Product & Gear
Custom
$92.00 each
8
Motor
Kollmorgen
RBE-01213-A02
$898.70 each
8
Servoamplifier
Kollmorgen
CE06200-1R1213A
$980.00 each
8
Servoamp Connectors
Kollmorgen
A-97251
$88.00 each
8
Servoamp Power Supply
Astrodyne
AS-320-24
$169.00 each
2
Encoder
Gurley Precision
R119B-01024Q-5L5-Al8SY-03MN
$327.00 each
8
Joint Angle Sensor
Measurand
S720
$375.00 each
7
Sensor Power Supply
Astrodyne
AS-25-5
$39.00 each
1
Cable
Sava Industries
1050SN
$1.17/ft
250
Cable End Fittings
Sava Industries
8062C
$0.47 each
32
Cable Splice Fittings
Sava Industries
7062A
$0.36 each
40
Cable Assemblies
Sava Industries
Custom
$11.70 each
30
Table C.1: Components List
Bearing Model
Bore
OD
Width
Flange Diam
Flange Height
FR3ZZ
0.1250
0.3750
0.156
0.440
0.080
FS1KDD7
0.2500
0.6250
0.196
0.690
0.042
Table C.2: Bearing Specs (all dimensions in inches)
123
4i.
Fs OASIS'
SORE' it 25'
Po
P1.
-
.JA
PIN HUB
bPz48
PFn
Ce4,gw
Jdrf
MAc$dAA
I4le4A (flvS
*eofrv)
Figure C-1: Small Pinion Gear Drawing
124
en
*.Wrw
I
#049
I
+
a---
UBLESS
?essutcA' td'
$aqaAeA S4ail
140f ith (Pkh4l
---
a
0.0.
4 31C'*
S,..6
t.4r)
Figure C-2: Large Pinion Gear Drawing
125
I
I
*fL'4
OC
RBE(H) 01210 MOTOR SERIES PERFORMANCE DATA
Symbol
Units
Max Coot. Output Power
at251C amb.
HP Rated
.lIP
P Ruted
Watts
106
ed
N Max
RPM
RPM
1300
o-in
1000
164
18000
Tc
N-m
0.115
Tp
o7-1a
N-m
Tal
ts.-..
N-rn
Speed
Rat
Max Me chanica Speed
Continuous Stall Torque
at 25C amb.
Peak Torque
.ax.Torque
fur Liaear KT
Motor Constant
............
Thermal Resistance*
Viscous Damping
Max Static Friction
Max Cogging
0.204
.
.
0243
.
lt
8100
152
960
01213
01214
0.272
0.290
203
7152
216
6230
18000
01215
0
.......
............ .....................
.....
000
18000
231 ......
00
18000
43.5
54.
66.2
404
0.223
0.307
0.387
0.467
0,639
404
0.342
114
0,806
160
1.18
222
1.57
202
1.99
435
3.07
4.4
0.342
4
0.806
.6
1.18
222
1.57
202
1.99
435
3.03
31.6
.
.
o1-.n
4.50
2.92
0.021
3.40
0.024
0.032
1.10
0.0078
1.37
0.0097
2.00
0014
OE-03
2.70E-03
400E-03
1.48E-05
12.1
1.9 E-05
151
2.32E-05
22.0
70
2.13
0.0120
015
o n
N-m
0.41
0.0029
0,0046
Jmf
or-in-seC2
7.30E-04
1.20E-03
1.70E-03
Weight
Wt
Kg a
(
5.1E-06
4.5
9,47E-06
7.2
.20E-05
9.6
Kg
1.260-01
2.03-01
2.74E-0
344E-01
4.28E-01
6.24E-01
Inertia
Jmn
or-tn-seC2
7.900-04
L(.0003
I0F-03
2.20E-03
2.10E-03
4.20E-03
5.37E06
11.3
9, 18-06
14.2
2,97E-05
16.8
1.55E-05
19.5
1.98E-05
Wth
Kg-mo
or
L27E-05
Weight
22.6
30.0
Kg
3.20E-01
4.02E0+0
4.77E-01
5.52E-01
6.41E-01
8.50E-01
5
9
Torque
Tf
Tcog
?
No. of poles
Winding Constants
Serobols
1:1111s .
A4
5.41
Current at Peak Torque
lp
Kt
Amps
15.0
06
oz-ia/Amp
3.34
4.64
Kb
ViKRPM
Motor
Resistanee
Rm
Motor
nductance
Lie
Olms
MH
constant
'Rth assumes a housed iotor mounted to a4,0' x 3.75"
1
8
5.8 3.63 9,06
189 20,0 10.6 26.8
2.60 180 930 3.72
2.
0.280 0.54
0.17
0.63
0.12
C
8.45
5.77
400
8.88
615
3.73
861
5.46
3.3
76
20.0
10.6
26.8
22.5
301
15.3
14
35.8
15.3
134
35.8
8.49
13.6
545
10.0-
13.4
14.5
1102
10.7
650
Lt
87
7
174
0.0571 0(23 0,203
0.08i
1
0.44
0.13
A.6AC
.36
13
0666
1.1
01
.49
1
.97
129 21.2
0336 0590
.25
0.71
4
919
18
4
0450
I9
0.36
01215
01210 0121i 01212 01223 0!214
a
RBE - 01210 Series
-
-
-
-
t
401
155 0,307
0,47 097
3.10
0.0459 0.0799 0132
5.08
equivalent
Continuous Duty Capability for 130*C Rise
seve
A
B
338
0.0236 0.0328 0.0183 0.0410 0.0657 0.0263 0.0600 0.062 0.0385 0,0707
147 3.43 192 4.29 6.8 2 75 628 0.1 4.03 7,41
0.691 138 0431 0664 .75 0.76 0803 2.11 0.334 0.73
x0.25" aluminum heatsink or
8
5.42
-
Amps
N-orAmp
0.8
0.0062
-
3,89 6.95
Ic
Torque Sensitivity
0.018
0.66
8
Torque
Curent at Cant
Back EMF
.
.
N-m
Inertia
Housed
Motor
0.142
8.4
13.9
11.7
0.59
7.12
4.00
oz-in W
Tm
0,130
0.098
0.083
0.067
0.050
0028
N-ociW
.................... ..................... .............. ............................................................................................
3.27
344
3.55
7.68
36
4.25
Ci ott
Rt
1.20E-03
7,78E-04
5.97E-04
4.46E-04
2.96-04
.30E-04
or ocROM
Fi
3.480-06
5490-06
4.22E-06
3.15E-06
2.09E-06
9. 80-07
N nRPM
Peak to Peak
Frameless
Motor
.
.
01212
01211
0110
Motor Parameters
a
t
0
0
7
4-.
KOLLMORGEN - Radford, Virginia
12
Figure C-3: Motor Spec Sheet 1
126
1-800-77 SERVO
DIMENSIONS
RBE-0121X-XOO
|M.1.04 iA
Mig. Req't
(1.88
046.61
Max.
5.08-
10.16 (.400)
Max.
-
(.200)
- A-
9.563 (.3765)
~
.
(1.835)
1I.852
Max.
2 pl.
pl.
0 9.38 (.
03073
55-
.... J4..V.
49.20 (1.937)
-
..-
0-49.15(1.935)
--
(1.210)
Min.
0.89 (.035
Mtg. Req'I
Dimensions in mm (inches).
designed in inches.
Metric conversions provided for reference only.
.Product
Notes:
I) For a C.W. rotation, as viewed liom lead end. energize per excitation
sequence table.
2) V-AB, V-BC and V-CA is back EMF of motor phases AB, BC and CA
respectively, aligned with sensor output as shown for C.'. rotation only.
3) Mounting surface is between 0 47.88 (1.885) and 0 49.17 (1.936) on both
sides.
MODEL
NUMBER
"A"
Dimension
"B"
Dimension
RBE01210
5.72
(0.225)
RBE01211
12.7
(0.500)
12.07
19.05
(0.475)
(0.750)
RBE01212
19.05
(0.750)
25.4
(1.000)
RBE01213
25.4
(1.000)
RBE01214
33.02
(1.300)
RBE01215
50.8
(2.000)
31.75
39.37
57.15
(1.250)
(1.550)
(2.250)
Tolerance ± .010 on "A" Dimension
RBEH-0121X-X00
(.3748)
09.520
9.512 (.3745)
0 9.520
9.512 (.3748)
(.3745)
-
1.52 (.06) -13.21(.520)
12.19(480)
~.
057.658
(2.270)
Max.
038.10
38.07
(1.500)
(1.499)
#6-32 X 5.08(.20)
deep, 4 holes on a
048.26(1.900) Basic
22.23
21.46
(.875)
(.845)
A
Dimensions in mm (inches).
Notes:
with a 9 lb reversing load, the axial displacement shall
be .013-.15 (.0005-.006).
2) For a C.C.W. rotation, as viewed from pilot end, energise per excitation
sequence table.
3) V-AB. V-BC and V-CA is back EMF of motor phases AB, BC and CA
respectively, aligned with sensor output as shown for C.C.W. rotation only.
Product designed in inches.
Metric conversions provided for reference only.
1) Shall end play:
RBE/RBEH LEADWIRE
Motor Leads: #20AWG Teflon coated per MIL-W22759/11, 3 leads, 152 (6.00) min 1g. ea. 1-black,
!-red, 1-white.
MODEL
NUMBER
"A"
Dimension
RBEH01210
43.05
(1.695)
RBEH01211
50.04
(1.970)
RBEH01212
56.39
(2.220)
RBEH01213
02.74
(2.470)
RBEH01214
70.36
(2.770)
RBEH01215
88.14
(3.470)
Sensor Leads: #26 AWG type "ET" Telon coated
per MIL-W-16878, 5 leads, 152 (6.00) min 1g. ea.
I-blue, I-brown, I-green, I -orange, I-yellow.
KOLLMORGEN - Radford, Virginia - 1-800-77 SERVO
13
Figure C-4: Motor Spec Sheet 2
127
OPTIONS - RBEH-0121X
BRAKE
- -
An integral electromagnetic fail-safe brake can be added to the rear of the
motor. Operating in the POWER OFF/BRAKE ON mode, the brake provides 48 ox-in of torque for static parking and emergency braking. To release
the brake, 24 VDC and 0.13 Amps max need to be applied.
- - - -
38.35
1
53
OPTION
-Fail-safe brake
-48 oz-in holding torque
-Release voltage of 24 VDC (0.13 Amps)
length
d od mo
Dimensions in mm (inches).
Product designed in inches.
Metric conversions provided for reference only.
RESOLVER OPTION
A frameless resolver is available to provide position feedback computable
with a wide variety of CNC and other position loop controllers. This option
is required for commutation when using SERVOSTAR or other resolver
based controller.
NORMAL
....
-
R2
(g
U
)UIAR
'RIMARY
dd to sid. -ros.
38
(1
er~h
R1
RO
RTDWoWHI
510)
Dimensions in
S3
SIA80
SECONDARi
m (inches).
CHARACTERISTIcG
AT
INPUT CURRENT
INPUT POWER
TRANSFORMATION RATIO (15%)
PHASE SHIFT
IMPEDANCES (115%)
ZRO
Zso
Zss
0.470
4" LEADING t 3'
48 +j7D
62+180
53+
ZRS
.RESOLVER
in(inches).
Pduesinn
Product designed in inches.
Metric conversions provided for reference only.
SCHEMATIC
PHASING
EOLUATIONS
UIS 03= KR l1-R2'30
STATOR
(1 10%)
33 01m
Ohm
ROTOR
NULL VOLTAGE
ELECTRICAL ERROR
OUTPUT VOLTAGE
-AE(11-1421 sIN.
ROM IogS
8CW
WII
VIEWED
g-g SNO
(S2S4
I-ROM
163
42+155
D.C. RESISTANCE
0~E
2S'
ROTOR
4.25V, 7 kHz
55 MA. MAX
0.12 WATTS
PRIMARY
INPUT VOLTAGE
OPERATING TEMPERATURE
16
20 MV MAX.
t 7 MINUT ES MAX.
-. DV t 5%
-55 TO +165"C
ENCODER OPTION
An incremental encoder is available having TTL quadrature and marker pulse
outputs. 200 to 2048 lines are available. The standard is 1024 lines with the
marker pulse.
2' 3
(.84) -
-
Aria
o
;td. max.
ength
Parameter
Temperature
Supply Voltage
Supply Current
Count Frequency
Velocity
Min
-40
4.5
30
Max
100
5.5
85
100
Units
10K
RPM
*C
Re
5sO*
1000
2000*
-0
2048*
Index
conversions provided for reference only.
KOLLMORGEN
Cycles/Rev.
Volts
mA
kl-Iz
Dimensions in mm (inches).
Product designed in inches.
Metric
Resulutios
0
option not yet available for
resolutions marked by *
37
Radford, Virginia - 1-800-77 SERVO
Figure C-5: Motor Spec Sheet 3
128
ORDERING INFORMATION
RBE(I
fl - Q2 12
-
A
00
L
T'YPE
-
I
RB - Frarneless Brushless Motor
R BE - Frameless
Bnishless Motor
with hail Sensors
RBEH - Housed
Brushless Motor
with Hall Sensors
Winding
A. B, C, etc.
Stack Length
10, 11, 12. etc.
Motor frame
004,005, 007, 012, 015,
018, 021, 030, 045, 062
OPTIONS
B - Fail-Safe Brake
E- - Encoder
R - Resolver (Drop Ist
KOLLMORGEN - Radford, Virginia
Mechanical Dev iations
00 - Standard
E)
43
1-800-77 SERVO
Figure C-6: Motor Spec Sheet 4
129
AMPLIFIER SPECIFICATIONSJ
Inputs
" Analog command: +10V
Resolver feedback models: 14 bit resolution provides up
to 16,000 to I dynamic speed range
Electrical characteristics
* Closed loop velocity bandwidth up to 400 Hz
* Motor current ripple frequency (32 kHz)
* Long term speed regulation (0.01%)
* Position loop update rate 500 pL8 (2 kHz)
- Velocity loop update rate 250 ps (4 klz)
Encoder feedback models: 15 bit resolution provides up
to 32.000 to 1dynamic speed range
" Remote enable: 24V
* Commutation update rate 62.5 ts (16 kHz)
" Three multi-purpose 24V inputs Configurable to: CW
limit switch, CCW limit switch, gear enable, start
motion, second current limit, change velocity to torque
* Current loop update rate 62.5 ps (16 kllz)
Fault protection
Output phase to phase short circuit protection
mode, home switch. search for home. move to home
Overvoltage
Undervoltage
Overtemperature (motor and amplifier)
registration capture, active disable, control fault relay,
hold position plus using two inputs, up to four stored
indexes or speeds can be executed
Overspeed
6
" Pulse command: up/down, pulse/direction, pulse or
Overcurrent
Feedback loss
Foldback
Supply loss
Excessive position error
quadrature encoder format into RS-485 receivers or
opto isolators
Communications
- RS-232 or RS-48S serial interface 9600 or 19.2 kb
Outputs
" Fault: contact closure rated for
Environmental
Operation range
- Ambient 0 to 45'C (derated above ambient)
Operational modes
" Torque control - from analog or serial command
" Velocity control - from analog or serial command
" Pulse following / Up-Down count
" Gearing from quad encoder input
" Position control
Velocity Loop Compensation
" Vel: Pl, PDFF or Pole Placement
selectable algorithmns
" Factory preset or field tunable
"
MOTIONLINK*
24 Volt
exceeded, current exceeded. amplifier in foldback, brake
enable, motion complete, in position, zero speed detect
- Storage -20'C to 70'C
Humidity (non-condensing) 10% to 90%
-
1Amp,
" One multi-purpose 24V output configurable to: speed
software provides tuning
programming via RS-232 or RS-485 serial interface
" Adjustable filters
Diagnostics
Seven segment LED display
Position Loop Compensation
Error history log
Internal variable monitoring
PC scope
PID
-
Motor Feedback
Resolver: sine/cosine 2V peak to peak (SERVOSTAR
CD provides 4.25V peak to peak for resolver excitation)
Encoder 5V quadrature with or without Halls, with or
without marker. up to 3 MHz before quadrature (12
MkIz after quadrature)
Model
Cx03
Cx06
Output Continuous
Current Per Phase
(RMStphase)
Output Peak
Current Per
Phase
(112 see)
3
6
9
18
Rated Outpnt
Continuous
Power
Internal Power
Dissipation
(Watts)
(kW)
'
37
84
1.1
2.2
PWM Switching
Frequency
(kHz)
I_(
16
16
KOLLMORGEN
10
AC Input
Line
Voltage
phase)
115-230
115-230
Regen.
Option
1.7
ER__-26
2.8
ERII-26
- Radford, Virginia - 1-800-77 SERVO
Figure C-7: Servoamplifier Spec Sheet 1
130
Rated
Input
Power
RESISTIVE REGENERATION SIZING/DIMENSIONS
I
Resistive Regeneration Sizing
Shunt regeneration is required to dissipate energy that is pumped
back into the DC bus during load deceleration. The amount of shunt
regeneration required is a fnction of the sum of simultaneously
decelerating loads. The loads need to be defined in terms of system
inertia. maximum speed, and deceleration time. In addition. the duty
a calcycle must be known. Application Note A-SU-001-H details
culation method to determine proper regeneration sizing.
Transformer Sizitg (Requind only For voltage matching)
The SERVOSTAR CD can be connected to a line. Built-in soft-start
circuitry protects power supply components and eliminates nuisance
tripping of breakers or fuse blowing due to large in-rusl currents.
In
Transformers are only required 1r voltage matching pusposes.
this case, the transformer should have a 115 or 230 VAC secondary
depending on the operating voltage. The kVA rating of the
transformer should take into account not only the servo output load
requirements but also losses in the system and power factor. For single phase operated systems such as these, the transfornier IVA ratings should be two times the CD amplifier output power rating.
Model | WttsOhmsI
ERH-26 | 200 1 20
30
-
60
(1.18)
17_
(.67)4
(
~
_(2.36)-
5.3
(.21)
215
(8.46)
175
(6.89)
196
(7.72)
Model Transformer KVA rating
2.2
Cx03
Cx06
4.4
5.3(.21)
13 (.514)
Resistive Regen ERB-26
~6
'-
0
85
CA3/6
36.5
(1.44)-
(.61)
. (6.42)
--
-15.5
-
3X 5.5
(.22)-
2X 010.0
--
163.0
2.0 (.08)
- 6.7
6
(.39)--(.26)
256.0
(10.08)
216.0
(8.50)
244.0
(9.61)
3 AMP
6 AMP
DIM. "A"
(2.65)
88.4 (3.48)
67.4
33.7 (1.33)
Dimensions in mm (inches)
11
KOLLMORGEN - Radford, Virginia - 1-800-77 SERVO
Figure C-8: Servoamplifier Spec Sheet 2
131
CONNECTOR INFORMATION
C2 - Resolver Feedback
(from Motor)
used on CRxx Models
C1 Serial Communications
0
0
3
8
0
4--;
9
o
0
Communications
(See manual for pin information)
-
Thermostat High
Thormostat Low
2-
240--Shield
23S
0
0
Reserved
Rx- (RS485)
Common
-
~
0
i
C7 Inter SERVOSTAR
Tx+ (RS485)
RECV (RXD) (RS232)
Tx- (RS485)
XMIT (TXD) (RS232)
Rx+ (RS485)
S0
S
0
Shield
2
0220
21
0
0
8
10
0r
rEncoder Channel B Output - (Low)
0
lo
Idexn
Encoder Channel B Output
3
0
0
2
-
AC Power
i+.
(High)
1
0
DC Common
E5V Supply
15
0
14
C2 - Encoder/Hall Feedback
(from Motor)
used on CExx Models
Input (Bus)
Motor Output Phase
0
0
B
240
Mc Motor Out put Phase C
B+
-.
-8C
01.
Externa
Regen Option
Reserved
C3 User 1/0
C4 Encoder Equivalent Output
1
3
Analog Signal Shield
--
0
3 0
4 f
5 0
Analog
2
5
9 0
0
Encoder Channel B Output
Shield Connecon
-
(Low)
Encoder Channel B Output + (High)
Index Chaeol Output - (Low)
DC Common
Encoder Index Channel Output + (High)
Encoder Channel A Output - (Low)
(ncoder
0
0
-
2
C
Eceder Channet A 0utpitt + (High)
Fault Output Relay Contact
Output Relay Contact
Fault
7
.u24 Volt Input
9
(-)
DC Common
6
8
Shield Connection
DilforentiAt (-)
Analog Dilterential
.
f
Remote Enable
-
3-
(10
0 23
Hall 2 A
0
Hall 2A
210
0 -
L2 AC Line Input Power
Srth
22
Thermostat High
Thermostat Low
Shield
Hall 3 A
Hall 3
Hall 1 A
Hall 1B
Shield
iE5V Re turn
0
E5V Supply
0'
'51
0 4E5V Return
ESV Supply
0
Shield
0
E5V Supply
0
- Encoder Channel B Input (Low)
0
Shield Connection
17
4
Encoder Channel B Input (High)
. -Encoder Index Channol Input (Low)
3
0
Shield Connection
0
Encoder Index Channel input (High)
0
Channel A Input (Low)
-Encoder
14 0
Shield Connection
Encoder Channet A Input (High)
'.
1Cx SERVOSTAR CD
Li AC Line Input Power
-
Shield
Ret High Out
Sine Low
Shield
Sine High
O
0
Ma Motor Output Phase A
- Mb
eo
Cosine High
Ref LowOut
2
0
Shield
Coa
cosine Low
Indexn
Earth
I
0'
-.01 0
17
Encoder ChanneA Input- (High)
Shied Connection
Encoder Channel A Input + (Hiil)
6 Q
0
+
s
200
C8 Remote Pulse or Encoder Input
Input
O
INI (Dig Input)
IN2 (Dig Input)
(110--- IN3
(Dig
Input)
120 -
01 (Dig Input)
13
Analog output
KOLLMORGEN - Radford, Virginia - 1-800-77 SERVO
12
Figure C-9: Servoamplifier Spec Sheet 3
132
.'
SYSTEM ORDERING INFORMATION
SERVOSTAR Family
CR2062
T
0 - G 402 B
Winding
0 - No Comp
C - SERVOSTAR CD Compact Drive
- Motor Frame and Stack
Feedback
000 - No Comp
R - Resolver
E- Encoder
Motor Model
Current Rating (Cont. A/0)
0 - No Comp
(Compact Drive: 03,06
Amp ratings only)
G - GOLDLINE (B, BE, M, ME, MT, EB)
R - RBE
H - SILVERLINE (H)
Voltage Level
0 - No Comp
2 - Standard
Y - Special Compensation
three digit extension follows
the Y designator
Model
200 - Standard model
KOLLMORGEN - Radford, Virginia - 1-800-77 SERVO
13
Figure C-10: Servoamplifier Spec Sheet 4
133
Enclosed switcng
AST F-DYNE
300
WaftPower Suppfles
115/230 VAC Sw. Sel. Input
Sries
High Efficiency
Regulated Outputs
3000V iscladan
Bulk in EMO F~ier
4
\,
Unit measures 4.6"W x 8.6"1.
U
Model
umber
SINGLE OUTPUT
AS320-5
AS-320-75
AS-320-12.
AS-320- 3.5
AS-320-15
AS-320-24
AS-320-27
AS-320-48a
5
.
x 2""N
.--....
Output
Voltage
Output
5VDC
7.5 VDC
50:
36:
26
22
12VD0C
13.5VDC
15 VDC.
24 VDC
27 VDC
48 VDC
Amps (MAX)
$169
$169
$169
$169
$ 169
20
12
11
6.5
Price
I
25
5
$169.
$169
$163
$163
$163
$163:
$163
$.163:
$163
$163
300 Myles Standish Blvd., Taunton, MA 02780
Fax: 508-823-8181
Ph: 1-800-823-8082
Figure C-11: Servoamplifier Power Supply Spec Sheet 1
134
Contact
Factory
for
High Volume
Pricing
Enclosed
ASTR " DYNE
Switching
300 Watt Power Supplies
Allspecifications are typical at nominal input, full toad, and 25DOegC
unless otherwise noted
Frequency Range
Inrush Current, typ*
Voltage and Current
Load Regulation
(0% to 100% Load)
Line Regulation
Voltage Tolerance
DC Voltage Adjust (typ)
Temperature Coefficient
Ripple/Noise
Over Voltage Protection
Short Circuit Protection
Setup, Rise, Hold Up Time
17as
vs.7
I 32.51
88-132 / 176-264 VAC
Switch Selected
47-440 Hz
20AI115VAC, 40A1230VAC
Input Voltage Range
*iESIN
MECHANICA
U- -P---A-----
150.0
45.5
117.5
+V
AD.
4-M
See Selection Chart
5 & 7.5V: +/- 1%, typ
All Others: +/- 0.5%, typ
+/- 0.5%, typ
5 & 7.5V: +/-2%, typ
All Others: +1-1%
+/-10%, typ
+/-0.03%/DegC
5 thru 24V: 150mV, typ
27V: 200mV, typ
48V: 240mV, typ
Clamp, 115-135%, typ*
Continuous, self-recovering
2S, 20mS, 20mS
2
-
s-sM-41-5.5K
150.0
---
4-144 L=Emm
AC Line-..
4
AC Neutral
FG
-Output
6
-Output
2
3
I/P-O/P: 3000VAC
l/P-Ground: 1500VAC
83%, typ
167Khz, (fixed, typical)
UL
Efficiency
Switching Frequency
Approvals
Safety
UL1950
FAN
16c,
215.0
32.5
A:
Input-Out Isolation
7Cm
+ Output
8
9
+
Output
UL File# E183223
S-320-15- 48
100
80
-10 to +60 DegC(See Derate)
-20 to +85 DegC *
20% to +90%, non-cond
403 kHrs
Mil Std 217, 25C
Oper. Temperature
Storage Temperature
Relative Humidity
MTBF
S60>0
20
-10
-- --Y-A-
Size
Construction
Weight
EC
S-320-5,7.5,12
0
S40-
CAT---
0
10
20
30
40
50
60 (HORIZONTAL)
AMBIENT TEMP. ('C)
4.6" x 8.6" x 2.0"
Enclosed
2.53 lb, (1.15Kg)
* These are stress ratings. Exposure of the devices to any of these conditions
may adversely affect long term reliability. Proper operation under conditions other
than the standard operating conditions is neither warranteed nor implied.
Astrodyneproducts are not authorized or warranteed for
use as critical components in life supportsystems,
equipment used in hazardous environments, nuclear
controlssystems, or other mission-criticalapplications.
300 Myles Standish Blvd., Taunton, MA 02780
Fax: 508-823-8181
Ph: 1-800-823-8082
Figure C-12: Servoamplifier Power Supply Spec Sheet 2
135
Gurley
I G IP11'""""
1,
Precision Instruments
ISO 9001 Certified I
Motion type:
Usage Grade:
Output:
Max. Resolution:
Rotary
Light industrial
Incremental
40,960 counts/rev
Model R119 Rotary incremental Mini-Encoder
SMALLEST HIGH
RESOLUTION ENCODER!
514 FULTON ST
a
The Model R119 optical incremental encoder is designed for light industrial
applications that require high resolution in a very small package. It is available in both shafted and blind hollow shaft versions. The two models share
these features:
*
19 mm body
* LED illumination for long life (>100,000 hours)
Differential photo-detectors for signal stability
o
* Single-board, surface-mount electronics for reliability
* RS-422 differential line driver output for noise immunity
* Zero index signal
* Monolithic integrated ASIC for internally interpolated resolutions up to
10,240 cycles/rev (40,960 counts/rev)
518-274-0336
TROY, NY 12181 a PHN 800-759-1844 a 518-272-6300 a FAX
encoders@gurley.com
http://www.gurley.com
Figure C-13: Encoder Spec Sheet 1
136
SPECIFICATIONS
See Note
Model R119B or Model R119S
1, 2
1, 3
1, 4
1024
10,240
40,960
IX, 2X, 5X or 1oX
4
24
0.15
Maximum line count on disc
Maximum cycles/rev (quad sq waves)
Max counts/rev (after quad decode)
Internal square wave interpolation
Instrument error, arcminutes
Quadrature error, ± electrical degrees
Interpolation error, ± quanta
Maximum output frequency, kHz
1X square waves
2X square waves
5X square waves
1 OX square waves
Starting torque, in-oz (N-m) @20'C
Running torque, in-oz (N-m) @20_C
Moment of inertia, in-oz-s' (g-cm")
Maximum weight, oz (g)
Sealing
Operating temperature, "F ('C)
Storage temperature, *F (*C)
Humidity, % rh, non-condensing
Shock
Vibration
100
150
300
500
0.07 (4.9 x 10')
0.04 (2.9 x 104)
3.4 x 10' (0.24)
0.5 (15)
IP50
32 to 158 (0 to 70)
0 to 160 (-18 to 71)
98
31 g (300 m/s2)
10 g (100 m/s!)
S = Shaft version; B = Blind hollow shaft version
NOTES:
1.
Total Optical Encoder Error is the algebraic sum of Instrument Error + Quadrature Error + Interpolation Error.
Typically, these error sources sum to a value less than the theoretical maximum. Error is defined at the signal
transitions and therefore does not include quantization error, which is ±1/2 quantum. ("Quantum" is the final
resolution of the encoder, after user's 4X quadrature decode.) Accuracy is guaranteed at 20'C.
2.
Instrument Error is the sum of disc pattern errors, disc eccentricity, bearing runout and other mechanical imperfections within the encoder. This error tends to vary slowly around a revolution.
3.
Quadrature Error is the combined effect of phasing and duty cycle tolerances and other variables in the basic
analog signals. This error applies to data taken at all four transitions within a cycle; if data are extracted from IX
square waves on a 1X basis (i.e., at only one transition per cycle), this error can be ignored.
Error in arcminutes = (60) x (error in electrical degrees) -. (disc line count)
4.
Interpolation Error is present only when the resolution has been electronically increased to more than four data
points per optical cycle. It is the sum of all the tolerances in the electronic interpolation circuitry.
Error in arcminutes = (21600) x (error in quanta) (countsirev)
As part of our continuing product improvement program, all specifications are subject to change without notice.
514 FULTON
ST a
TROY, NY
http://www.gurley.com
12191
a PHN 300-759-1844 * 518-272-6300 a FAX 518-274-0336
encoders@gurley.com
Figure C-14: Encoder Spec Sheet 2
137
INPUT POWER
+5 VDC @100 mA max.
SQUARE WAVE OUTPUT
Quadrature square waves at 1, 2, 5 or 10 times the line count on the disc. On all channels: EIA/RS-422
balanced differential line driver, protected to survive an extended-duration short circuit across its output.
May be used single-ended for TTL-compatible inputs. Index is %-cycle wide, gated with the high states of
channels A and B.
OUTPUT WAVEFORMS (CW rotation shown)
CHANNEL
A
CHANNEL / A
CHANNEL
CHANNEL/
B
B
1/4-cycle gated
INDEX
I INDEX
ELECTRICAL CONNECTIONS
FLEXIBLE SHAFT COUPLING
Output Functions
A
Wire Colors
Conn. Code P
Conn. Code Y
Orange
2
1A
Yellow
3
Pos. No.
B
Violet
6
1A
Gray
7
IND
Green
4
/ IND
Blue
5
+V
Red
1
COMMON
White
8
R119B Tether Mount
Maximum parallel offset,
in (mm)
Maximum angular misalignment, degrees
Maximum axial extension
or compression, in (mm)
0.002
(0.05)
2.0
0.008
(0.2)
NOTE: Flexible couplings are intended to
absorb normal installation misalignments and run-outs in order to prevent
undue loading of the encoder bearings.
To realize all the accuracy inherent in
the encoder, the user should minimize
misalignments as much as possible.
NOTE: Channel A leads Channel B for clockwise
shaft rotation, viewed from the shaft end.
514 FULTON ST * TROY, NY 12181 - PHN 800-759-1844 o 518-272-6300 o FAX 518-274-0336
http://www.gurley.com
encoders@gurley. corn
Figure C-15: Encoder Spec Sheet 3
138
/
-
-024.0
M2.6
[0 1.111
3.5 [.14]
MAY VARY)
2 PLCS
o28.1
TETHER MOUNT ROTATED
90* THIS VIEW FOR CLARITY
M2. 2 PLCS
(SHCS SHOWN,
19.0 [.75]
V.941
[1
B.C
.
019.0
0"D"
8 CONDUCTOR
RIBBON CABLE
07.810.301
--
[0.75]
--
\
6.5[.26] MAX
SHAFT INTRUSIOW10
[.39]
1.5 1.06])~
1~~
R119B (BASE CODE A)
"1"TABLE
R119B"D"
R119S 'D
CODE
4
Im___ N/
04M
4mm h6
[
03M
3mm h6
0.125"
02E
NA
3mm H7
0125"
W03
1.2 (.05]
/-1 5.0[0.59]
23.0 (.91] MAX
6.0 [.24]
--
M2x3
2 PLCS
019.0
(0.751
/
N
07.5 (0.30]
8 CONDUCTOR
RIBBON CABLE
-
-J_
--
1.5[.061
101.39
R119S (BASE CODE B)
514
FULTON ST
* TROY, NY
12181
PHN
800-759-1844
SIS1-272-6300 9 FAX 518-274-0336
http://www.gurley.com
Figure C-16: Encoder Spec Sheet 4
139
encodersegurley.com
ORDERING INFORMATION
R119 SHAFT - LINES Q - 5 L INTERP - BASE CAB S CONN - DIA SF
CONN - Connector
P
Pigtails (no connector)
Y
8-pos ribbon cable socket connector
(Berg 71602-308 or equal)
SHAFT
S Shaft version
B
Blind hollow shaft
LINES - Disc line count
00360, 00500, 00512, 00900, 01000, 01024
Bold counts exist; others will be added.
Consult factory for other line counts
INTERP - Interpolation factor
01, 02, 05, 10
BASE
A
B
Use with R1 19B
Use with R119S
DIA - Shaft diameter
04M 4 mm (SHAFT = S)
03M 3 mm (SHAFT = S or B)
02E 1/8" (SHAFT = S or B)
SF - Special features
#
Issued at time of order to cover special
customer requirements
N
No special features
CAB - Cable length, inches
18 Standard
SPECIAL CAPABILITIES
For special situations, we can optimize catalog encoders to provide higher frequency response, greater
accuracy, wider temperature range, reduced torque, non-standard line counts, or other modified parameters. In addition, we regularly design and manufacture custom encoders for user-specific requirements.
These range from high-volume, low-cost, limited-performance commercial applications to encoders for
military, aerospace and similar high-performance, high-reliability conditions. We would welcome the opportunity to help you with your encoder needs.
WARRANTY
Gurley Precision Instruments offers a limited warranty against defects in material and workmanship for a
period of one year from the date of shipment.
R119 data sheet.doc
5-Jul-00
514 FULTON ST e TROY, NY 12181 * PHN 800-759-1844 a 518-272-6300 e FAX 518-274-0336
http://www.gurley.com
encoders@gurley.com
Figure C-17: Encoder Spec Sheet 5
140
S720 MINIATURE JOINT ANGLE SHAPE SENSORTM
Revision 000613
sensor. Can be used to measure the angle
of any small 1 degree of freedom joint
two channel 12 bit A/D and Windows
software allowing the display and storage
of sensor data. Power for up to two
sensors is supplied by the A/D.
including fingers, toes, or mechanical
parts. Because of its small size, the S720
Options: The S720 SHAPE SENSOR' can
is a
The S720 SHAPE SENSOR"
comfortable, flexible, bipolar joint angle
can be mounted with a reusable, flexible
allows easy
adhesive polymer, which
adjustment to a natural form along the
neutral axis of the joint. The polymer may
be used either directly on the skin, on a
be made longer to extend the distance
from the electronics to the sensor for
measurements in magnetic-sensitive and
explosive environments. It can also be
glove or on biocompatible tape.
environments.
Stand
power
a high
supply
Alone: Apply your own regulated
supply, 5 to 15 volts. The output is
level signal, ratiometric with the
voltage, that requires no additional
hermetically sealed to operate
in harsh
Larger Joints: For larger one degree of
freedom joints you can use our S700 or
S710 Joint Angle SHAPE SENSOR".
signal conditioning. This sensor is ready to
make measurements right out of the box.
Multiple Joints: For multiple joints or
joints with multiple degrees of freedom try
As a Package: A package includes the
S720 and an S270 12 bit data acquisition
system. The S270 comes complete with a
our SHAPE TAPE'
"the tape that knows
where it is."
Measurand Inc.
Figure C-18: Joint Angle Sensor Spec Sheet 1
141
-- ALA
35 -
S720
SHAPE SENSOR'
34
00
2mm
curvature sensing
zone
gain
offset
-
20015
0 5
.
T
Aie-pi
fiber
3.2mm x 1m cable
og
see
optic leads coated
ihuehs
with
urethane
(insensitive to curvature)
tdimensions in millimeters unless otherwise indicated)
CHARACTERISTICS
These typical characteristics are approximate and subject to change without notice
g = gram: gf = gramforce = 9.8 mN: G = acceleration of gravity.
Characteristics are for 5 VDC supply.
Full scale (FS) range: ± 1.0 V for ± 900 joint angles.
Output voltage for straight sensor: 2.5 V, ± 0.2 V.
Accuracy: ±2% of FS.
Resolution: 0.05'.
Noise floor: 0.07 mVrms/Hz
2
3dB Bandwidth: 1.0 kHz.
0
Environmental: -40 C to +70
0
C.
0
Temperature sensitivity, offset: ±2% of FS, -40 C to +70
0
C.
Excitation: 5 to 15 VDC (Supply current at 5 VDC, 15'C: s 5 mA).
Electrical Connections: Red: Power Supply (5 to 15 volts regulated); Black: Ground(Power
Supply and Signal); Clear: Sensor Output.
Measurand Inc.
921 college Hill Road
Fredericton, NB Canada E3B 6Z9
Tel: 506-462-9119; Fax 506-462-9095
Email: sales@measurand.com
www.measurand.com
Figure C-19: Joint Angle Sensor Spec Sheet 2
142
Enclosed
Switching
25 Watt Power Supplies
" D-YN
ASTR 17DYNC
*
Universal 85-265VAC Input
AS-25
*
High Efficiency
Series
*
Regulated Outputs
*
3000V Isolation
U Built in EMI Filter
1J
C
I
Unit measures 3.88"W x 3.96"L x 1.4"H
Model Number
Output
Voltaae
Output
Amps (MAX)
Price
25
I
SINGLE OUTPUT
AS-25-5
AS-25-12
AS-25-15
AS-25-Z4
5VDC
12 VDC
1s V0C.
24 VC
5
$39:
2.1
$39
1.7
:1.1
$39
$39
$35
$35
$35
$35
300 Myles Standish Blvd., Taunton, MA 02780
Fax: 508-823-8181
Ph: 1-800-823-8082
Figure C-20: Sensor Power Supply Spec Sheet 1
143
Contact
Factory
for
High Volume
Pricing
Enclosed Switching
ASTR"
R14iF DYNE
25 Watt Power Supplies
All specifications are typical at nominal input, full load, and 25DegC
unless otherwise noted
Input Voltage Range
Frequency Range
Inrush Current, typ:
85-264 VAC
47-440 Hz
15A @ 115VAC Input *
30A @ 230VAC Input
- -~-- ~
+oTI
55
5.5
,nl-
Voltage and Current
Load Regulation
(0% to 100% Load)
Line Regulation
Voltage Tolerance
DC Voltage Adjust (typ)
Temperature Coefficient
Ripple/Noise
Over Voltage Protection
Short Circuit Protection
Setup, Rise, Hold Up Time
J 3
See Selection Chart
5V: +/- 1% of FS, typ
All Others: +/- 0.5%, typ
+/- 0.5, typ
5V: +/-2%, typ
All Others: +/-1%
5V: +10%, -5% of FS
All Others: +/-10%
+/-0.03%/DegC
5V: 50mV Pk-Pk, typ
All Others: 1OOmV Pk-Pk, typ
Clamp, 115-135% *
Continuous, self-recovering
8OOmS, 50mS, 10mS/115VAC
300mS, 50mS, 80mS /230VAC
98.5
87
6.5
1
2
3
Input-Out Isolation
-t
7
+
4
/P-O/P: 3000VAC
AC Neutral
AC Line
5
I/P-Ground: 1500VAC
76%, typ
Efficiency
56Khz, (fixed, typical)
Switching Frequency
UL / TUV /CE
Approvals
Safety
EN60950, 1EC950, TUV File# R9653551
UL1012, UL File# E127738
output*
Output
FG.
-.
100
80
o60
Go-
Oper. Temperature
Storage Temperature
Relative Humidity
EMC
MTBF
Size
Construction
Weight
40 -
-10 to +60 DegC(See Derate)
-20 to +85 DegC *
10% to +95%, non-cond *
CISPR22 (EN55022)
IEC801-2,3,4
26 kHrs
Mil Std 217, 25C
20
-10
-10
0
0
10
20
30
40
50
45
60 (VERTICAL)
55 CHORIZONTAL
AMBIENT TEMP. ()
Astrodyne products are not authorized or warranteed for
use as criticalcomponentsin life support systems,
equipment used in hazardous environments,nuclear
controlssystems, or other mission-criticalapplications.
3.88" x 3.96" x 1.4"
Enclosed
0.8 oz, (370g)
These are stress ratings. Exposure of the devices to any of these conditions
may adversely affect long term reliability. Proper operation under conditions other
than, the standard operating conditions is neither warranteed nor implied.
300 Myles Standish Blvd., Taunton, MA 02780
Fax: 508-823-8181
Ph: 1-800-823-8082
Figure C-21: Sensor Power Supply Spec Sheet 2
144
Appendix D
Appendix D
-
Pro/Engineer
Drawings
145
2
For Educati
al Use
Only
---------
-o
0f
V
LiL
A
ISOMETRIC
VIEW
14-Mov-00
DESIGNER
NossoC
K. Jugenheimer
TOLERANCES
XCV
MATERIAL
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Anlcs
Shect
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TOLE
0.002
*-0.
5 deg
AI
F _________
ALL DIMENSIONS
I AC SN
UNLESS SPECIFIED OTHENISE
For
Educati
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elostRomle
Ichnology
of Eni enol g
Deparfmenf
of M=caIcal
In
Ii "e 1 'ng
02139
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Angle
ANGLEKCASINGI
Orowitg File
SCALE 0.750
SHEET I OF 2
2
For Educoti
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3.63
NOTE:
ALL BENDS HAVE OUTSIDE
RADIUS EQUAL TO SHEET
THICKNESS (1/8')
S.25
2.75
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For Educofi, al
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05 deg
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I NTERPRET
PER ANSI
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ALL DIMENSIONS IN INCHES
ISE
UNLESS S'ECIFIED OHEO
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Istitute of Techrology
MassachuselIs
TOLERANCES
ProlE
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2
Drawing File
ANGLKECAS ING-2
SIZE A
SCAL.E 0.750
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2.13
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1.500
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ALL ROUNDS I/4 UNLESS
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Finger Flexure
RifFRIRE7
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UNILESS SPECIE LED OTHERWISE
For Educati4al
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-
FINGER -FLEXURE
SIZE A
I
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SHEET
I or 2
ring
2
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1
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TITLE
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TOLERANCES
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TAERWI SE
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Pro/E
Drawing
-
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file
MA INETOP
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750
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Bibliography
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