Design and Development of Elbow Rehabilitation Machine

A Project Report Submitted

In Partial Fulfillment of the Requirements for the

Degree of Bachelor of Technology

In

Mechanical Engineering

Submitted by

RUDRANSH NATH TRIPATHI (2020051124)

SAURABH DUBEY (2020051131)

RAHUL KUMAR MISHRA (2020051113)

GARVIT SINGH CHAUHAN (2020051073)

OM PANDEY (2020051097)

Under the guidance of

Dr. RAM BILAS PRASAD

Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

Madan Mohan Malaviya University of Technology, Gorakhpur (U.P.) –

India

June 2024
i
© M. M. M. University of Technology, Gorakhpur, (U.P.) – 273010, INDIA

ALL RIGHTS RESERVED

ii
 CANDIDATE’S DECLARATION

We declare that this written submission represents our work and ideas in our own
words and where others' ideas or words have been included, we have adequately
cited and referenced the original sources. We also declare that we have adhered to
all principles of academic honesty and integrity and have not misrepresented or
fabricated or falsified any idea/data/fact/source in our submission. We understand
that any violation of the above will be cause for disciplinary action by the
University and can also evoke penal action from the sources which have thus not
been properly cited or from whom proper permission has not been taken when
needed.

Rudransh Nath Tripathi Saurabh Dubey

(2020051124) (2020051131)

Rahul Kumar Mishra Garvit Singh Chauhan Om Pandey

(2020051113) (2020051073) (2020051097)

Department of Mechanical Engineering

Date:

iii
 CERTIFICATE

Certified that Rudransh Nath Tripathi (2020051124), Saurabh Dubey

(2020051131), Rahul Kumar Mishra (2020051113), Garvit Singh Chauhan
(2020051073), Om Pandey (2020051097) has carried out the project work
presented in this report entitled “Design and Development of Elbow Rehabilitation
Machine” for the award of Bachelor of Technology from Madan Mohan Malaviya
University of Technology, Gorakhpur under my supervision. The project report
embodies result of original work and studies carried out by students themselves and
the contents of the project report do not form the basis for the award of any other
degree to the candidate or to anybody else.

Signature of Supervisor
Dr. Ram Bilas Prasad
Assistant Professor
Department of Mechanical Engineering
M. M. M. U. T. Gorakhpur

Date:

iv
 APPROVAL SHEET

The project report entitled "Design and Development of Elbow Rehabilitation Machine”
by Rudransh Nath Tripathi (2020051124), Saurabh Dubey (2020051131), Rahul Kumar
Mishra (2020051113), Garvit Singh Chauhan (2020051073), Om Pandey (2020051097)
is approved for the degree of Bachelor of Technology in Mechanical Engineering.

Examiner

Supervisor

Head of Department

Date:

Place:

v
 ACKNOWLEDGEMENT

During the year as a student, we would like to express our sincere gratitude and regards
to our supervisor, Dr. Ram Bilas Prasad, Asst. Professor of Mechanical Engineering
Department, Madan Mohan Malaviya University of Technology, Gorakhpur. His
guidance, support, encouragement, and inspiration throughout the work has been a
major factor for the successful completion of the project work. The project work would
not have culminated into the preset form without his valuable suggestions and generous
help. We would like to thank everyone in the department, and my classmates for their
valuable suggestions and helpful discussions.

We would like to acknowledge the contribution of Mr. Dev Narayan Lal, B.tech. final
year student of Electronics and Communication Engineering, whose participation and
feedback during the testing phase provided critical insights into the machine's practical
effectiveness. Last but not least, we would be grateful to our family members, especially
beloved parents, for their encouragement.

Rudransh Nath Tripathi (2020051124)

Saurabh Dubey (2020051131)

Rahul Kumar Mishra (2020051113)

Garvit Chauhan (2020051073)

Om Pandey (2020051097)

Date:

Place:

vi
 LIST OF FIGURES

Figure No. Description of Figure Page No.

Figure 2.1 Normal range of motion of elbow joint 5
Figure 2.2 Elbow cpm machine prototype 6
Figure 2.3 CPM machine prototype 7
Figure 3.1 Range of Motion for Rehabilitation Machine 9
Figure 3.2 Force distribution 9
Figure 3.3 Force acting on forearm link 10
Forces acting at different angle viz., a) 0o, b) 30 o, c) 60 o, d)
Figure 3.4 10
90 o, and e)120 o
Figure 3.5 Maximum torque calculation. 11
Figure 3.6 Uniformly distributed force is applied at forearm link 12
Figure 3.7 Top view of Elbow rehabilitation machine CAD model 14
Figure 3.8 Front view of Elbow rehabilitation machine CAD model 14
Figure 3.9 Isometric view of Elbow rehabilitation machine CAD model 15
Figure 3.10 Left side view of Elbow rehabilitation machine CAD model 15
Figure 3.11 Electrical Circuit used 16
Figure 4.1 Steel rod used as forearm support. 18
Figure 4.2 PVC pipe used as upper arm holder 18
Figure 4.3 Servo motor 19
Figure 4.4 Arduino Uno 19
Figure 4.5 Supporting structure made with pvc pipe. 19
Figure 4.6 Frame of machine 20
Figure 4.7 HCH 6002 bearing. 20
Figure 4.8 Rocker Switches 20
Figure 4.9 LCD display panel 20
Figure 4.10 Final Fabricated elbow rehabilitation machine 22
Figure 5.1 Patient using elbow rehabilitation machine. 26

vii
 LIST OF TABLES

Table No. Description of Table Page No.

Table 3.1 Specification of technical parameters 9
Table 3.2 Torque Required at different angles. 11
Table 3.3 Selection of bearing 13
Table 4.1 Cost calculation of various items. 22
Table 5.1 Graph of Comfortability 24
Table 5.2 Graph of effectiveness 25

viii
 ABSTRACT

RUDRANSH NATH TRIPATHI (2020051124)

SAURABH DUBEY (2020051131)

RAHUL KUMAR MISHRA (2020051113)

GARVIT SINGH CHAUHAN (2020051073)

OM PANDEY (2020051097)

Under the guidance of

Dr. RAM BILAS PRASAD

This project work presents a cost-effective and user-friendly elbow rehabilitation

machine that caters to the specific needs of patients recovering from elbow-related
injuries or surgeries. The primary goal is to facilitate targeted exercises for muscle
groups within defined ranges of motion. The machine's design emphasizes safety and
patient comfort to ensure an effective rehabilitation process. This project focuses on the
development of a specialized machine capable of providing controlled motion and
exercises tailored to the specific needs of elbow rehabilitation. The presented elbow
rehabilitation machine has the potential to be used by person who is recovering from
their elbow injuries in gaining strength. This particular technology although it exists, it
was expensive and generally unavailable to people. The system is built around an
innovative mechanical design for a elbow rehabilitation machine. It is hoped that this
work will be useful to a wide range of people.

ix
 TABLE OF CONTENTS

Candidate’s Declaration ................................................................................................ iii

Certificate ..................................................................................................................... iv
Approval Sheet .............................................................................................................. v
Acknowledgement ......................................................................................................... vi
List of Figures .............................................................................................................. vii
List of Tables............................................................................................................... viii
Abstract........................................................................................................................ ix
Table of Contents ........................................................................................................... x
CHAPTER 1: INTRODUCTION....................................................................................1
1.1 What is Rehabilitation? ..................................................................................1
1.2 Requirement of Elbow Rehabilitation Exercise ................................................2
1.3 Need for Machine ...........................................................................................3
CHAPTER 2: LITERATURE REVIEW .........................................................................5
2.1 Human Elbow Joint ........................................................................................5
2.2 Biomechanics of Elbow Joint ...........................................................................5
2.3 Previous Development.....................................................................................6
2.4 Objective of Project ........................................................................................7
CHAPTER 3: DESIGN AND SELECTION OF COMPONENTS .....................................8
3.1 Mechanical Design ..........................................................................................8
3.2 Specifying Technical Parameters .....................................................................8
3.4 Selecting dimensions of sheet. ........................................................................ 11
3.5 Selection of Bearing ...................................................................................... 12
3.6 CAD Model .................................................................................................. 14
3.7 Circuit design for servo motor ....................................................................... 16
3.8 Program for operating servo motor ............................................................... 17
CHAPTER 4: FABRICATION AND ASSEMBLY ......................................................... 18
4.1 Components Used ......................................................................................... 18
4.2 Assembly of Elbow Rehabilitation Machine ................................................... 21
4.3 Cost Calculation ........................................................................................... 22
CHAPTER 5: TESTING & SURVEY REPORT ............................................................ 23
5.1 Testing & Survey Results .............................................................................. 23
5.1.1 Comfortability of machine usage ............................................................... 23
5.1.2 Effectiveness ............................................................................................. 24
5.2 Discussion .................................................................................................... 25

x
 5.3 Patient Case Study ........................................................................................ 26
CHAPTER 6: CONCLUSIONS .................................................................................... 28
REFERENCES ............................................................................................................ 29

xi
 CHAPTER 1

INTRODUCTION

Elbow injuries are pervasive across various demographics, affecting athletes,

labourers, and individuals of all age groups. Ranging from minor strains to severe
fractures, these injuries often lead to substantial discomfort and hindered functionality.
Effective rehabilitation is crucial for the recovery of elbow joint mobility, muscle
strength, and overall functionality. The development of an elbow rehabilitation machine
represents a pivotal advancement in orthopaedic rehabilitation. This specialized device
is engineered to assist individuals afflicted with elbow injuries in reclaiming their range
of motion, bolstering muscular strength, and reinstating functional capabilities. Its
applications extend to a broad spectrum of elbow injuries, encompassing fractures,
dislocations, ligament sprains, and arthritis, among others.

Safety and comfort are paramount considerations in the design of this rehabilitation
apparatus. Incorporating state-of-the-art safety features, such as automatic emergency
stop mechanisms and intuitive ergonomic support, ensures that patients can engage in
rehabilitative exercises without compromising their well-being. Moreover, the
machine’s user-friendly interface allows for seamless navigation, empowering patients
to take charge of their own rehabilitation journey.

1.1 What is Rehabilitation?

Rehabilitation is a process that helps patients recover from injury or illness and
regain their strength and mobility. Rehabilitation can help people regain skills, abilities,
or knowledge that may have been lost or compromised due to illness, injury, or
disability. Rehabilitation usually includes exercises adapted to the unique characteristics
of the neurological defect, activities needed for daily function, and more. Rehabilitative
treatment is intended for persons suffering from various defects and limitations resulting
from injury or illness and should be commenced as soon as possible after the event
occurs. Rehabilitation will usually include:

• Physical and functional assessment

• Improvement of mobility and prescription of accessories
• Practicing daily activities, exercises, and general activity

1
• Instructing the patient and his family regarding continued independent exercising
and advice regarding maintenance of an active life

Rehabilitation frameworks include: initial rehabilitation during acute

hospitalization, rehabilitation in specific departments within general hospitals, in
rehabilitation centres and in geriatric centres, day rehabilitation and rehabilitation in the
community; at home or in an outpatient institute[1]. The general aim of rehabilitation is
to improve strength and mobility and to find ways around any problems. For example, if
someone has had a fall, a physiotherapist may recommend using some equipment to
help with walking and an exercise programme to improve balance and strength, proper
rehabilitation is very crucial in such conditions.

Effective rehabilitation is a person-centred process, with treatment tailored to the

individual patient’s needs and, importantly, personalized monitoring of changes
associated with intervention, with further changes in goals and actions if needed.

Rehabilitation has been found effective in most setting such as in intensive care units,
hospitals, nursing homes or even at home.:

• Probably in intensive care unit.

• Specialist rehabilitation inpatient wards
• Out-patient and day-hospital settings
• Nursing homes
• Even at home

It is specifically important to note that rehabilitation out of hospital, after discharge, is

effective. One may conclude that rehabilitation is likely to be beneficial to a person with
disability at any stage of their illness and whatever the nature of their prognosis,
including when receiving palliative care: rehabilitation can benefit people with
advanced cancer[2].

1.2 Requirement of Elbow Rehabilitation Exercise

Elbow rehabilitation is often necessary following injury or surgery to restore
function, strength, and mobility to the elbow joint. Several reasons contribute to why
elbow rehabilitation may be required:

2
• Injury Recovery: Elbow injuries such as fractures, dislocations, ligament sprains,
or tendon tears can result from accidents, sports activities, or overuse. Rehabilitation
helps the injured tissues heal properly and regain their strength and flexibility.

• Surgical Intervention: In some cases, surgery may be necessary to repair severe

elbow injuries or conditions like tennis elbow or golfer’s elbow. Thus, further
exercises are required for regaining normal strength.

• Pain Management: Elbow pain can significantly affect daily activities and quality
of life. Rehabilitation techniques such as exercises, manual therapy, and modalities
like ultrasound or electrical stimulation can help alleviate pain and improve joint
mobility.

• Functional Restoration: Elbow injuries or conditions can impair the ability to

perform basic tasks like lifting, gripping, or reaching. Rehabilitation aims to restore
these functional abilities through targeted exercises and therapeutic interventions.

• Prevention of Complications: Without proper rehabilitation, elbow injuries can

lead to complications such as stiffness, weakness, instability, or chronic pain.
Rehabilitating the elbow helps minimize these risks and promotes long-term joint
health.

• Optimizing Performance: For athletes or individuals involved in sports or physical

activities, elbow rehabilitation is essential for returning to pre-injury performance
levels safely and effectively.

Overall, elbow rehabilitation exercise plays a crucial role in promoting recovery,

minimizing complications, and restoring optimal function and quality of life following
elbow injuries or surgical procedures. It involves a comprehensive approach tailored to
the specific needs and goals of each individual patient.

1.3 Need for Machine

This machine aims to solve the following problems.

• Lack of assistance to patient: It is not possible that a physiotherapist is always

available to perform this therapy efficiently since it sometimes involves very long
and repetitive exercises.

3
• Affordability: There are some conventional cpm machines are available but are very
expensive. Hence there is need of an affordable option.

• Post surgery rehabilitation: Post-surgical rehabilitation is crucial to facilitate proper

healing, prevent complications, and restore optimal function.

4
 CHAPTER 2

LITERATURE REVIEW

2.1 Human Elbow Joint

The elbow joint, a hinge joint located in the human upper extremity, serves as a
pivotal anatomical articulation linking the humerus, radius, and ulna bones. It is a
complex structure that provides an important function as the mechanical link in the
upper extremity between the hand, wrist and the shoulder. The elbow's functions include
positioning the hand in space for fine movements, powerful grasping and serving as a
fulcrum for the forearm. The elbow is a critical element for a functional upper extremity.
Loss of elbow function can cause significant disability and affect activities of daily
living, work-related tasks, and recreational activities[3].

Askew et al.[4] studied the isometric elbow strength in over 100 people. Elbow flexion,
extension, pronation, and supination were measured with the elbow at 90° flexion in
neutral rotation. The results showed men to be twice as strong as women and the
dominant arm to be, on average, 6% stronger than the nondominant arm. Generally
speaking, there is one DOF (Degree of freedom) in elbow joint.

Figure 2.1: Normal range of motion of elbow joint [5]

2.2 Biomechanics of Elbow Joint
The elbow is a complex articulated joint composed by the humeroulnar and
humeroradial joints (for the flexion-extension movement) and the proximal radioulnar
articulation (for the pronation-supination movement). The flexion-extension movement,
in the majority of the cases, has an angular range of movement between 0 and 150
5
degrees, but in the ADL the functional range is estimated between 30 and 120 degrees.
In the pronation-supination movement, the averages are 71 degrees of pronation and 81
degrees of supination as shown in Figure 2.1. During the flexion-extension movement
of the elbow joint, the centre of rotation changes and this articulation cannot be truly
represented as a simple hinge joint[5].

2.3 Previous Development

Elbow rehabilitation machines play a crucial role in regaining range of motion,
strength, and stability after injuries or surgeries. These devices can improve patient
outcomes and expedite the recovery process. Here's a review of previous developments
in this field.

Zuccon et al.[6] proposed Elbow rehabilitation machines as shown in Figure 2.2,

exemplified by designs such as CADEL, primarily employ cable-driven systems
customized for elbow articulation assistance. These systems consist of high-strength
cables routed along the anatomical pathways of the elbow joint, transmitting forces
from actuators to points on the user's arm for targeted assistance or resistance during
exercises. Actuators, which may include electric motors or pneumatic actuators,
generate the necessary forces while sensors such as encoders and accelerometers
monitor joint movements and provide feedback to the control system.

Figure 2.2: Elbow cpm machine prototype[6]

6
Hamzah et. al.[7] made elbow rehabilitation machine as shown in Figure 2.3, by
utilizing a DC motor mounted below an aluminium table where the patient's arm is
secured. This motor drives the table through an L-shaped linkage. A round disk (3D
printed) connects the linkage to four lead screws. Finally, an arc (also 3D printed) and
handle are attached to the lead screws. By controlling the DC motor, the table moves,
causing the entire linkage, round disk, lead screws, arc, and handle to rotate in a
controlled manner, facilitating elbow flexion and extension exercises. A potentiometer
linked to the motor via a gear measures the angular displacement of this movement,
allowing for monitoring of the range of motion (ROM) in the elbow joint.

Figure 2.3: CPM machine prototype [7]

These conventional devices used for providing continuous passive motion for elbow
joints include shafts, gears, springs, magnets, motors, and cable arrangements. However,
these devices are not portable, have complex circuits, are not easy to operate, and are
bulky and expensive.

2.4 Objective of Project

The main objective of our project is to:

• Development and fabrication of elbow rehabilitation machine.

• Design a cost-effective and easy to-use elbow rehabilitation machine.

7
 CHAPTER 3

DESIGN AND SELECTION OF COMPONENTS

3.1 Mechanical Design

The mechanical design of the Elbow Rehabilitation Machine is a critical aspect
in ensuring its effectiveness in performing the required exercises for flexion and
extension of the human elbow. This section outlines the key considerations and design
principles employed to create a robust and efficient mechanical system. Factors such as
power requirements, torque specifications, and the dynamics of forces within the system
are carefully analysed to develop a design that meets the needs of rehabilitation
exercises.

3.2 Specifying Technical Parameters

Specifying technical parameters in the design of an exercising machine like the
Elbow Rehabilitation Machine is crucial for achieving optimal performance, safety, user
experience, compatibility, manufacturability, and cost-effectiveness. It provides a
framework for decision-making throughout the design process and ensures that the final
product meets the needs and expectations of users and stakeholders.

According to Copaci et al.[5], average healthy person of weight 70kg, height 1.7m, have
a trajectory in elbow joint between 0° to 150° degrees. For daily activities one generally
requires range of motion for flexion and extension to be 10° to 130°. So for proper
elbow rehabilitation it considered to exercise elbow with a Range of Motion in flexion
and extension of 10° to 130° as shown in Figure 3.1.

As per studies by S. Załuska et al.[8], the length of the right forearm in men ranged
from 20 to 30.5 cm, with average of 25.40, and the left one ranges from 20 to 30 cm,
with average of 25.3cm). So, we consider length of forearm link for the elbow
rehabilitation machine to be 30cm.The forearm link is the movable link for
rehabilitation machine and the upper arm link will be a fixed link with support. Also, the
fixed link i.e, upper arm link is of length 15cm with required support. For proper
rehabilitation, the angular velocity at which the forearm link will oscillate should be
between 0.5 to 3.5 degrees/sec [9].

8
Following is the schematic diagram for specifying technical parameters for elbow
rehabilitation machine.

Table 3.1: Specification of technical parameters

S. No. Parameter Value

1. Angle of Rotation 120° (10° to 130°)
2. Length of forearm link 30cm
3. Length for upper arm support 15cm

Figure 3.1: Range of Motion for Rehabilitation Machine

3.3 Calculation of torque required to lift forearm

We need to find the torque required to lift the forearm.

Consider that r be length of rotating link. As shown in

Figure 3.2, force Fx & Fy are the forces acting in x and y r
direction respectively, and Fe is the resultant force acting
due to resultant of forces in x and y axes. Now, the
moment about the joint generated by the force acting on Figure.3.2: Force distribution.
the rotating link is given by
Torque required, τ = r.Fe

= r.(-Fx sin(θ) + Fy cos(θ) )

= - r.Fx sin(θ) + r.Fy cos(θ)

Here Figure 3.3 shows forces acting on forearm link of length L rotated about an angle
of θ. the forces acting in x and y direction are 0 & mg respectively,

Thus Fy = mg, & Fx = 0, and

These force acts at distance from joint, r = L/2,

9
 Figure 3.3 Force acting on forearm link
Hence, Torque moment at any θ angle is given by τ = - r.Fx sin(θ) + r.Fy cos(θ)

Torque, τ = -(L/2)(0)sin(θ) + (L/2)(mg)cos(θ)

𝑚𝑔𝐿.cos⁡(θ)
τ =
2

𝑚𝑔𝐿.cos⁡(0) 𝑚𝑔𝐿.(1) 𝑚𝑔𝐿

At θ = 0o, Torque required = = =
2 2 2

𝑚𝑔𝐿.cos⁡(30) 𝑚𝑔𝐿.(√3/2) √3𝑚𝑔𝐿

At θ = 30o, Torque required = = =
2 2 4

𝑚𝑔𝐿.cos⁡(60) 𝑚𝑔𝐿.(1/2) 𝑚𝑔𝐿

At θ = 60o, Torque required =⁡ = =
2 2 4

𝑚𝑔𝐿.cos⁡(90) 𝑚𝑔𝐿.(0)
At θ = 90o, Torque required = = =0
2 2

𝑚𝑔𝐿.cos⁡(120) 𝑚𝑔𝐿.(−1/2) −𝑚𝑔𝐿

At θ = 120o, Torque required =⁡ = =
2 2 4

L/2 L/2
L/2 mg cos(θ)

mg cos(θ)
mg (c)
(b)
(a)
-mg cos(θ)
L/2
L/2

(d) (e)

Figure 3.4: Forces acting at different angle viz., a) 0 o, b) 30 o, c) 60 o, d) 90 o, and

e)120 o.

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 Table 3.2 Torque Required at different angles.

ANGLE TORQUE REQUIRED

0° 75 kg-cm
30° 65 kg-cm
45° 53.03 kg-cm
60° 37.5 kg-cm
90° -
120° -37.5 kg-cm
Thus, maximum torque is required at θ = 0°. Hence, magnitude of max. torque is
mgL/2.

It is known that weight of human forearm is considered to be 1.62 % of total human

body weight [10].

Now, considering the weight of forearm and weight of frame as follows:

Weight of forearm = 1.62% of human body weight

= 1.62% x 70kg

= 1.134kg ≈ 2kg

Weight of frame is assumed to be 3 kg Figure 3.5: Maximum torque calculation.

Thus, total weight = weight of forearm + weight of frame

= 2+3 kg = 5kg

Hence, torque required to lift is = weight x distance = 5 kg x 15 cm = 75 kg.cm

Thus, we need to produce a torque of 75kgcm for machine which could be achieved by
the mechanism explained later here.

3.4 Selecting dimensions of sheet.

Consider that the load is acting by forearm on arm rest of length l, let the load acting be
uniformly distributed load with w N/mm as shown in Figure 3.6, thus CG of resulting
load is l/2 from support.
𝑤𝑙 2
Now bending moment at point A will be as follows: (Mb) A =
2

11
 Figure 3.6 Uniformly distributed force is applied at forearm link
𝑦 ℎ
And bending stress, σb = (Mb) A. , where y = ,
𝐼 2
h = thickness of sheet,
𝑏ℎ3
I= = moment of inertia
12
total weight, (w x l) = 5 kg
l = 300 mm, b = 100mm
𝑤𝑙2 ℎ
.
2 2 3𝑤𝑙 2 300
σb = 3 = = 3 x 50 x
𝑏ℎ 𝑏ℎ2 100ℎ2
12
300 𝑁
for h=3 mm, (σb) calculated = 3 x 50 x = 18
100∗52 𝑚𝑚2
For considering aluminum alloy 64430, we have Sut= 200 MPa
Factor of Safety, fs = 5 for medical purpose/devices.
Thus, permissible bending stress is (σb)per = Sut / fs
200 𝑁
(σb)per = = 40⁡𝑀𝑃𝑎⁡𝑜𝑟 𝑚𝑚2
5

Since, (σb)per > (σb) calculated

Hence our design is safe to be considered.

3.5 Selection of Bearing

The expression for the equivalent dynamic load is written as,

P = X V Fr + Y Fa
where,
P = equivalent dynamic load (N)
Fr = radial load (N)
Fa = axial or thrust load (N)
V = race-rotation factor

12
X and Y are radial and thrust factors respectively and their values are given in the
manufacturer’s catalogues.
The race-rotation factor depends upon whether the inner race is rotating or the outer
race. The value of V is 1 when the inner race rotates while the outer race is held
stationary in the housing. The value of V is 1.2 when the outer race rotates with respect
to the load, while the inner race remains stationary.
Here inner race of bearing rotates, thus V = 1,
Radial Load on bearing, Fr = 50 N
Also force acting in axial direction is 0. So, this is a case of pure radial load. When the
bearing is subjected to pure radial load Fr,
P = Fr = 50 N
Since we have shaft diameter as 15 mm.
So, inner diameter of bearing must be same as diameter of shaft i.e, 15mm.
We can see some bearing with inner diameter of 15mm as shown in Table 3.3.
Table 3.3: Selection of bearing
Inner Outer Width, Static Load Dynamic Load Bearing
diameter diameter B Capacity, C Capacity, Co Number
15 mm 24mm 5 1560 815 61802
15 mm 32mm 9 5590 2500 6002
15mm 35mm 11 7800 3550 6202
15mm 42mm 13 11400 5400 6302

Since the support pipe is of inner diameter of 32 mm so there is need to have bearing
which has outer diameter of 32 mm only. As it can be seen in above table that bearing
which fulfils these criteria in bearing no. 6002
For Bearing No. 6002,
𝐶 𝑝 5590 3
L10 = [ ] = [ ] = 13.9⁡x⁡⁡104 ⁡million revolutions
𝑃 50

Bearing life of 13.9⁡x⁡⁡104 ⁡million revolutions is enough for machine.

This is much more than enough required for the machine to operate in entire lifespan.

13
3.6 CAD Model

The CAD model of the Elbow Rehabilitation Machine, created using SOLIDWORKS®
2022, offers a comprehensive visual representation of the machine's design and
functionality. The meticulously crafted model provides a detailed insight into the
structural elements, mechanical components, and overall layout of the machine,
facilitating a clear understanding of its fabrication and operation. Figure 3.7 shows the
top view of model, where hand position is quiet visible. Figure 3.8 and Figure 3.9 shows
the front and isometric view of model respectively. In Figure 3.10 showing left side
view of CAD model it is visible the position of LCD panel. Overall, the CAD model of
the Elbow Rehabilitation Machine serves as a valuable tool for visualizing the
machine's design, facilitating fabrication, and aiding in the understanding of its
operation. It provides a comprehensive representation of the machine's functionality and
ensures alignment between the design concept and the fabricated product.

Figure 3.7 Top view of Elbow rehabilitation machine CAD model

14
 Figure 3.8 Front view of Elbow rehabilitation machine CAD model

Figure 3.9: Isometric view of Elbow rehabilitation machine CAD model

Figure 3.10: Left side view of Elbow rehabilitation machine CAD model

15
3.7 Circuit design for servo motor

The Arduino Uno R3 is programmed with a specific set of instructions tailored to

control the servo motor. This program facilitates communication by sending signals to
the servo motor, commanding it to move to predefined positions or execute oscillatory
motions as part of the rehabilitation process. The servo motor's inherent capabilities in
precision and speed control are maximized through the coordinated efforts of the
Arduino. The program ensures accurate positioning and regulated speed, crucial factors
in creating controlled and effective rehabilitation exercises. Circuit, shown in Figure
3.11, is designed on Autodesk’s TinkerCAD web application.

Figure 3.11: Electrical Circuit

The servo motor is integrated mechanically with the rehabilitation machine to facilitate
the required angular movement. The Arduino Uno R3 is connected electrically to the
servo motor, establishing a communication channel that allows the Arduino to exert
precise control over the motor's actions. A specific program in C language is designed
and implemented on the Arduino Uno R3 to orchestrate the servo motor's movements.
This program is crafted to interpret user input or pre-set parameters, translating them
into signals that drive the servo motor to perform the desired rehabilitation exercises.

16
3.8 Program for operating servo motor

Following code is involved is uploaded in Arduino board for proper operation of

rehabilitation machine:

#include <LiquidCrystal.h>
#include <Servo.h>
Servo slideas;
int angle;
LiquidCrystal lcd(12, 11, 4, 5, 6, 7);
int i = 0;
void setup () {
slideas.attach(9); // All signal pass through pin 10
lcd.begin(16, 2); // Initialize the LCD: 16 columns and 2 rows
lcd.setCursor(0, 0); // Set cursor to the first row
lcd.print("Number of motion: ");
}
void clearSecondRow() {
lcd.setCursor(0, 1); // Set cursor to the second row
lcd.print(" "); // Overwrite each char with a space
lcd.setCursor(0, 1); // Reset cursor to the beginning of the second row
}
void loop() {
clearSecondRow(); // Clear the second row
lcd.print("Count ");
lcd.print(i); // Display the current motion number
for (angle = 10; angle < 100; angle++) {
slideas.write(angle);
delay(50); }
i++;
delay(1000); // Delay for better readability
for (angle = 100; angle > 10; angle--) {
slideas.write(angle);
delay(50); }
}

17
 CHAPTER 4

FABRICATION AND ASSEMBLY

4.1 Components Used

The elbow rehabilitation machine comprises several essential components meticulously
integrated to facilitate effective and personalized rehabilitation of the elbow joint. The
following components constitute the core elements of the machine:

i. Steel Rod: The steel rod, shown in Figure 4.1, serves as primary support structure
for the forearm during rehabilitation exercises, offering stability and assistance in
performing controlled movements. Here we have used two steel rods of 45 cm each.

Figure 4.1 Steel rod used as forearm support.

ii. Upper Arm Holder (PVC Pipe): Crafted from PVC pipe, the upper arm holder,
shown in Figure 4.2, securely accommodates the upper arm, providing support and
alignment during rehabilitation sessions.

Figure 4.2 PVC pipe used as upper arm holder

iii. Servo Motor: The servo motor, shown in Figure 4.3, functions as the main driving
component of the machine, generating controlled movements and adjustments
essential for executing rehabilitation exercises with precision. This servo motor has
rated torque of 150kgcm.

18
 Figure 4.3: Servo motor.
iv. Arduino Microcontroller: The Arduino microcontroller, shown in Figure 4.4,
serves as the central control unit, sending signals to the servo motor to execute
predefined rehabilitation protocols and adjust parameters as needed.

Figure 4.4 Arduino Uno

v. Supporting PVC Pipe: Additional PVC pipes are utilized to provide structural
support, shown in Figure 4.5, and stability to various components of the machine,
ensuring durability and reliability during operation.

Figure 4.5 Supporting structure made with pvc pipe.

vi. Base Plate: The base plate serves as a stable foundation, supporting the upper arm
holder and providing a secure platform for rehabilitation exercises.

vii. Frame/Body: Constructed to enhance structural integrity, the frame of the machine,
shown in Figure 4.6, ensures rigidity and stability, minimizing vibrations and
facilitating smooth operation during rehabilitation sessions.

19
 Figure 4.6: Frame of machine.

viii. Bearing: Attached to the main shaft, two set of HCH 6002 bearings, shown in
Figure 4.7, provide support and facilitate smooth rotation, minimizing friction and
ensuring consistent performance of the machine.

Figure 4.7 HCH 6002 bearing.

ix. Rocker Switches: These switches, shown in Figure 4.8, serve as control
mechanisms, allowing users to initiate and regulate the operation of the machine,
facilitating ease of use and customization of rehabilitation exercises.

Figure 4.8: Rocker Switches

x. LCD Panel: The LCD panel, shown in Figure 4.9, enhances user interactivity by
displaying essential information for exercise progress such as step count, which
fosters engagement and motivation during rehabilitation sessions.

Figure 4.9 LCD display panel.

20
 xi. Slider for Forearm Length Adjustment: Incorporated for versatility, the slider
mechanism enables easy and precise adjustment of forearm length, catering to
individuals of varying arm lengths and physical characteristics.

xii. Screws and Nuts: Essential for assembly and maintenance, screws and nuts are
utilized to secure components, ensuring stability and integrity of the system during
operation.

xiii. Fork End: Serving as a linkage component, the fork end connects the steel rod with
the main shaft, transmitting motion and facilitating controlled movements during
rehabilitation exercises.

Each component of the elbow rehabilitation machine is carefully selected and integrated
to deliver a comprehensive and efficient rehabilitation solution, tailored to the unique
needs and requirements of patients recovering from elbow injuries or surgeries.

4.2 Assembly of Elbow Rehabilitation Machine

In the fabrication process of the Elbow Rehabilitation Machine, meticulous attention is given to
crafting a robust structural frame and forearm support system. This involves selecting materials
known for their durability and strength, such as steel or aluminium. These materials are then
precisely cut and shaped according to design specifications, ensuring they meet the required
dimensions and form. Welding or joining techniques are employed to assemble the frame and
upper arm support, guaranteeing secure connections that can withstand the forces experienced
during rehabilitation exercises. The installation of the servo motor is a crucial step in the
fabrication process, as it serves as the driving force behind the controlled motion of the forearm
support mechanism. The motor is securely mounted onto the frame using appropriate fixtures,
ensuring stability and proper alignment. Connections are established between the servo motor
and the forearm support mechanism, allowing for smooth and precise transmission of motion.
Wiring is carefully routed and connected to the Arduino Uno R3 microcontroller, which controls
the operation of the servo motor. Extensive testing is conducted to verify the motor's
functionality and range of motion, ensuring it meets the requirements of the rehabilitation
exercises.

Integrating the LCD display panel into the machine involves mounting it in a prominent
position for easy viewing by the user. Connections are established between the display panel
and the Arduino Uno R3 microcontroller, allowing for real-time feedback to be displayed during
rehabilitation exercises. The microcontroller is programmed to interface with the display panel,
ensuring accurate and timely presentation of information such as the number of completed

21
oscillations. Thorough testing is conducted to confirm the proper functioning of the display
panel and its ability to provide relevant feedback to the user.

Figure 4.10 Final Fabricated elbow rehabilitation machine.

Once all components are assembled, as shown in Figure 4.10, the final phase of fabrication
involves comprehensive testing and validation. The machine is fully integrated, and calibration
procedures are performed to ensure optimal performance of the servo motor and display panel.
Functional tests are conducted to verify the operation of all components, including motion and
feedback accuracy. User testing is also conducted to gather feedback on usability and
effectiveness, allowing for any necessary adjustments or refinements to be made. Finally, the
successful deployment and ongoing operation of the Elbow Rehabilitation Machine is done.

4.3 Cost Calculation

Table 4.1 Cost calculation of various items.

S.No. COMPONENT COST (in INR)

1. Arduino Board 415

2. AC to DC adapter 150

3. Battery 30

4. Servo Motor 3500

5. HCH Bearing 6002 200

6. Steel Pipe & PVC Pipe 150

7. LCD panel 16x2 150

8. Miscellaneous 4000

9. Total 8595

22
 CHAPTER 5

TESTING & SURVEY REPORT

5.1 Testing & Survey Results

To assess the machine's effectiveness and user satisfaction, a comprehensive survey was
conducted among individuals who have utilized the device for rehabilitation purposes.
The survey aimed to evaluate two key aspects: comfortability during machine usage and
the perceived effectiveness of the machine in enhancing recovery from elbow injuries.

As the success of any rehabilitation device hinges on its ability to provide a comfortable
and user-friendly experience, understanding user perspectives on comfortability is
paramount. Moreover, gauging the perceived effectiveness of the machine in facilitating
recovery from elbow injuries is essential for assessing its real-world utility and impact
on patient outcomes.

By gathering insights through this survey, we aim to gain a deeper understanding of user
experiences with the Elbow Rehabilitation Machine and identify areas for improvement.
This information will inform future iterations of the machine's design and functionality,
ultimately enhancing its efficacy in supporting individuals on their journey to recovery
from elbow injuries.

5.1.1 Comfortability of machine usage

• The survey results, as shown in Table 5.1, indicate that the majority of participants
reported a high level of comfort when using the Elbow Rehabilitation Machine.
Specifically, 67.5% of respondents strongly agreed and 25% agreed that their hand
was placed comfortably during machine usage. This suggests that the design of the
machine effectively accommodates the user's hand, contributing to a positive user
experience.
• Regarding the ease of fitting the hand into the machine,57.5% of participants
strongly agreed and 37.5% agreed that the hand could easily fit into the machine.
This indicates that the dimensions and layout of the machine's forearm support
mechanism effectively accommodate a wide range of hand sizes, enhancing user
comfort and usability.

23
• In terms of usability and handling, the survey results show that the majority of
respondents (70%) strongly agreed that the Elbow Rehabilitation Machine is easy to
use and handle. This suggests that the machine's design and user interface are
intuitive, minimizing the learning curve for users and facilitating a smooth
rehabilitation process.
• Regarding stability during operation, 85% of participants either agreed or strongly
agreed that the Elbow Rehabilitation Machine is stable and experiences minimal
movement during operation. This indicates that the machine's structural integrity
and design effectively support the user's forearm and minimize unwanted
movement, ensuring a safe and effective rehabilitation experience.

Table 5.1 Graph of Comfortability

COMFORTABILITY
30 28
27

25 23 23

20
No.of people

15
15
11
10
10
7
4
5
2 2
1 1 1 1 1
0 0 0 0
0
My Hand was place Hand can easily fit into The device is easy to The device is stable
comfortable while the machine use and handle and less moving while
using the machine operating

Strongly Agree Agree Neutral Disagree Strongly Disagree

5.1.2 Effectiveness
• In terms of user preference, the survey results, as shown in Table 5.2, show that
most participants (90%) either agreed or strongly agreed that they like to use the
Elbow Rehabilitation Machine. This positive sentiment suggests that users find the
machine enjoyable to use, which may contribute to increased compliance with
rehabilitation protocols.
• Regarding the ease of learning how to use the machine, 60% of respondents strongly
agreed that most people can quickly learn how to use the Elbow Rehabilitation

24
 Machine. This indicates that the machine's design and user interface are user-
friendly and intuitive.
• Regarding effectiveness in enhancing recovery from elbow injuries, the survey
results show that most participants (62.5%) strongly agreed that the Elbow
Rehabilitation Machine can effectively enhance recovery. This suggests that users
perceive the machine as a valuable tool in their rehabilitation journey, offering
targeted exercises and support for elbow injury recovery.

Table 5.2 Graph of effectiveness

EFFECTIVENESS
35
29
30
24 25
25
No. of people

20

15 12
9
10 7
4 5
5 2 3
1 0 0 1 1
0
Do you like to use this product? Most people can learn how to Do you think this product can
use this product quickly effectively enhance recovery
from patients with elbow
injuries?

Strongly Agree Agree Neutral Disagree Strongly Disagree

These survey results provide valuable insights into user experiences and perceptions
regarding the comfortability and effectiveness of the Elbow Rehabilitation Machine.
The high level of satisfaction expressed by participants highlights the machine's
potential to positively impact the rehabilitation process for individuals recovering from
elbow injuries.

5.2 Discussion
Overall, the survey results indicate a positive response regarding the comfortability and
effectiveness of the Elbow Rehabilitation Machine. Most participants agreed or strongly
agreed that their hand was placed comfortably, and they could easily fit their hand into
the machine. Additionally, respondents found the device easy to use and handle, with a
high percentage reporting stability during operation.

25
In terms of effectiveness, participants expressed a favourable attitude towards the
product, with a significant number indicating they liked using it and believed it could
enhance recovery from elbow injuries. Most respondents also agreed that the machine is
easy to learn how to use, suggesting its suitability for a wide range of users.
However, a small percentage of participants expressed neutral or negative opinions
regarding certain aspects of the machine's comfortability and effectiveness. This
feedback highlights areas where potential improvements could be made to further
enhance the user experience and effectiveness of the device.
In conclusion, the survey findings support the notion that the Elbow Rehabilitation
Machine is generally well-received by users and holds promise as an effective tool for
elbow rehabilitation. Continued efforts to address any areas of concern identified in the
survey will be crucial in maximizing the machine's impact on patient recovery and
satisfaction.

5.3 Patient Case Study

The Elbow Rehabilitation Machine's efficacy is further exemplified through a patient
case study. Mr. Dev Narayan Lal, a 23-year-old individual, experienced a fracture in his
right hand due to an accident last year, which resulted in challenges with proper elbow
motion. Following medical consultation, Mr. Dev Narayan Lal commenced using our
Elbow Rehabilitation Machine for a one-month period in April 2024.

The patient’s experience underscores the machine's effectiveness in facilitating

significant mobility and strength gains. Despite initial limitations stemming from the
fracture, consistent use of the Elbow Rehabilitation Machine yielded tangible
improvements over the course of a month. This outcome highlights the machine's

Figure 5.1 Patient using elbow rehabilitation machine.

26
capacity to address functional deficits and aid in the recovery process effectively.

Patient’s experience serves as a testament to the long-term benefits and sustainability of

utilizing the Elbow Rehabilitation Machine. By incorporating elbow rehabilitation
exercises and providing consistent feedback, the machine facilitated gradual
improvement in his mobility and strength. These gains are not only significant in the
short term but also contribute to his overall functional recovery in the long run.

In conclusion, Mr. Dev Narayan Lal's case study exemplifies the transformative impact
of the Elbow Rehabilitation Machine in facilitating recovery from elbow injuries.
Through its tailored approach, collaborative integration with healthcare professionals,
and sustainable long-term benefits, the machine emerges as a valuable tool in promoting
Mr. Dev Narayan Lal's rehabilitation and well-being.

27
 CHAPTER 6

CONCLUSIONS

By the completion of our final year mechanical engineering project, the design and
development of the Elbow Rehabilitation Machine, we have successfully fulfilled the
objectives we set out to achieve. Through careful planning and innovative design, we
have created a rehabilitation machine that is not only cost-effective but also user-
friendly. The incorporation of accessible materials, such as steel rods and PVC pipes,
combined with the use of an Arduino Uno R3 microcontroller and a high-torque servo
motor, has ensured that the machine remains affordable without compromising on
functionality or quality. The positive feedback from survey participants on
comfortability and ease of use further confirms that the machine is intuitive and
convenient for users, meeting our objective of creating an easy-to-use rehabilitation
tool.
We have successfully developed and fabricated the Elbow Rehabilitation Machine,
transforming our CAD designs into a fully functional prototype. The fabrication process
involved meticulous assembly, integration of electronic components, and rigorous
testing to ensure reliability and effectiveness. The successful rehabilitation case study of
Mr. Dev Narayan Lal, who regained significant mobility and strength in his elbow after
using the machine, stands as a testament to the machine's effectiveness and our
successful fabrication efforts.
In conclusion, the Elbow Rehabilitation Machine project has achieved its intended
goals, providing a cost-effective, easy-to-use solution for individuals recovering from
elbow injuries. The project's success is evidenced by positive user feedback, successful
patient outcomes, and the seamless integration of design and functionality. This project
not only demonstrates our technical and engineering capabilities but also contributes a
valuable tool to the field of physical rehabilitation.

28
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