NANYANG TECHNOLOGICAL UNIVERSITY

School of Mechanical and Aerospace Engineering

2009/2010

MP3005 – Computer Aided Design Project

Submitted by:

TAN SIA NGUAN EUGENE 082289D03

HENG CHER GUAN DANIEL XXXXXX

Submitted Date: 13/11/2009

Submitted to: Prof Tor & Prof Lee Yong Sui

Contents
1. INTRODUCTION...................................................................................................................3
1.1 Background............................................................................................................................3
1.2 Objectives..............................................................................................................................3
1.3 Scope......................................................................................................................................4
2. PRODUCT DEFINITION.......................................................................................................4
2.1 Product Brief.....................................................................................................................4
2.2 Problem Definition............................................................................................................4
2.3 Design Requirements........................................................................................................5
Rationale behind Design Requirements:.....................................................................................5
3. PRODUCT DETAILS.............................................................................................................6
3.1 Design Rationale...............................................................................................................6
3.1.1 Structure..........................................................................................................................6
3.1.2 Massage Head Frame......................................................................................................7
3.1.3 Massage Head.................................................................................................................7
3.2 Materials............................................................................................................................8
3.2.1 Cushion & Cushion Cover..............................................................................................8
3.2.2 Structure..........................................................................................................................8
3.2.3 Frame..............................................................................................................................8
3.2.4 Massage Head.................................................................................................................8
3.3 Sequence of Operation...........................................................................................................8
4. DYNAMIC SIMULATION...................................................................................................11
4.1 Stress Points.........................................................................................................................11
4.2 Dynamic Behavior of Mechanism.......................................................................................12
5. CONCLUSION......................................................................................................................14
6. REFERENCES......................................................................................................................16
REFERENCES

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1. INTRODUCTION

1.1 Background

In recent years, the global health care industry has been booming due to the increased demands
for healthy lifestyle products, as the consumers of today place intense emphasize in maintaining
a healthy lifestyle. Owing to today’s hustle and bustle working life, the majority of the populace
is unable to delicate quality time to engage in physical activities. Many have taken the easy way
out by turning to massage therapy in order to maintain their fitness in health.

With massage therapy gaining in popularity, more and more people understand the importance of
the health benefits received during regular massage treatments as it helps relieve aches, pains and
discomforts in the body. Then again, many people simply do not have the time or inclination to
go see a massage therapist on a regular basis thus leading to a new potential market demand
which gave rise to the birth of a massage chair. The massage chair is an excellent alternative to a
massage therapist as it gives you flexibility to receive a massage of any time duration at any time
of the day.

After identifying the potential growth aspect of this industry, we have conducted further market
analysis and discovered that the massage chairs are relatively costly. Hence, most market players
target the high income and/or white collar professionals. In order to undertake a substantial share
in the industry, we have decided to focus on the lower income populace by design a cheaper
variant by the introduction of cheap, simple mechanical mechanisms (double crank mechanism)
in hope of gaining a substantial market share in the health care industry.

1.2 Objectives

The objectives of the project are:

i. Determine the essentials of design through Product Development Process
ii. Familiarize CAD/CAM functionalities and capabilities in SolidWorks 2009
iii. Comprehend the physical constraints and correlations between mechanisms
iv. Analyze data obtain from dynamic simulation
v. Express and present rendered images and animations

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1.3 Scope

The main focus of the project is to allow us to understand the importance of design in the
Product Development Process which consists of 6 stages Planning, Concept Development,
System-Level Design, Detail Design, Testing and Refinement, Production Ramp-Up. With the
introduction of CAD/CAM applications, the designing interface of the product largely dictates
the Product Development Process from paper to the physical prototype. Hence, the project aims
to familiarize the essentials of CAD/CAM functionalities and capabilities in SolidWorks 2009.
From the SolidWorks friendly user interface, we were able comprehend the physical constraints
and correlations between mechanisms and analyze data obtain from dynamic simulation. In
addition, SolidWorks is capable of displaying the 3D model in rendered images and animations
for presentations which aid the explanations of the designer’s intend during conceptualization
process.

1. PRODUCT DEFINITION
With the intention of re-engineering the components in the massage chair, we propose the
introduction of a double crank mechanism. The double crank mechanism is a mechanical feature
whereby rotary motion is translated into 2 linear motions. Hence, we intend to transform the
rotary motion from a stepper motor to 2 linear outputs (like the pistons in a combustion engine).
The impact forces developed by the 2 linear outputs would ideally be the massaging components
which eases the tense muscles of the end user.

1.1 Product Brief

The product is designed with a double crank mechanism and cheap, simple mechanical
mechanisms to massage the end users. In addition, the massage chair must be ergonomic and
aesthetic to appeal to consumers.

1.2 Problem Definition

Reports and surveys have showed that some massage chairs are unable to target localized areas
desired by end users as different consumers demand massages on different locations of the body.
Hence, the massaging component must be able to access multiple locations across the chair. As
the degree of intensity of the massage is also essential, we have proposed the massage option of
increasing or decreasing the rate of the massage (fast or slow) which is determined by the speed
of the motor.

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1.3 Design Requirements

In comparison to the data acquired through the market analysis and surveys conducted, we have
finalized a list of design requirements which determines our product competitive edge and
selling points. We believe that the achievement of each requirement is essential as it dictates the
consumers’ needs and wants which drives the consumers to purchase the product to satisfy their
desires.

Design Requirements
1. Cheap
2. Comfortable
3. Wide area of massage
4. User Friendly
5. Aesthetic
6. Ease to Manufacture

Rationale behind Design Requirements:

Cheap – The low cost of the product is our main selling point. Our aim is to lure our potential
consumers into purchasing our product due the low cost and high functionality aspect.

Comfortable – The massage chair must be ergonomic and comfortable to seat on. We believe
that a comfortable chair who bestow the potential customers a form of assurance that their
dollars and cents are well spent; thus insuring them that our product is a good bargain.

Wide area of massage – The large coverage of massage area would allow the user to be able to
select the specific regions required to ease his/her tensed muscles.

User Friendly – A user friendly product interface encourages the user to operate the product
with ease, thus contributing to customer satisfaction with the product.

Aesthetic – Appearance is essential for our product. The design of the product has to look
attractive and outstanding when compared to our competitor as we aim to draw attention of the
consumer network in the current market.

Ease to Manufacture – Manufacturability determines to the cost factor mentioned above, hence
it is directly linked to our main selling point. The ease of manufacture of the product determines
the time and cost required with depends on the processes and materials used. With the intention
to reduce the product fabrication time cycle, we attempt to reduce the number of components
used and design simple, symmetry parts.

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1. PRODUCT DETAILS

1.1 Design Rationale

With accordance to the design requirements specified earlier, we have design our product such
that it fulfils all requirements. However, during the CAD design phase large emphasis has been
placed under the “ease of manufacture” requirement with the intention of reducing the cost and
time frame of producing the product. As mentioned early, the reduced cost would draw the
attention of the current consumer market whereas the reduced fabrication time allows us to
produce mass number products within a specific time. The latter enables us to capture the
markets’ attention as fast as possible before the consumer trend changes due to the introduction
of a competitor’s product(s).

3.1.1 Structure Frame

Structure

Arm

Securing
Bolts

Securing
Bolts
Seat
Support

The basic outlook of the design chair is adapted from a lounge chair concept. With the intention
of allowing the user to lie down in a relaxed state, we decided that a lounge chair would
ergonomically transcend this state of tranquility to the user.

3.1.2 Massage Head Frame Securing Bolts

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 Massage
Head
Frame

Securing
3.1.3 Massage Head Bolts

When one arm

extends, the
other retracts

Rack &
Pinnon
Cam
Linkage
Arms
Rack &
Pinnon

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1.2 Materials

The rectangle-shaped machine housing, handle and lid is basically make of a high gloss plastic to
give a shiny and reflective feeling. Plastic is also quite strong and can help to protect the internal
parts of the ice-cream pounder device. The shaft, links, pounder housing and pounder are all
made from light aluminum alloy to cut down on any unnecessary weight. As a result, the overall
weight of the ice-cream pounder device is light. This light-weight factor is important as it will
increase the portability of the device. Users can now easily carry the ice-cream pounder device
around. By using aluminum alloy too, it cut down on the probably that the device may rust. As it
is important that food consume by people is not contaminate. The Bevel gears are made of cast
iron to ensure the durability of the gear.

3.2.1 Cushion & Cushion Cover

3.2.2 Structure

3.2.3 Frame

3.2.4 Massage Head

3.3 Sequence of Operation

Initially, the user lies down on the massage chair before selecting the desired mode of massage.
Once selected, the massage head would automatically move to it designated areas of massage
and commences the massaging operation.

Stage 1

After user select mode of massage, electric signals are transmitted to the 2 stepper motors (horizontal and
vertical). The stepper motor assigned to vertical translation is actuated first. The motor then translates the

Rack &
Pinnon
massage head up or down the frame of the massage chair.

UP

DOWN

Stage 2
Once the vertical stepper motor stops operating, the horizontal stepper motor commences and
translates the massage head left or right.

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 LEFT

RIGHT

Stage 3
Upon reaching the desired location specified by the user, the massage head begins operation.
DEPTH?
The motor within the massage head begins rotating. As rotational motions are translated into
reciprocating motions via the double crank system, the rotary motion causes the massaging arms
to reciprocate in and out.

V-Belt
Motor

V-Belt

IN
ROTARY
MOTION

OUT

Stepper
Motor

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2. DYNAMIC SIMULATION
As seen from Figure 3, as the handle is turned 360 degree clockwise it causes one of the bevel
gear align to it to turn clockwise as well. The second bevel gear is aligned to the first bevel gear
at 90 degree, hence causing the second bevel gear to turn anti-clockwise. This in turn causes the
two links to turn anti-clockwise as well. The pounders then rise and sink linearly in the vertical
direction to pound the ice-cream out of the nozzle into the ice-cream cone.
Lid
Handle
Machine
Ice-Cream
Pounder
2Shaft
Pounder
Nozzle
Ice-Cream
Bevel
Links Gears
Housing
Cone

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 Figure 3

4.1 Stress Points

Stress points/Contact forces are areas that measure the average amount of force exerted per unit
area of a surface within a deformable body on which internal forces act. In other words, it is a
measure of the intensity or internal distribution of the total internal forces acting within a
deformable body across imaginary surfaces. These internal forces are produced between the
particles in the body as a reaction to external forces applied on the body. External forces are
either surface forces or body forces. [4]

Stress points are found at areas such as the 2 bevel gears because when the handle turns the bevel
gear it is in contact with, the force transmitted from this bevel gear to the next creates a lot of
contact force, hence creating the stress points too. Stress points are also found at the 4 parallel
pins too, as it is use to hold the links to the shaft and the pounder, hence when the pounder is
lifted by the links, force is exerted on the part of the parallel pins creating stress points.

4.2 Dynamic Behavior of Mechanism

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From the graphs, we can obtain statistical data to analyze and improve the dynamic motion
simulation of the double crank mechanism.

The motor of the double crank mechanism is used as a replacement for the user’s hand
movement of the handle of the ice-cream pounder. It is assume that the hand will rotate the
handle at a constant speed of 10 rpm.

Angular Velocity (motor) vs Time

Figure 4: Angular velocity of motor vs Time

As seen from Figure 4, it shows a periodic curve that starts from 0s to the end of the whole
stimulation process. The angular velocity of the motor peaks at 74 deg/s for time at 5.0 seconds
and at its lowest at 46 deg/s for time 7.3 seconds for the first period. Since there are no
fluctuations throughout the whole stimulation process; meaning no sudden surge in velocity
occasionally shows that the motor life-span would be longer.

Angular Acceleration (motor) vs Time

Figure 5: Angular Acceleration of motor vs Time

As seen from Figure 5, the angular acceleration kept fluctuating throughout the whole simulation
process. The period when the angular acceleration was lower (11.5 deg/s^2) indicates the period
when the handle was turn, it requires more energy/force to pound the ice-cream out therefore the
acceleration at that time was lower. The higher angular acceleration (18 deg/s^2) illustrates the
period when the handle was turn, it requires less energy to lift the pounder up.

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 Trans Velocity (pound) vs Time

Figure 6: Trans velocity of pound vs Time

Trans Acceleration of pound vs Time

Figure 7: Trans Acceleration of pound vs Time

As seen from Figure 6 and 7, the trans velocity kept fluctuating throughout the whole simulation
process. The period when the trans velocity was lower (34 mm/s) indicates the more
energy/force to pound the ice-cream out therefore the velocity at that time was lower. The higher
trans velocity (45 mm/s) illustrates the period when it requires less energy to lift the pounder up.

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At the instances when the trans velocity is at 34 mm/s and 45 mm/s, the trans acceleration is 0
mm/s^2 (red dotted lines). This is because the velocity is at a constant, therefore there is no
acceleration.

3. CONCLUSION
SolidWorks is a 3-D modeling tool. Unlike other 3-D modeling tools, SolidWorks is not fully
three dimensional. From SolidWorks, we learnt how to draw individual parts such as; sketch in a
plane and then extrude it to form a 3D-solid from the plane, planes are used to obtain position in
three dimensional space. SolidwWorks files consist of parts, assemblies and 2D orthographic
drawings. Individual parts are made and combined together in an assembly.
In SolidWorks we also learnt how to do orthographic assembly drawings, exploded view,
rendered view, dynamic stimulation video, NC machining tool paths.

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4. REFERENCES
“Antique Ice Cream Scoops,” 14 June 2008 [Online]. Available:
http://antiques.lovetoknow.com/Antique_Ice_Cream_Scoops [Accessed Oct 24, 2009]
“You will never buy another ice cream scooper,” July 31, 2009 [Online]. Available:
http://www.amazon.com/review/R31J95OU6GMP6L [Accessed Oct 25,2009]
“Introduction to solidworks,” 2009[Online]. Available:
http://ocw.mit.edu/NR/rdonlyres/E558854E-4D0E-4520-8098-
8EAEA2ECE0A6/0/solidworks.pdf [Accessed Oct 25,2009]
“Stress (mechanics),” 3 November 2009 [Online] . Available:
http://en.wikipedia.org/wiki/Stress_(mechanics) [Accessed Nov 4, 2009]

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