Document Revision No.: 2 Revised: 02/03/2015 RIT KGCOE MSD Program

P15010 Arc Wheelchair Swing

Test Plans & Test Results

Table of Contents

MSD I: WEEKS 8-10 PRELIMINARY TEST PLAN

1INTRODUCTION AND OVERVIEW

Project Background

Individuals that require certain types of sensory stimulation look to the Arc of Monroe County’s Day Service Program for assistance. More often than not, members of our community bound to a wheelchair are unable to experience types of mobility supporting a wide range of vestibular movement that those without wheelchairs can experience with ease.

This project focuses on the development and implementation of a mechanism that enables individuals constrained to a wheel chair to experience the motion of swinging without exiting their standard or powered wheelchairs. In addition, the system needs also have an easy switch to a basic platform swing for those who require more intense stimulation and are not in a wheelchair. The goal of this project is to integrate the needs of Arc’s Day Services program participants and volunteers into a safe product that can provide the motion of swinging both indoors and outdoors without exceeding a budget of $2,500. The expected result is an implemented, fully functional dual platform-wheelchair swing prototype that meets or exceeds requirements delivered to the customer no later than May 2015. Furthermore, the design will focus greatly on ensuring that future developments for the product can be done with ease if possible.

Project Testing Overview

The end user of the product needs to be completely safe while utilizing the system. For this reason, strength, fatigue and stress tests will be critical to system testing. Testing will be broken up into two phases, simulation and mathematical testing using strength analysis techniques and computer tools available such as SolidWorks. The second phase of testing will be physical testing of each subsystem and the final product as a whole.

2SUBSYSTEM FUNCTIONS AND TESTING

Frame

2.1.1Associated Engineering Specifications

Rqmt. # / Source / Functional Decomposition Function / Detailed Function / Engr. Requirement / Unit of Measure / Marginal Value / Ideal Value / Comments/Status
S3 / CR2/ CR3/ CR12/ CR16 / Provide Safe Experience/Start Movement/Stop Movement / System accommodates for elongation or vertical movement of platform caused by increased weight / Platform can complete intended motion at increased weights. / lbs / 400-800 / 750 / Maximum value calculated using maximum participant weight and maximum wheelchair weight. Weight was confirmed with ARC of Monroe. Customer signoff completed.
S7 / CR6 / Assemble Swing / Disassembled mechanism can fit through Arc's facility doors / When disassembled, pieces fit through approximately 5' x 7.5' space. / feet / 5.5'x7'-6'X'6 / 4'X'4 / Door Values at Arc between inside and outside.
S8 / CR10/ CR9 / Assemble Swing / Two Arc facilities management employees can move/assemble apparatus / When disassembled, pieces are less than 102 lbs each. / lbs / 52-102 / 75

2.1.2Testing Phase I

Critical Values / *Use Figure in 2.1.3 for Reference
Stress Analysis Beam 1, 2
Moment of Inertia / 15.21842 / in^4 / (width*height^3) - ((inside_width*inside_height^3)/12)
Static Deflection / 0.01472 / in / ((length^3 * force)/(48 * E * MI))
Dynamic Deflection / 0.01589 / in / ((length^3 * force)/(48 * E * MI))
Active Deflection / 0.00116 / in / Dynamic - Static
Stress / 2500.47511 / psi / ((force * length)/(MI / (0.5 * height))
Stress Analysis Beam 4
Moment of Inertia / 0.67373 / in^4 / (pi/64)*((OD^4)-(ID^4)
Static Deflection / 0.00052 / in / (Load*length^3)/(48*Elastic Modulus*Moment of Inertia)
Dynamic Deflection / 0.00077 / in / (Load*length^3)/(48*Elastic Modulus*Moment of Inertia)
Active Deflection / 0.00025 / in / Dynamic - Static
Stress / 604.43399 / psi / (Load*length)/(4*outer radius)
Stress Analysis Beam 5-8
Moment of Inertia / 0.67373 / in^4 / (pi/64)*((OD^4)-(ID^4)
Static Deflection / 0.004339358 / in / (Load*a^2*b^2)/(3*Elastic Modulus*Moment of Inertia*Length)
Dynamic Deflection / 0.00468 / in / (Load*a^2*b^2)/(3*Elastic Modulus*Moment of Inertia*Length)
Active Deflection / 0.00034 / in / Dynamic - Static
Stress / 325.35501 / psi / (Load*a*b)/(Outer Diameter*Length)
Stress Analysis Beam 9-12
Moment of Inertia / 0.67373 / in^4 / (pi/64)*((OD^4)-(ID^4)
Static Deflection / 0.002069731 / in / (Load*a^2*b^2)/(3*Elastic Modulus*Moment of Inertia*Length)
Dynamic Deflection / 0.00304 / in / (Load*a^2*b^2)/(3*Elastic Modulus*Moment of Inertia*Length)
Active Deflection / 0.00097 / in / Dynamic - Static
Stress / 211.10448 / psi / (Load*a*b)/(Outer Diameter*Length)
Stress Analysis Beam 13, 14
Moment of Inertia / 0.08936 / in^4 / (pi/64)*((OD^4)-(ID^4)
Static Deflection / 0.1598665 / in / ((Load*a)/(24*Elastic Modulus*Moment of Inertia))*((3*Length^2)-(4*a^2))
Dynamic Deflection / 0.17251 / in / ((Load*a)/(24*Elastic Modulus*Moment of Inertia))*((3*Length^2)-(4*a^2))
Active Deflection / 0.01264 / in / Dynamic - Static
Stress / 306.55308 / psi / (Load*a)/Outer Diameter

2.1.3Testing Phase II

Subsystem/ Function/ Feature Name: Frame

Date Completed: ______

Performed By: ______

Tested By: ______

Test # / Specification (description) / Unit of Measure / Marginal Value / Comments/Status
2.1 / TS1 / Beam 1/ Weldment Connection 1-6/ 1-5 Strength in Frame / In / 0.5 / Insert Beam 1 into Weldments. Clamp Weldments to table/sturdy structure. Hang weight (404 lb) from center of beam 1. Measure displacement in Beam 1/Weldments
2.1 / TS2 / Beam 2/ Weldment Connection 2-7/ 2-8 Strength in Frame / In / 0.5 / Insert Beam 2 into Weldments. Clamp Weldments to table/sturdy structure. Hang weight (404 lb) from center of beam 2. Measure displacement in Beam 2/Weldments
2.1 / TS3 / Beam 13/ Weldment Connection 13-8/ 13-5 Strength in Frame / In / 0.5 / Insert Beam 13 into Weldments. Clamp Weldments to table/sturdy structure. Hang weight (50 lb) from center of beam 13. Measure displacement in Beam 13/Weldments
2.1 / TS4 / Beam 14/ Weldment Connection 14-6/ 14-7 Strength in Frame / In / 0.5 / Insert Beam 14 into Weldments. Clamp Weldments to table/sturdy structure. Hang weight (50 lb) from center of beam 14. Measure displacement in Beam 14/Weldments
2.1 / TS5 / Beam 7/8/ Weldment Connection 8-2/ 7-2 / In / 0.5 / Insert Beams 2, 8 and 7 into weldments. Clamp footers down to floor. Apply support to weldments so assembly stands upright. Hang weights (404 lbs) from Beam 2 and Measure deflection in Beams 7, 8. Inspect weldments for wear.
2.1 / TS6 / Beam 5/6/ Weldment Connection 5-1/ 6-1 / In / 0.5 / Insert Beams 1, 5 and 6 into Weldments. Clamp Footers Down to Floor. Hang Weights (404 lbs) From Beam 2 and Measure Displacement in Beams 7/8 and Weldments.
2.1 / TS7 / Beams 9-12, Top Weldment / In / 0.5 / Clamp bottom weldments to table/floor. Insert Beams into weldments and put top weldment onto beams. Hang weights (514 lbs) from top weldment and measure the displacement in beams 9-12 and the top weldment connections.
2.1 / TS 8 / Propulsion and Frame Inspection / in / 0.5 / Complete full assembly of propulsion system and frame and apply weight (808 lbs) to center of Beam 3. Inspect weldments for wear and all horizontal Beams for total system deflection.

2.1.4Approval

Sean Kennelly:______

Elizabeth Cutolo:______

Owen Breese:______

Maggie Bates:______

Gerry Garavuso: ______

Wheelchair Swing Shaft

2.1.5Associated Engineering Specifications

Rqmt. # / Source / Functional Decomposition Function / Detailed Function / Engr. Requirement / Unit of Measure / Marginal Value / Ideal Value / Comments/Status
S2 / CR2 / Provide Safe Experience/Start Movement/Stop Movement / Platform can complete motion without hitting the ground. / Platform can complete motion within range of 2" to 12" off ground at rest. / inches / 2.0-12.0 / 4 / Ideal value calculated with possible 50''x40''' platform and 8' swing arm.
S3 / CR2/ CR3/ CR12/ CR16 / Provide Safe Experience/Start Movement/Stop Movement / System accommodates for elongation or vertical movement of platform caused by increased weight / Platform can complete intended motion at increased weights. / lbs / 400-800 / 750 / Maximum value calculated using maximum participant weight and maximum wheelchair weight. Weight was confirmed with ARC of Monroe. Customer signoff completed.
S6 / CR4 / Start Movement/Stop Movement / Force to push swing will be equal to or less than the frictional force between the aid and ground. / Estimated force to push participant is at minimum 46.46 lbft and at maximum 425 lbft based on calculations so frictional force must be greater than or equal to that. / lbf / 25-100 / 50 / Investigate the dynamic force required to get swing to max height in 5 pushes.
S7 / CR6 / Assemble Swing / Disassembled mechanism can fit through Arc's facility doors / When disassembled, pieces fit through approximately 5' x 7.5' space. / feet / 5.5'x7'-6'X'6 / 4'X'4 / Door Values at Arc between inside and outside.
S8 / CR10/ CR9 / Assemble Swing / Two Arc facilities management employees can move/assemble apparatus / When disassembled, pieces are less than 102 lbs each. / lbs / 52-102 / 75
S9 / CR7/ CR11/ CR4 / Provide Safe Experience/Start Movement/Stop Movement / Degree of motion enables vestibular stimulation but also does not endanger participant safety or aid safety / Has a swing motion of 30 degrees / degrees / 15 - 45 / 30* / Action Item- need to calculate the amount of force required for stimulation . As of now these are just educated estimates.
S11 / CR11 / Stop Movement / Braking system can be safely operated by aid. / Braking system is within 24" (arm length) of the aid at all times throughout operation / inches / 12''-36'' / 24 / Adjusted according to number of oscillating periods required to slow and stop swing. (Current oscillating period is 3 seconds, so 2 periods is 6 seconds hence the engineering req.
S12 / CR14 / Provide Safe Experience/Start Movement/Stop Movement / Swing will not exceed a safe swinging velocity / Swing will not exceed a speed of 12 feet per second / feet/second / 12sec-3sec / 5 / Based on Pendulum Calculations. 4.4 ft/s calculated from a .3 ft maximum swing height.

2.1.6Testing Phase II

Subsystem/ Function/ Feature Name: Frame

Date Completed: ______

Performed By: ______

Tested By: ______

Test # / Specification (description) / Unit of Measure / Marginal Value / Comments/Status
2.2 / TS1 / Bearing Housing Secure 1 / In / 0.5 / Housing for bearing is welded on frame. Hang weight off of inside side of housing. Measure displacement.
2.2 / TS2 / Bearing Housing Secure 2 / In / 0.5 / Housing for bearing is welded on frame. Hang weight off of inside side of housing. Measure displacement.
2.2 / TS5 / Vertical Movement when swinging / In / 0 / Place Beam 3 with bushings into welding housing. Attach the wheelchair swing. Swing wheelchair swing with weight. Measure displacement in Beam 3.
2.2 / TS6 / Horizontal Movement when swinging / In / 0.5 / Place Beam 3 with bushings into welding housing. Attach the wheelchair swing. Swing wheelchair swing with weight. Measure displacement in Beam 3
2.2 / TS6 / Swing-Shaft Attachment Stability / X / X / Does swing rotate around shaft when shaft moves? Answer should be NO.

2.1.7Approval

Sean Kennelly:______

Elizabeth Cutolo:______

Owen Breese:______

Maggie Bates:______

Gerry Garavuso: ______

Wheelchair Swing Platform

2.1.8Associated Engineering Specifications

Rqmt. # / Source / Functional Decomposition Function / Detailed Function / Engr. Requirement / Unit of Measure / Marginal Value / Ideal Value / Comments/Status
S2 / CR2 / Provide Safe Experience/Start Movement/Stop Movement / Platform can complete motion without hitting the ground. / Platform can complete motion within range of 2" to 12" off ground at rest. / inches / 2.0-12.0 / 4 / Ideal value calculated with possible 50''x40''' platform and 8' swing arm.
S3 / CR2/ CR3/ CR12/ CR16 / Provide Safe Experience/Start Movement/Stop Movement / System accommodates for elongation or vertical movement of platform caused by increased weight / Platform can complete intended motion at increased weights. / lbs / 400-800 / 750 / Maximum value calculated using maximum participant weight and maximum wheelchair weight. Weight was confirmed with ARC of Monroe. Customer signoff completed.
S7 / CR6 / Assemble Swing / Disassembled mechanism can fit through Arc's facility doors / When disassembled, pieces fit through approximately 5' x 7.5' space. / feet / 5.5'x7'-6'X'6 / 4'X'4 / Door Values at Arc between inside and outside.
S8 / CR10/ CR9 / Assemble Swing / Two Arc facilities management employees can move/assemble apparatus / When disassembled, pieces are less than 102 lbs each. / lbs / 52-102 / 75
S9 / CR7/ CR11/ CR4 / Provide Safe Experience/Start Movement/Stop Movement / Degree of motion enables vestibular stimulation but also does not endanger participant safety or aid safety / Has a swing motion of 30 degrees / degrees / 15 - 45 / 30* / Action Item- need to calculate the amount of force required for stimulation . As of now these are just educated estimates.
S10 / CR8 / Enter Swing/Provide Safe Experience/Exit Swing: / Platform accommodates both standard and powered wheelchairs / Platform is 40" wide by 50" long / inches / 30+ X 50+ / 40 X 50
S11 / CR11 / Stop Movement / Braking system can be safely operated by aid. / Braking system is within 24" (arm length) of the aid at all times throughout operation / inches / 12''-36'' / 24 / Adjusted according to number of oscilating periods required to slow and stop swing. (Current oscilating period is 3 seconds, so 2 periods is 6 seconds hence the engineering req.
S12 / CR14 / Provide Safe Experience/Start Movement/Stop Movement / Swing will not exceed a safe swinging velocity / Swing will not exceed a speed of 12 feet per second / feet/second / 12sec-3sec / 5 / Based on Pendulum Calculations. 4.4 ft/s calculated from a .3 ft maximum swing height.

2.1.9Testing Phase II

Subsystem/ Function/ Feature Name: Frame

Date Completed: ______

Performed By: ______

Tested By: ______

Test # / Specification (description) / Unit of Measure / Marginal Value / Comments/Status
2.3 / TS1 / Weldment Inspection 1 / Inspect weldments of the square tubing frame for completion
2.3 / TS2 / Diamondplate Deflection / in / Assemble wheelchair platform and load with 350 lbs. Measure larges deflection along Diamondplate. Note that Max Deflection is expected in center of areas not supported by square tube directly underneath. Beams have been placed accordingly to support distributed load of wheelchair but due to size variation of wheelchairs it is not ever the same width for all.
2.3 / TS3 / Q-Straints Inspection / in / 1/4 / Secure powered wheelchair to platform using Q-Straints. Have test participant forcefully adjust position inside chair. Measure movement of wheels.

2.1.10Approval

Sean Kennelly:______

Elizabeth Cutolo:______

Owen Breese:______

Maggie Bates:______

Gerry Garavuso: ______

Wheelchair Swing to Frame Attachment

2.1.11Associated Engineering Specifications

Rqmt. # / Source / Functional Decomposition Function / Detailed Function / Engr. Requirement / Unit of Measure / Marginal Value / Ideal Value / Comments/Status
S2 / CR2 / Provide Safe Experience/Start Movement/Stop Movement / Platform can complete motion without hitting the ground. / Platform can complete motion within range of 2" to 12" off ground at rest. / inches / 2.0-12.0 / 4 / Ideal value calculated with possible 50''x40''' platform and 8' swing arm.
S3 / CR2/ CR3/ CR12/ CR16 / Provide Safe Experience/Start Movement/Stop Movement / System accommodates for elongation or vertical movement of platform caused by increased weight / Platform can complete intended motion at increased weights. / lbs / 400-800 / 750 / Maximum value calculated using maximum participant weight and maximum wheelchair weight. Weight was confirmed with ARC of Monroe. Customer signoff completed.
S7 / CR6 / Assemble Swing / Disassembled mechanism can fit through Arc's facility doors / When disassembled, pieces fit through approximately 5' x 7.5' space. / feet / 5.5'x7'-6'X'6 / 4'X'4 / Door Values at Arc between inside and outside.
S8 / CR10/ CR9 / Assemble Swing / Two Arc facilities management employees can move/assemble apparatus / When disassembled, pieces are less than 102 lbs each. / lbs / 52-102 / 75
S9 / CR7/ CR11/ CR4 / Provide Safe Experience/Start Movement/Stop Movement / Degree of motion enables vestibular stimulation but also does not endanger participant safety or aid safety / Has a swing motion of 30 degrees / degrees / 15 - 45 / 30* / Action Item- need to calculate the amount of force required for stimulation . As of now these are just educated estimates.

2.1.12Testing Phase II

Subsystem/ Function/ Feature Name: Frame

Date Completed: ______

Performed By: ______

Tested By: ______

Test # / Specification (description) / Unit of Measure / Marginal Value / Comments/Status
2.4 / TS1 / PN: ST-002 Beam Inspection 1 / Insert Beams 15 and 16 into weldment/threaded connection. Attach to frame. Hang 200 lbs from end of EACH beam. Ensure beams/connection can withstand tensile stress. Inspect connection for wear
2.4 / TS2 / PN: ST-002 Beam Inspection 2 / Insert Beams 17 and 18 into weldment/threaded connection. Hang connection point over sturdy horizontal beam/frame. Hang 200 lbs from end of EACH beam. Ensure beams/connection can withstand tensile stress. Inspect connection for wear
2.4 / TS3 / Beam to Platform Inspection / Insert Beams 15-18 through designated holes in Diamondplate/Square tubing. Thread ST-003 (Hex Nuts) onto beams. Apply 400 lbs to center of platform. Inspect threads/hex nuts for wear.
2.4 / TS4 / Beam 3 to Shaft Clamp Inspection / in / Install wheelchair swing to Beams 15-18. Roll wheelchair onto platform/secure with Q-straints. Have test participant forcefully twist inside chair. Inspect shaft clamps for movement on Beam 3.

2.1.13Approval

Sean Kennelly:______

Elizabeth Cutolo:______

Owen Breese:______

Maggie Bates:______

Gerry Garavuso: ______

Footers

2.1.14Associated Engineering Specifications

Rqmt. # / Source / Functional Decomposition Function / Detailed Function / Engr. Requirement / Unit of Measure / Marginal Value / Ideal Value / Comments/Status
S2 / CR2 / Provide Safe Experience/Start Movement/Stop Movement / Platform can complete motion without hitting the ground. / Platform can complete motion within range of 2" to 12" off ground at rest. / inches / 2.0-12.0 / 4 / Ideal value calculated with possible 50''x40''' platform and 8' swing arm.
S3 / CR2/ CR3/ CR12/ CR16 / Provide Safe Experience/Start Movement/Stop Movement / System accommodates for elongation or vertical movement of platform caused by increased weight / Platform can complete intended motion at increased weights. / lbs / 400-800 / 750 / Maximum value calculated using maximum participant weight and maximum wheelchair weight. Weight was confirmed with ARC of Monroe. Customer signoff completed.
S7 / CR6 / Assemble Swing / Disassembled mechanism can fit through Arc's facility doors / When disassembled, pieces fit through approximately 5' x 7.5' space. / feet / 5.5'x7'-6'X'6 / 4'X'4 / Door Values at Arc between inside and outside.
S8 / CR10/ CR9 / Assemble Swing / Two Arc facilities management employees can move/assemble apparatus / When disassembled, pieces are less than 102 lbs each. / lbs / 52-102 / 75
S9 / CR7/ CR11/ CR4 / Provide Safe Experience/Start Movement/Stop Movement / Degree of motion enables vestibular stimulation but also does not endanger participant safety or aid safety / Has a swing motion of 30 degrees / degrees / 15 - 45 / 30* / Action Item- need to calculate the amount of force required for stimulation . As of now these are just educated estimates.

2.1.15Testing Phase II

Subsystem/ Function/ Feature Name: Frame

Date Completed: ______

Performed By: ______

Tested By: ______

Test # / Specification (description) / Unit of Measure / Marginal Value / Comments/Status
2.5 / TS1 / Footer slippage/stability / inches / 0.1 / Attach beams 5 to individual footers. Clamp footers to floor/table. Hang weights from end of beams. Measure slippage in footers. Repeat for Beams 6-8.
2.5 / TS2 / Footer slippage/stability with wheelchair swing / inches / 0.1 / Construct wheelchair portion of frame. Hang weights from beams 1 and 2. Measure slippage in footers.
2.5 / TS3 / Footer slippage/stability with platform swing / inches / 0.1 / Construct entire swing frame. Hang weights from top weldment. Measure slippage in footers. Swing weights in full arc of motion of swing. While weights are swinging, measure slippage in footers.

2.1.16Approval

Sean Kennelly:______

Elizabeth Cutolo:______

Owen Breese:______

Maggie Bates:______

Gerry Garavuso: ______