Prototypes

The design process was iterative, and several linkages and various materials were considered. The first prototype incorporated a sort-of pulley system, where the links were connected by string. We abandoned this idea to incorporate a design more closely resembling the concepts we covered in lecture. The final design is comprised of a 5-bar-geared linkage built upon the knee brace and its geared hinge. We machined all of the parts in the UT machine shop, with the exception of the motor and the right angle gear attachments. 

The most prevalent problems encountered during the machining and assembly process related to mechanical interference. It was challenging to construct a device which would fit closely to the leg without having the moving parts get in each other's way.

It was also a challenge to base our design off of what we were comfortable machining ourselves. A lot of the parts we would have like to have used were too expensive to purchase or difficult to construct with our current skill level in the machine shop. All of our engineering skills (design, fabrication, programming, etc.) were bettered by the process of completing this project, and our final prototype is representative of our optimum design, based on time, financial, and skill constraints.

First Prototype

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Finalized Design

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Fabrication