Introduction

This project started as a simple assignment: design and prototype a piece of exercise equipment that uses a cranking motion. Our team set off and used questionnaires to develop a market research document that allowed us to tailor our main objectives and price point. Due to the nature of the pandemic during this time our customers specified something that could be used at home with a price point around $100 USD. With these objectives in mind we set off on the initial concept development.

Concept Development

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After working through some different concepts the team decided on a design that would mount to a desk using a table clamp. This design would be constructed in a way that allows the user to mount both in the horizontal and vertical positions to provide completely different exercises with minimal setup change.

The resistance mechanism was originally planned to be electrically controlled but in order to maintain a lower price point the team decided it would be better to pursue a mechanical slipper clutch style mechanism using friction pads and high resistance springs.

initial Prototype

The main resistance mechanism utilized a machined stainless steel disk sitting on a threaded shaft embedded into the enclosure. When the user tightens the resistance adjustment at the top of the device, the system is compressed and the spring exerts greater force on the floating friction disk under the main stainless disk. This gives a nice progressive resistance that is easily adjustable.

The team tested both the overall resistance strength and the stability of the platform to ensure it would both give the maximum strength workout and provide enough stability for smooth use. Once the design was refined the enclosure and final features were investigated.

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Final Prototype

The final prototype developed the initial concepts further in order to arrive at a more refined product. The exterior of the unit was FDM printed as one piece. Built into this enclosure were two mounting points for the included table clamp that allows it to be used in both the horizontal and vertical positions. There are also handgrips and each side for easy transportation. Other features of the unit include a quick release system to allow the customer to use different shape grips that allow for different muscle groups to be targeted. The knurled straight trip includes a handle printed out of TPU for soft touch grip.