1.

0 Implementation of Final Design

1.1 Drawing & Design Description

Image 1.1: CAD drawing for out finalize design using CREO CAD Drawing

Contents
Components/Parts
Material
Dimensions (L x W x H)
Weight
Maximum Weight Capacity
Motor

Description
13
Duralumin
420 x 320 x 1505
15kg
80kg
4P Single Phase Induction AC Geared-Motor
Model:M81X25G4GGA
Cost Estimation
RM
Table 1: Specification of Design

The picture above shows our CAD drawings of the finalize design of motorized leg brace and the
designs specification. The drawing is drew using CREO Parametric 3.0, a student version of

CAD drawing software which is commonly used in UNITEN. The drawing consists of 13
different types of components which consists total of 30 parts as shown in the picture below:

Image 2: Bill of Material (BOM) of Drawing

A circular shape pipe was chosen for the links because of its benefits of lightness, since it has
high moment of inertia compare to other cross-sectional shapes [1]. From the drawing, several
analysis has been done to determine the capability of this design and find out if the design fulfill
the criteria and sub-system from the initial planning. Those analysis carried out such as stress
analysis, mass and volume analysis, cost analysis and safety analysis. This analysis is under
suggestion of the project supervisor, Mr. Adzly which is important to determine the criteria of
this motorized leg brace especially safety and stress analysis because it need to be confirmed that
this motorized leg brace is safe to wear and safe to function by user and prevent any kind of
injuries happen to the user. The design of the motorized leg brace are focused more on teenagers
age range between 16 to 20 years old as it is requested by Mr. Adzly.

Image 3: Picture of a person wearing motorized leg brace and walking aid
Image above shows that a person wearing a motorized leg brace and holding a walking aid.
Because of the motorized leg brace design cant fully support a person weight and the user might
have fall down, the design is so that the user have to use a walking aid to support them from
falling in front. Besides, the design is installed with a back support to prevent the user from
falling behind. The dimension of the motorized leg brace is design based on an 18 years old
disabled teenager boy from the survey conduct by Mr. Adzly and his team. The boy lower body
dimensions are shown below:
1)
2)
3)
4)

Left to right pelvis:

Waist to knee:
Knee to ankle:
Foot:

1.2 Mass and Volume

38mm
48mm
45mm
22mm

Image 4: Mass and volume analysis of back support

Image 5: Mass and volume analysis of the belt

Image 6: Mass and volume analysis of the leg

Image 7: Mass and volume analysis of the foot slipper

Image 8: Mass and volume analysis of the leg thigh

Pictures above show the mass and volume analysis of the parts from the motorized leg brace
using CREO Parametric 3.0. The software used the density of the material to calculate the total
volume and masses of the component. Duralumin is selected as the material for the components
because of its low cost, excellent strength to weight ratio and having good strength while being
lightweight. Furthermore, it is extremely hard and though, with high resistance to stress
corrosion and erosion [2]. The density of duralumin is 2790 kg/mm 3 [3]. Therefore, the total
mass of the components above is 9.4 kg and its volume is 3320 cm 3. The mass of nuts, screws
and bearing are excluded because of it light weight and does not affect much to the weight of the
design. The weight of each motors are 1kg and a total of 4kg for 4 motor. The leg braces are
either made of plastic or metal and we choose plastic because of it is soft and comfortable unless
metal which is hard and strained [4]. So, it can be said that the leg braces on the motorized leg
brace are also neglected because of light weight of plastic. Therefore the total mass of the
designed motorized leg brace is 13.4 kg with a volume of 3320 cm3.

1.3 Stress Analysis

Image 9: Free Body diagram (FBD) of back support

Image 10: Stress Analysis Result of back support

Image 11: Free Body Diagram (FBD) of the leg

Image 12: Stress Analysis Results of the leg

Image 13: Free Body Diagram (FBD) of the foot slipper

Image 14: Stress Analysis Results of the foot slipper

Image 15: Free Body Diagram (FBD) of the thigh

Image 16: Stress Analysis Result of the thigh

1.4 Factor of Safety (FOS)

Tensile Yield Strength of Duralumin = 140 MPA [5]

Max Von Misses Stress from stress analysis results

Max Von Misses Stress of back support = 8.964 x 103 kpa
Max Von Misses Stress of leg = 2.296 x 104 kpa
Max Von Misses Stress of foot slipper = 1687.29 kpa
Max Von Misses Stress of thigh = 41238 kpa

FOS=

Tensile Yield Strength

Max Von Misses Stress

Factor of Safety for each component

FOS of back support=

FOS of leg=

140 MPA
=15.62
8.964 x 103 kPA

140 MPA
=6.10
2.296 x 10 4 kPA

FOS of foot slip per=

FOS of thigh=

140 MPA
=82.99
1687 kPA

140 MPA
=3.39
41238 kPA

References
[1 Jung-Hong Kim, Jeong Woo Han, Deog Young Kim, Yoon Su Baek, "Design of a
] Walking Assistance Lower Limb Exoskeleton for Paraplegic Patients and Hardware
Validation Using COP," International Journal of Advanced Robotic System, p. 6,
2012.
[2 "Answer.com," [Online]. Available:
] http://www.answers.com/Q/What_are_the_advantages_of_using_duralumin?
#slide=1. [Accessed 27 Aug 2016].
[3 T. E. ToolBox, "Metals and Alloys - Density," [Online]. Available:
] http://www.engineeringtoolbox.com/metal-alloys-densities-d_50.html. [Accessed
27 Aug 2016].
[4 "Hanger Clinic," [Online]. Available: http://www.hangerclinic.com/bracing] support/adult-le/Pages/default.aspx. [Accessed 27 Aug 2016].
[5 Wikipedia, "7075 Aluminium Alloy," [Online]. Available:
] https://en.wikipedia.org/wiki/7075_aluminium_alloy. [Accessed 27 Aug 2016].

Appendices
1) Screw

2) Nut

3) Right Leg Brace

4) Left Leg Brace

5) Back Support

6) Leg Brace

7) Right Foot

8) Left Foot

9) Walking Aid

10) Bearing

11) Lower Leg

12) Upper Leg

13) Motor

14) Hip Belt