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Design, Frame Analysis and Manufacture of Handcycle Prototype

To cite this article: Rela Adi Himarosa and Sunardi 2020 J. Phys.: Conf. Ser. 1471 012058

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1st Bukittinggi International Conference on Education IOP Publishing
IOP Conf. Series: Journal of Physics: Conf. Series 1471 (2020) 012058 doi:10.1088/1742-6596/1471/1/012058

Design, Frame Analysis and Manufacture of Handcycle

Prototype

Rela Adi Himarosa1*, Sunardi1

1
Mechanical Engineering Department, Universitas Muhammadiyah Yogyakarta

*[email protected]

Abstract. Handcycle is a transportation tool for individuals with lower limb disabilities. This
study designed a handcycle as a mode of transportation to facilitate the accessibility of persons
with disabilities. The design of the handcycle was designed on a prototype scale. It referred to
recumbent and synchronous frame geometry types for arm crank set up to do finite element
analysis studies using Autodesk Fusion 360 software to find the value of the strength of the
handcycle frame design. A decent frame at 160 kg loading with a critical value of 330 MPa was
designed and became a reference for the handcycle production process.

Keyword : handcycle, recombang, frame analysis, FEA

1. Introduction
Persons with disabilities in Indonesia have counted for 2.45% of the population. About 10.26% of
them have suffered defect in the lower limb [1]. Handcycle is a combination of wheelchairs and bicycles
that began to be developed since 1900 [2]. This has been an alternative transportation for them who had
a lower limb defects [3][4]. Handcycle has begun to be contested as one of the Paralympic sports since
2004 [5].
Handcycle is a bicycle whose riders in the front ride it using an arm in chain and crank transmission.
Handcycle riders have relied on the handcycle design [6]. Handcycle has two types of arm cranksets:
synchronous and asynchronous. The synchronous design has equated the motion of the crank in the
same direction of motion, in contrast to the asynchronous crank paralleled like a crank chase on a
bicycle. Frame geometry is divided into three i.e. upright styles, hand cycle attachment, and recumbent
[2]. Anthropometric data must be recognized to determine the characteristics of persons Anthropometric
data must be recognized to determine the characteristics of persons with various disabilities [7][8].
There has been no handcycle product made in Indonesia. Based on Indonesian anthropometric
data and compared to existing anthropometric data, frame design and finite element analysis studies,
prototyping has been performed. This study has designed handcycles and has made prototypes based on
frame design, finite element analysis, and anthropometry.

2. Methodology

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IOP Conf. Series: Journal of Physics: Conf. Series 1471 (2020) 012058 doi:10.1088/1742-6596/1471/1/012058

Handcycle is design based on antropometry data. The characteristics of antropometry data from
Indonesian National Standards for People With Disability in Indonesia [9] is given in Table 1. The
geometry design of the frame used a recumbent model that allows straightening the foot position. The
handcycle was designed to incorporate all the subsystems of the vehicle. A CAD Model was prepared
in Autodesk Fusion 360 to make the design process easier to incorporate.

Table 1. Antropometry Data People with Disability

No Measurement Male Female

Avg. 5%ile 95%ile Avg. 5%ile 95%ile
1 Sitting shoulder height 569.0 563.1 575.0 506.9 499.4 514.3
position
2 Elbow height sitting 216.7 214.3 225.1 131.8 124.9 138.7
position
3 Popliteal depth 485.5 481.5 489.5 459.5 452.4 466.6
4 Popliteal height 430.3 425.9 434.7 339.2 331.3 347.0
5 Shoulder breadth 460.6 455.9 465.2 416.8 410.0 423.6
6 Hip breadth 328.9 324.0 333.9 320.9 313.2 328.5
7 Elbow breadth 455.5 451.9 459.1 446.7 442.8 450.5

Material Selection
The frame was made with material that is widely available on the market, safe, has reliability, low
cost, and good weldability. In the simulation, the material used was structural steel with material
properties given in Table 2.

Table 2. Material Properties

Density 7.8 x 10-6 kg/mm3

Young’s modulus 200 GPa
Poisson’s ratio 0.26
Yield strength 248.2 MPa
Ultimate tensile strength 475.7 MPa
Cost (IDR/ kg) IDR 12,000

Frame Desain
CAD was designed by Autodesk® Fusion 360 software by considering three criteria i.e. avalaibility
of steel tube material forms, manufacturing processes, and ergonomic factors from anthropometric data.

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IOP Conf. Series: Journal of Physics: Conf. Series 1471 (2020) 012058 doi:10.1088/1742-6596/1471/1/012058

.
Figure 1. Handcycle Frame Design
Finite Element
Frame simulation is calculated using a static loads method with constrained fixed and meshing
divide of 202,049 nodes, 95,016 tetrahedral elements for complex geometry model. Tetrahedral solved
problems with high strain gradients element [10]. It is based on user load handcycle with a maximum
weight. The load on the frame is 1570 with a maximum driver mass of 160 kg.

Figure 2. a) Static Load on the Frame; b) Mesh Viewed

3. Result and Discussion

The results of the analysis showed that frame design was safe and did not fail to static loading. The
maximum value Stress von Mises from Fig. 3 of 330 MPa was found only in a few areas of the frame.
The maximum displacement is given in Fig. 4 occuring at 5.66 mm that was still within safe limits and
did not interfere with the function of handcycle work. In general, frame design had a safety factor value
of 6 Fig 5.

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IOP Conf. Series: Journal of Physics: Conf. Series 1471 (2020) 012058 doi:10.1088/1742-6596/1471/1/012058

Figure 3. Stress von Mises result

Figure 4. Displacement Result

Figure 5. Safety Factor

Handling Ability

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IOP Conf. Series: Journal of Physics: Conf. Series 1471 (2020) 012058 doi:10.1088/1742-6596/1471/1/012058

Handling Ability calculated the ability of handcycle to turn Fig. 6. The maximum swivel angle limit
can be detected through measurements when the bicycle handlebars turned right at 20º, if more than 20º
there would be friction in the chain against the bicycle frame. Whereas, to turn to the left there were no
obstacles.

Figure 6. Angle Limit

Assembly Design
The final result of the handcycle assembly design Fig. 8 was equipped with an adjustable chair to
adjust the driver's distance to the crank. This design was a reference for the handcycle manufacturing
process.

Figure 7. Handcycle from Sideview

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IOP Conf. Series: Journal of Physics: Conf. Series 1471 (2020) 012058 doi:10.1088/1742-6596/1471/1/012058

Figure 8. Final Assembly Design

Manufactured Product
Completely manufactured handcycle Fig. 9 had weight of 24 kg and production costs of IDR
3,500,000. This product was easy to use in sports for people with lower disabilities. More studies are
needed to analyze biomechanics and develope more ergonomic designs.

Figure 9. Handcycle Prototype

4. Conclusion
Handcycle can be designed and made according to the required criteria. This design is the initial
stage of the development of handcycle in Indonesia. The safety frame design is used by riders with a
maximum weight of 160 kg. Development is needed to reduce the weight of handcycle and develop
more more dynamic designs.

References

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