DAR ES SALAAM INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL
ENGINEERING

BACHELOR OF
MECHANICAL ENGINEERING

NTA LEVEL 8

SENIOR PROJECT- II

TITLE: MODIFICATION OF STATIONARY ELLIPTICAL TRAINER.

PROJECT TYPE: MODIFICATION

PRESENTED BY: SADICK BENJAMINI

ADMISSION NO: 140545403017

CLASS: BENG 14ME

July, 2017
 Certification

CERTFICATION
The undersigned certify that he has read and hereby recommend for acceptance by the Dar es
Salaam Institute of Technology (DIT), a project titled Modification of Stationary Elliptical
trainer in fulfillment of the requirements for the Bachelor degree of mechanical engineering of
Dar es salaam Institute of Technology.

Signature………………………..
Date……………………………..
Loibanguti Solomon
(Project Supervisor)

i
 Declaration

DECLARATION
I, Sadick Benjamin hereby declare to the best of my knowledge that this project is my original
work and it has not been copied from somewhere or someone else. All the contents found in this
project are due to my knowledge in Mechanical Engineering, information obtained from my
supervisor, literature review as well as different experts in the Mechanical field.

Signature………………………………….
Date……………………………………….
Benjamin Sadick
(A student)

ii
 Abstract

ABSTRACT
Stationary elliptical trainer is a stationary exercise machine used to simulate stair climbing,
walking or running without causing excessive pressure to the joints, hence decreasing the risk of
impact injuries.
The purpose of this project is to modify the Stationary elliptical trainer which will contribute in
the development of Exercise machine to be used for home use.
This report involve introduction, literature review, methodology, preliminary data collected and
methods of data analysis chapter. From each chapter there are sub-sections which have been
explained in details. The introduction provides the prior information about what the project is
concerned. In literature review, several existing types of Elliptical trainer have studied which
give an initial step for design of this machine. In methodology, various methods have used to
achieve the main objective of this project. Through data collection, data have been collected
from various places as shown in chapter four of this book. The collected data have analyzed in
data analysis chapter and the best alternative of the design was finally obtained.
The model of the stationary elliptical trainer is made with two handlebar, Flywheel, frame, Pedal
and roller for resistance mechanism. The development of this project will have the following
advantages, the trainer will save the monthly cost for gym, it will save the running cost because
the machine will not use electricity, the machine will be used with any one even those who have
no education because the machine eliminate the use of panel which is difficult to some people.

iii
 Acknowledgement

ACKNOWLEDGEMENT
It is my pleasure to express my gratitude to different people who have been contributed much
toward the accomplishment of this work. I would like also to extend my sincere gratitude to all
who participated in one other for courage me undergo this modification, which led me to start
from selection of Project title to the Data analyzing and Selection of best alternative. It is not
easy mention everybody in names, but led this represent all of them.
May I also express my sincere thanks to my supervisor Loibanguti S, a member of staff from
Mechanical Engineering Department, who spent their time and energy for advising directing and
building for their constructive idea.

iv
 Contents

CONTENTS

CERTFICATION.............................................................................................................................i
DECLARATION.............................................................................................................................ii
ABSTRACT...................................................................................................................................iii
ACKNOWLEDGEMENT..............................................................................................................iv
CONTENTS....................................................................................................................................v
LIST OF FIGURES.......................................................................................................................vii
LIST OF TABLES.......................................................................................................................viii
LIST OF ABREVIATIONS...........................................................................................................ix
CHAPTER ONE..............................................................................................................................1
INTRODUCTION.......................................................................................................................1
1.1 BACKGROUND...............................................................................................................1
1.2 PROBLEM STATEMENT................................................................................................2
1.3 PROJECT OBJECTIVES..................................................................................................2
CHAPTER TWO.............................................................................................................................4
LITERATURE REVIEW............................................................................................................4
2.1 EXAMINATION OF THE EXISTING ELLIPTICAL TRAINER.......................................4
2.2 DIFFERENCE BETWEEN CROSS TRAINER AND ELLIPTICAL TRAINER...........7
2.3 THE DIFFERENCE TYPES OF ELLIPTICAL DRIVES................................................8
CHAPTER THREE.......................................................................................................................14
METHODOLOGY....................................................................................................................14
3.0 INTRODUCTION...........................................................................................................14
3.1 LITERATURE REVIEW................................................................................................14
CHAPTER FOUR.........................................................................................................................15
DATA COLLECTION..............................................................................................................15
4.1 INTRODUCTION...............................................................................................................15
 Project Work for Bachelor of Mechanical Engineering Student, DIT

CHAPTER FIVE...........................................................................................................................18
DESIGN OF STATIONAL ELLIPTICAL TRAINER.............................................................18
5.1DESIGN SPECIFICATION.............................................................................................18
5.2 CONCEPTUAL DESIGN...............................................................................................18
5.3 DESIGN ALTERNATIVES............................................................................................19
5.4 DERTEMINING WEIGHT FACTOR............................................................................26
5.5 DESIGN CALCULATIONS...........................................................................................28
CHAPTER SIX..............................................................................................................................38
CONCLUSION AND RECOMMENDATION........................................................................38
6.1 CONCLUSION................................................................................................................38
6.2 RECOMMENDATION...................................................................................................38
REFERENCES..........................................................................................................................39
APPENDICES...........................................................................................................................40
Appendix A................................................................................................................................40
PPROJECT COST ESTIMATION........................................................................................40
Appendix B................................................................................................................................42

vi
 List of Figure

LIST OF FIGURES
FIGURE 2.1 ELLIPTICAL GLIDER (FITNESS L. , 2016)......................................................................5
FIGURE 2.2 ELLIPTICAL CROSS TRAINER (FITNESS L. , 2016).........................................................7
FIGURE 2.3 FRONT DRIVE ELLIPTICAL TRAINER (AMAZON, 2017)................................................11
FIGURE. 2.4 REAR DRIVE ELLIPTICAL TRAINER (FITNESS O. , 2017)............................................12
FIGURE. 2.5 CENTER DRIVE ELLIPTICAL TRAINER (FITNESS O. , 2017)...........................................2
FIGURE 5.3.1.1 FRONT DRIVE WITH CHAIN DRIVE AND ROLLER RESISTANCE................................21
FIGURE 5.3.2.1 CENTER DRIVE WITH DIRECT DRIVE AND MAGNET RESISTANCE.............................1
FIGURE 5.3.3.1 REAR DRIVE WITH DIRECT DRIVE AND ROLLER RESISTANCE...............................25

vii
 List of Tables

LIST OF TABLES
TABLE 4.1 SPECIFICATION OF FRONT DRIVE ELLIPTICAL TRAINER SOLE E95................................1
TABLE 4.2 SPECIFICATION OF CENTER DRIVE ELLIPTICAL TRAINER PRECOR AMT 835................1
TABLE 4.3 SPECIFICATION OF REAR DRIVE ELLIPTICAL TRAINER...................................................1
TABLE 5.2.1.1 MORPHOLOGICAL CHART.......................................................................................19
TABLE 5.3.1 DESIGN ALTERNATIVES..............................................................................................20
TABLE 5.3.2 (A) AND (B) COMPATIBLE SUB SOLUTION FOR ALTERNATIVE A...............................20
TABLE 5.3.3 AVERAGE MARKS FOR ALTERNATIVE A...................................................................22
TABLE 5.3.4 (A) AND (B) COMPATIBLE SUB- SOLUTION FOR ALTERNATIVE B..............................22
TABLE 5.3.2.1 AVERAGE MARKS FOR ALTERNATIVE B...................................................................1
TABLE 5.3.2.2 (A) AND (B) COMPATIBLE SUB- SOLUTION FOR ALTERNATIVE C.............................1
TABLE 5.3.1.1 AVERAGE MARKS FOR ALTERNATIVE C.................................................................26
TABLE 5.4.1 WEIGHT FACTOR........................................................................................................26
TABLE 5.2.2 RANKING THE DESIGN ALTERNATIVE..........................................................................1
TABLE 5.5.1 HUMAN PERFORMANCE.............................................................................................28
TABLE 5.6.......................................................................................................................................37
 List of abbreviations

LIST OF ABREVIATIONS

ABREVIATONS DESCRIPTION
DIT Dar es salaam Institute of Technology
ME Mechanical
Mm Millimeters
Kg Kilogram
NTA National Technical Award
N Newton
T Torque
http Hypertext transfer protocol

ix
 Chapter one

CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND
One of very popular machine which is found in GYM station is Stationary Elliptical Trainer.
This is exercise machine used to simulate stair climbing, walking or running without causing
excessive pressure to the joint, hence decreasing the risk of impact injuries. Used for physical
fitness, weight loss and physical therapy. With elliptical trainer, the lower body motion is across
between an upright stationary cycle and a stepper; expect that the feet move in an egg shaped, or
elliptical pattern, as opposed to a circular path. Since the feet does not leave the footpads, ground
reaction or impact forces in the feet are purported to be lower, resulting in fewer orthopedic
injuries to the lower extremities. When you step into a gym, you will likely see several lines of
cardiovascular machines, including treadmills, exercise bikes, stationary bikes, rowers and stair
climbers. Another popular piece of machinery is the elliptical machine[ CITATION Pec12 \l
1033 ]. Not only are they available at most gyms, but they are also used in homes. To use an
elliptical, stand on top of the pedals and grab the handles. Move your legs in a gliding back-and-
forth motion. Other than their ease of use, these machines feature with an array of additional
benefits. With Elliptical machine people will benefit the following:
Non-Impact exercise; There are a lot of people who suffer from bone and joint conditions, such
as ligament tears, osteoporosis and arthritis. Those suffering from such ailments can benefit from
elliptical training because it does not place a lot of impact on joints. Being that your feet stay still
on the gliding platforms, there is no impact, which makes the elliptical a safer exercise option for
a variety of people, including those who are elderly, rehabbing from knee surgery, have varicose
veins or are obese.[CITATION lea14 \l 1033 ]
Total body workout; when you are running either outside or on a treadmill, you burn calories and
get a lot of leg muscle recruitment. However, when you use the elliptical, you can work the
upper and lower body at the same time. Elliptical machines work the legs, chest, shoulders, back
and arms. With this machine, you can complete a full-body workout in as little as 20 minutes.

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

Lower body exercise; Elliptical trainers use a lot of muscles in the legs, which is an area a lot of
people want to target. For an effective leg workout, place your hands on the center handrail, and
just use your legs to move the pedals. To add a little variation to this, you can reverse the
direction of the pedals, which will work your legs more intensely.[CITATION lea14 \l 1033 ]
Calories burned; According to Harvard Health Publications, you can burn up to 400 calories in
just 30 minutes exercising on an elliptical machine, depending on your weight. The heavier you
are, the more weight you'll burn in this time frame. The intensity of your workout also impacts
the amount of calories you burn, so increase the machine's resistance or interval train on the
machine to increase the amount of energy you expend during workout sessions.[CITATION
lea14 \l 1033 ]

1.2 PROBLEM STATEMENT

The currently used stationary elliptical trainer or cross trainer machine have the following
problems: first is providing limited range of exercise and this is due to the setting of the machine,
second is costly piece of exercise equipment this is due to the cost paid for gym membership
each monthly, third is lack of conformability this is due to staying in one place for long time and
last is waste of time during travelling to the GYM station.

1.3 PROJECT OBJECTIVES

The following are the project objectives

1.3.1 MAIN OBJECTIVES

The main objective is modification of stationary Elliptical trainer.

1.3.2 SPECIFIC OBJECTIVES

i. To review different types of elliptical trainer including its mechanism and operation.
ii. To prepare drawings.
iii. To Designing some parts according to specification requirement and estimating the cost
involved.
iv. To Manufacturing of the Prototype.
v. To test prototype.

2
 Chapter One

1.3.3 SIGNIFICANCE OF THE PROJECT

On manufacture of the Mobile elliptical trainer it will assist the user to benefit the following:

i. Physical fitness, weight loss, physical therapy, human powered transport and outdoor
adventure.
ii. Unlimited range of exercise.
iii. Remove monthly cost paid for gym membership.
iv. Provide conformability during exercise.

3
 Chapter Two

CHAPTER TWO

LITERATURE REVIEW

2.1 EXAMINATION OF THE EXISTING ELLIPTICAL TRAINER

This chapter will concern about what other people have been done related to Elliptical machine,
now the task will be to find some different Elliptical machine and see the advantages,
disadvantages and the operating mechanism.
Elliptical machines are classified according to the movement of the machine. And those
classifications are:
i. Elliptical Glider.
ii. Elliptical cross-trainer.
iii. Elliptical Trainer.

2.1.1 ELLIPTICAL GLIDER

An elliptical glider looks very much like an elliptical trainer. There are stationary handlebars, no
moving arms and foot platforms, or pedals. However, the pedals move up and down at a slight
backward angle. They do not circle like elliptical trainers and cross-trainers. Elliptical gliders do,
however, work the legs through knee and hip extension. You can pedal both forwards and
backwards on the elliptical glider, as you can with other elliptical. Resistance from the machine
comes only from forward movement.
The Trainer Elliptical provides extra comfort and added stability with its high-density foam
covered handlebars and nonskid foot platforms. The patented, dual-action split suspension gives
complete range of motion when you exercise.[CITATION lea14 \l 1033 ]
2.1.1.1 Advantages of Elliptical Glider
i. You can Pedal both forward and backward
ii. Provide extra comfort and added stability
iii. Give range of motion when you exercise
iv. Its flexible
2.1.1.2 Disadvantages of Elliptical Glider
i. Have no inclination option

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

ii. Resistance comes only for forward motion

iii. It provide only forward and backward motion

Figure 2.1 Elliptical Glider[ CITATION Lif16 \l 1033 ]

2.1.2 ELLIPTICAL CROSS TRAINER.

The elliptical cross-trainer is a cardio machine that works the upper and lower body. It has the
same pedal platforms as the elliptical trainer, and moves in the same elliptical pattern -- hence
the name. The cross-trainer has moving arms that work the upper body as you push on the
pedals; you push and pull on the metal arms in an alternating pattern to your feet. Instead of just
targeting the legs through knee and hip extension, other joints that get worked include the

5
 Chapter Two

Shoulders and elbows. You also retract, or pull back, and protract the shoulder blades and
collarbones when using an elliptical trainer to work your upper back and chest.
Elliptical cross trainers is more simply known as elliptical trainers -- aren't perfect; some of them
have limited stride lengths, which means they only fit a limited cross-section of the population.
Most gym elliptical trainers, however, will suit a wide range of body types, and they offer a
range of benefits that's just as wide. Elliptical trainers offer a low-impact, full-body workout that
burns calories to the tune of 800 per hour, depending on your body weight.
A low impact workout; because your feet never leave an elliptical trainer's pedals, you don't have
to worry about the repeated pounding your joints take when you run on a treadmill. Even
walking offers a certain degree of impact albeit much less that you can avoid by using an
elliptical trainer. Yet elliptical trainers still offer all the benefits of a weight-bearing workout,
which helps build bone density in your legs, hips and spine.
Work those arms; some elliptical trainers have moving handlebars. Push and pull on those
handlebars as you pedal for a true full-body workout. The back-and-forth motion targets your
chest, back, shoulders and arms, while the pedals work every major muscle in your lower body.
[CITATION Sta96 \l 1033 ]
2.1.2.1 Advantages of Elliptical cross trainer
i. A Low-Impact Workout
ii. Work Those Arms
2.1.2.2 Disadvantages of Elliptical cross Trainer.
i. It has no inclination mechanism
ii. High maintenance cost due drive mechanism

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

Figure 2.2 Elliptical cross trainer [ CITATION Lif16 \l 1033 ]

2.1.3 ELLIPTICAL TRAINER.

An elliptical trainer machine is a lower-body-only cardio machine that has foot pedals you stand
on and a stationary handlebar to hold onto. You use the machine by standing on the pedals and
pushing on them to make circular, elliptical movements. Exercising on the elliptical trainer
requires knee and hip extension, which works the quads, glutes and hamstrings.
This is good news for the large number of people who are looking for a high-intensity, low-
impact substitute to jogging. While the popularity of elliptical trainer has virtually exploded,
research on their benefits is relatively scarce.

2.2 DIFFERENCE BETWEEN CROSS TRAINER AND ELLIPTICAL TRAINER.

An elliptical cross trainer has arms that move but the incline of the leg pedals is not adjustable.
The moving arms allow you to tone your upper body by pushing and pulling the arms while
pedaling. Controlling the incline, however, lets you choose to emphasize the hamstrings and
gluts more. If you want to increase your intensity while exercising, you can increase your speed

7
 Chapter Two

or resistance level from the pedals on all the machines, but the cross-trainer increases intensity in
the arms, too. Raise the incline to increase intensity on the elliptical glider and elliptical trainer.
Because there are options to control your intensity with each of the machines, you cannot truly
say that one burns more calories than the other. On average though, ShapeFit.com says that a 145
lb. person can burn 300 calories in 30 minutes on an elliptical.[CITATION lea14 \l 1033 ]

2.2.1 DIFFERENCE IN MUSCLES USED.

The cross trainer will use muscles in the upper body that the elliptical trainer or glider will not.
All three machines require hip and knee extension from using the pedals. Hip extension happens
courtesy of the thigh and buttocks muscles, including the gluteus Maximus, biceps femora’s,
semitendinosus, semimembranosus and adductor Magnus. The quads are responsible for knee
extension. These muscles work with all three machines, but the body must also perform shoulder
flexion and extension, elbow flexion and extension, and protraction and retraction of the
shoulder blades to move the arms. This is going to involve the back, shoulder, chest and forearm
and upper arm muscles including the traps, rhomboids, lats, pecks, serrates anterior, elevator
scapulae, biceps, brachialis, brachioradialis, triceps, anconeus, terse major and coracobrachialis.
None of those upper body muscles work when using an elliptical trainer or glider.[CITATION
lea14 \l 1033 ]

2.2.2 DIFFICULT TO USED

When used as intended, the elliptical cross trainer will be more challenging to your balance and
coordination than elliptical trainers or gliders. The challenge to your balance occurs because
there is no point of contact between your body and the machine that does not move. You can
hold onto the stationary handlebars of a cross trainer to get around this, but that defeats the
purpose of using a cross trainer instead of an elliptical glider or elliptical trainer. The
coordination is harder because as your right arm goes forward your right foot goes backwards,
and the left side of your body is doing the opposite motions. Disabled or elderly individuals may
find elliptical gliders and trainers easier to use because of the handlebars that do not move; but if
you want to improve your balance and coordination try the elliptical cross trainer.[CITATION
lea14 \l 1033 ]

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 Chapter Two

2.3 THE DIFFERENCE TYPES OF ELLIPTICAL DRIVES.

Rear drive, back drive and center drive. What do these mean when you are looking at elliptical
trainers? Don’t worry, it is not similar to driving a car and has nothing to do with changing gears.

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 Project Work for Bachelor of Mechanical Engineering student, DIT

The drive type of an elliptical machine is only referring to the placement of the flywheel or
drives system that controls how smooth the machine feels and gives the trainer its resistance. An
elliptical with the flywheel in the back is known as a “rear-drive”, one with the flywheel in the
front is called a “front-drive”, and if the drive system is on both sides it is, amazingly, a “center-
drive”. The rule of thumb is that the heavier the flywheel, the smoother the motion of the
machine will be. That part is fairly simple, but which drive type is best for you? Let’s have a
look at the benefits of each type in order to find out.[CITATION Ind16 \l 1033 ]

2.3.1 FRONT DRIVE

The very first elliptical trainers for home use had the flywheels located in the front and were
front drive trainers. They are still popular because they are usually more compact and cheaper
than elliptical with other drive types. This design tends to encourage you to lend forward just a
bit when you are working out; this makes front drive elliptical more favorable among people
who like the climbing motion, as they will feel more like they are using a stair climber.
[ CITATION Ind16 \l 1033 ]
Front drive elliptical are usually very close to the ground and they don’t have many parts sticking
out like hurdles for you to jump over when getting on or off the machine. This makes them
somewhat safer to mount than rear drive machines. Some of these elliptical will allow you to
manually adjust the incline of the ramp, but more often than not the incline is fixed.
The main drawback of using a front drive elliptical trainer is the higher maintenance costs that
usually incur because they use roller tracks with urethane wheels. The tracks and wheels both
need to be cleaned regularly for the machine to keep functioning optimally. The thought of
having to go the extra mile to clean the roller track every so often, just to be sure you don’t run
into any performance issues, is by no means attractive. This regular maintenance is why some
people prefer not to go with front drive elliptical.[CITATION Ind16 \l 1033 ]
2.3.1.1 Advantages of Front Drive
i. Are cheaper than other types

2.3.1.2 Disadvantages of Front Drive

i. Higher maintenance costs that usually incur because they use roller tracks with urethane
wheels.

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 Chapter Two

ii. It needs regular maintenance.

Figure 2.3 Front drive Elliptical trainer[ CITATION Ama17 \l 1033 ]

2.3.2 REAR DRIVE

Rear drive elliptical have the flywheel at the back of the machine. This type of elliptical is more
commonly found in gyms and they are popular in the commercial elliptical market. They also
tend to be more expensive than front drive machines because they let you adjust the incline

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 Chapter Two

manually or automatically. Also, they don’t have as many moving parts, which translates into
lower maintenance costs.
.[ CITATION Ind16 \l 1033 ]
2.3.2.1 Advantages of Rear drive
i. Have inclination option which is manual or automatic.
ii. Lower maintenance cost due to less moving parts.
iii. It can be folded to give more compact in storage
2.3.2.2 Disadvantages of Rear drive
i. It’s expensive than front drive

Figure. 2.4 Rear drive Elliptical trainer[ CITATION Opt17 \l 1033 ]

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 Chapter Two

2.3.3 CENTER DRIVE

The newest drive type to be used on elliptical machines is the center drive. On center drive
elliptical trainers the drive system or flywheel is located on both the left and right sides of the
machine instead of at the back or front. You will normally see this design on elliptical that are
more compact for home use, such as the Best Fitness E1 Elliptical Trainer by Body Solid.
Elliptical with a center drive design tend to be more expensive, but they are known to be very
quiet, provide a smooth natural movement, and are easy on the joints. These types of elliptical
typically have the foot pedals closer together than on traditional machines; this pedal placement
is what helps to give the elliptical a more natural feel and the ability to reduce stress on your
back or hips. As the weight of the machine is evenly distributed on both sides, these machines
will also feel more stable.[ CITATION Ind16 \l 1033 ]
The one drawback of having an elliptical with a center drive is that they do not come with an
incline option. Incline on an elliptical allows you to work more of your muscle groups but, alas,
those with a center drive design do not have this ability. This is because their physical design
does not use a ramp, and ramps are needed to change the angle of the incline. Incline is an
optional feature on elliptical; your machine will still be able to give you a good, total body
workout without it, but if you absolutely must have the incline feature then you should look at
machines with a front or back drive.

So which drive type is better? I would say it all comes down to your personal preferences. If you
like the climbing motion, go for a front drive elliptical. If you prefer a machine that you can
potentially fold up, you should look at back drive models. If you want a machine that is firm and
stable, then a center drive will likely be your best option. Now that you know the benefits of each
type, you can choose the one that will best suit your needs.[ CITATION Ind16 \l 1033 ]
2.3.3.1 Advantages of Center drive
i. Are very quiet
ii. Provide smooth natural movement
iii. Easy on Joint
iv. More stable due to distribution of weight
2.3.3.2 Disadvantages of Center drive
i. More expensive

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

ii. Does not have incline option

Figure. 2.5 Center drive elliptical trainer[ CITATION Opt17 \l 1033 ]

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 Chapter Three

CHAPTER THREE

METHODOLOGY

3.0 INTRODUCTION
This chapter describes about the methods and procedures that are required to follow for the
successful completion of the modification and manufacture of Mobile Elliptical Trainer. The
following procedures will be taken to accomplish this project:-

3.1 LITERATURE REVIEW

In this area, Literature Review gives an overview of the related topics or act as a stepping stone
of the project. It gives the information on the progress of the various types of the Elliptical
machines, existing machines and its mechanisms. This information is mainly obtained through
browsing various internet websites, reading related engineering books, through the information
obtained the gap is discovered so that further action can be taken to bridge the gap.

3.1.1 DATA COLLECTION

These are the information gathered from different sources concern with the Elliptical machines
which are of more importance in developing the project. From the main three method of
collecting data; collecting data by interviewing, observation and questionnaires. But only two
methods were used to collect data; interviewing and observation.
3.1.2 ANALYSIS OF DATA
The collected data were analyses so as to make sure that the design is correct and optimal.
3.1.3 PREPARATION OF TECHNICAL DRAWING
All technical drawing was prepared in detail so as to help in manufacture of the prototype.
3.1.4 MANUFACTURE OF PROTOTYPE.
Prototype is manufactured per design and technical drawing.

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 Chapter Four

CHAPTER FOUR

DATA COLLECTION

4.1 INTRODUCTION

These are the information gathered from different sources concern with the Elliptical machines
which are of more importance in developing the project. From the main three method of
collecting data; collecting data by interviewing, observation and questionnaires. But only two
methods were used to collect data; interviewing and observation.

4.1.1 INTERVIEW METHOD

By using Interview with GYM trainer and some user of this machine, the following information
was obtained:
i. The difficult of using this machine when the Electricity is cut off, some of this machine
have battery which store charge for some time but the battery does not take much time so
this limit the use of machine.
ii. Lack of specialist for maintenance of these machines, most of people who are used for
maintenance of this machine have no much knowledge on operation principle of this
machine this lead to destruction of this machine.
iii. Most of the user failure to operate the machine especially in doing some setting on
control panel of the machine, this give the trainer extra job to configure the machine.
iv. Damage of screen panel due to careless of some user.

4.1.2 OBSERVATION METHOD

By using observation in GYM Centre the following data was obtained depending on Types of
machine and model by looking on name plate, User manual and make physical measurement of
the machine. This was done by visiting the following area Deffee fitness Centre which is located
at Ilala bungoni, Alfaque fitness store which is located Opposite Benjamin mkapa High school.

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

4.1.2.1 FRONT DRIVE ELLIPTICAL TRAINER.

This was specification for Sole E95

Table 4.1 Specification of Front drive Elliptical trainer Sole E95

PROPERTIES PARAMETERS

Incline: 0-20 degrees

Stride Length: 20 inches

Flywheel: 27 LBS

Programs: 10 programs

Weight Capacity: 400 LBS

Dimensions: 82" L x 31" W x 67" H

4.1.2.2 CENTER DRIVE ELLIPTICAL TRAINER

This was specification for Precor AMT 835

Table 4.2 Specification of Center drive Elliptical trainer Precor AMT 835
PROPERTIES PARAMETERS

Incline: 13 - 40 degrees

Stride Length: 0 - 36 inches

Flywheel: N/A

Weight Capacity: 500 LBS

Dimensions: 80" L x 32" W x 68" H

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

4.1.2.3 FOR REAR DRIVE ELLIPTICAL TRAINER

This was specification for Precor EFX 245

Table 4.3 Specification of Rear drive Elliptical trainer

PROPERTIES PARAMETERS

Incline: 0 - 25 degrees

Stride Length: N/A

Flywheel: N/A

Programs: 25 preset workouts or 16 that you can create

Weight Capacity: 500 LBS

Dimensions: 76" L x 29" W x 65" H

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 Chapter Five

CHAPTER FIVE

DESIGN OF STATIONAL ELLIPTICAL TRAINER

5.1 DESIGN SPECIFICATION

According to the data I have collected the project managed to come with another solution for
designing of Simple and Portable Stationary Elliptical trainer for home use.

5.2 CONCEPTUAL DESIGN

The design process deals with ability of making varieties of the design where the optimal
solution is found. The process has some steps to consider. This chapter will deal with evaluation
alternatives and selecting the optimal alternatives. The major reason of these different designs is
to look for concept design, concept evaluation, to know the capacity of the machine, source of
power, modeling/prototyping and other parameters which will assist to obtain the optimal
solution that will solve the project statement of the design.
The optimal design can be obtained by considering the Stationary elliptical rainer into the
following features:
i. Placement of drive in Stationary Elliptical Trainer.
ii. Means of drive for Stationary Elliptical Trainer.
iii. Means of Resistance for Stationary Elliptical Trainer.
iv. Portability of the Stationary Elliptical trainer in shifting from one place to another.
The consideration for these feature are important so as to achieve with optimal safety,
ergonomic, capacity, durability , maintaining , aesthetic etc.
However the best alternative is in accord with the customer requirement, that is should be in
price, running costs, ease of maintenance etc.

5.2.1 THE MORPHOLOGICAL CHART

The morphological chart is a method to generate ideas in an analytical and systematic manner.
Usually; function of the product are as a starting point. The various function and sub function of
a product can be established through a function analysis.
However, function analysis does not guarantee that all the relevant (sub) function are identified.
Often a number of solution to solutions to these (sub) function are already known, while others

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are through up by you. These solutions will form the components in the morphological chart.
The morphological method thus yields a matrix of functions and components.
A Morphological chart incorporation these list shown in table 5.2.1.1 which shows the feature
and means for fulfillment the respective feature.

Table 5.2.1.1 Morphological chart

Feature Means

Placement of drive Front drive Center drive Rear drive

Means of drive Chain Belt Direct

Means of Magnetic Roller

resistance

For the above morphological chart there are eight means of achieving the six functions. And
hence there is a staggering 18 possible stationary elliptical trainer design in the chart.
But some of these are not practical solution and imply incompatible option. For this reason only
three options has been identified for the selection of best alternative .And this has been indicated
in table 5.2.1.1

5.3 DESIGN ALTERNATIVES

From the Morphological chart, three alternatives have been identified for a design follows

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 Chapter Five

Table 5.3.1 design alternatives

S/N ALTERNATIVE DESIGN TYPE
o

1 Front drive with chain drive and roller resistance mechanism A

2 Center drive with direct drive and magnetic resistance mechanism B

3 Rear drive with direct drive and roller resistance mechanism C

Table 5.3.2 (a) and (b) Compatible sub solution for alternative A
Feature Means

Placement of drive Front drive Center drive Rear drive

Means of drive Chain Belt Direct

Means of Magnetic Roller

resistance

Placement of drive Front

Means of drive Direct
Means of resistance Roller

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5.3.1 ALTERNATIVE A
Front drive with direct drive and Roller resistance mechanism

Working Principle

The Elliptical trainer has Drive which is placed at front of the machine where this drive normal
provide resistance for the trainer so that controls how smooth the machine feels, machine have
handlebar which is bolted at the center with support and at bottom is connected with pedal. The
pedal also connected with drive. So the movement of this machine start when the operator push
the pedal with legs which is linked with drive by chain so that to make the exercise perfect but
this motion give effect to handlebar involve the movement of shoulder.

Figure 5.3.1.1 Front drive with chain drive and roller resistance
5.3.1.1 Advantages of Front Drive
i. Are cheaper than other types
5.3.1.2 Disadvantages of Front Drive
i. It needs regular maintenance.
ii. It has noise due to chain

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 Chapter Five

Table 5.3.3 Average marks for Alternative A

Interviewee Safety Maintainabilit Efficiency of Operation Ergonomic Cost

y s

1 4 4 4 5 2

2 3 3 4 4 3

3 4 3 4 4 2

4 5 3 4 4 3

5 5 4 5 4 3

Average 4.2 3.4 4.2 4.2 2.6

Table 5.3.4 (a) and (b) Compatible sub- solution for alternative B.
Feature Means

Placement of drive Front drive Center drive Rear drive

Means of drive Chain Belt Direct

Means of Magnetic Roller

resistance

(a)

Placement of drive Center

Means of drive Direct
Means of resistance Magnetic
(b)

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5.3.2 ALTERNATIVE B
Center drive with direct drive and Magnetic resistance mechanism

Working Principle

The Elliptical trainer has driven which is placed at center of the machine where this drive normal
provide resistance for the trainer so that controls how smooth the machine feels, machine have
handlebar which is bolted with support and at bottom is connected with pedal. The pedal also
connected with drive. So the movement of this machine start when the operator push the pedal
with legs which is linked with drive so that to make the exercise perfect but this motion give
effect to handlebar involve the movement of shoulder.

Figure 5.3.2.1 Center drive with direct drive and magnet resistance
5.2.3.1 Advantages of Center drive
i. Are very quiet
ii. Provide smooth natural movement
iii. Easy on Joint
5.3.2.2 Disadvantages of Center drive
i. More expensive
ii. Does not have incline option

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 Chapter Five

Table 5.3.2.1 Average marks for Alternative B

Interviewee Safety Maintainability Efficiency of Operation Ergonomics Cost

1 4 2 3 3 1

2 3 3 3 4 2

3 4 2 3 3 1

4 3 3 3 3 1

5 3 2 3 4 2

Average 4.2 3.0 3 3.4 1.4

Table 5.3.2.2 (a) and (b) Compatible sub- solution for alternative C.
Feature Means

Placement of drive Front drive Center drive Rear drive

Means of drive Chain Belt Direct

Means of Resistance Magnetic Roller

(a)

Placement of drive Rear

Means of drive Direct
Means of resistance Roller
(b)

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5.3.3 ALTERNATIVE C
Rear drive with direct drive and resistance mechanism

Working Principle

The Elliptical trainer has drive which is placed at rear of the machine where this drive normal
provide resistance for the trainer so that controls how smooth the machine feels, machine have
handlebar which is bolted with support and at bottom is connected with pedal. The pedal also
connected with drive. So the movement of this machine start when the operator push the pedal
with legs which is linked with drive so that to make the exercise perfect but this motion give
effect to handlebar involve the movement of shoulder.

Figure 5.3.3.1 Rear drive with direct drive and Roller resistance

5.3.3.1 Advantages of Rear drive

i. Have less moving part
ii. Easy in maintenance.
iii. It can be folded to give more compact in storage

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

iv. Has feeling like you are jogging

5.3.3.2 Disadvantages of Rear drive
v. It’s expensive than front drive
vi. Low maintenance cost

Table 5.3.1.1 Average marks for Alternative C

Interviewee Safety Maintainabilit Efficiency of Operation Ergonomics Cost

y

1 4 4 5 4 4

2 3 5 4 3 5

3 5 4 5 5 4

4 4 4 4 4 4

5 5 4 4 4 4

Average 4.2 4.2 4.4 4.0 4.2

5.4 DERTEMINING WEIGHT FACTOR

This was done by interview different people based on the objective of the project to determine
the weight of each pre-selected factors.

Table 5.4.1 Weight factor

Interviewee Safety Maintainability Eff. of operation Ergonomics Cost Total(x)

1 4 4 5 4 5

2 5 4 2 3 4

3 4 5 4 3 4

Total(y) 13 13 11 10 13 60

Weight 0.217 0.217 0.183 0.166 0.217

factor (F)

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 Chapter Five

Where;

x
Weight factor (F) = …………………………………………………….………………… (5.1)
y

Table 5.2.2 Ranking the design alternative

Total weight

Rank order
Alternatives

Factors

Safety Maintainability Efficiency Ergonomics Cost

of
operation

Weighting 0.217 0.217 0.183 0.166 0.217

Factors

A Weight 4.2 3.4 4.2 4.2 2.6

Score 0.911 0.738 0.769 0.133 0.564 3.115 2

B Weight 4.2 3.0 3 3.4 1.4

Score 0.911 0.651 0.549 0.564 0.304 2.979 3

C Weight 4.2 4.2 4.4 4.0 4.2

Score 0.911 0.911 0.805 0.664 0.911 4.202 1

Therefore from the table above the best alternative is ALTERNATIVE C which is Rear drive
with direct drive and resistance mechanism.

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 Chapter Five

5.5 DESIGN CALCULATIONS

After selecting the best alternatives that is alternative C, It is necessary to perform design
calculations for proper selection of the sizes of the various components of this Stationary
Elliptical trainer. The designed Trainer consists of the following components namely;

1. Handlebar
2. Handlebar Support
3. Strider(Platform)
4. Pins
5. Bearings
6. Flywheel
7. Shaft
8. Main Frame

Table 5.5.1 Human Performance

1 2 3 4 5 6 7
Degree Pul Push Up Dow In Out
of elbow l n
flexion
L R L R L R L R L R L R
π 222 231 187 222 40 62 53 75 58 89 36 62
5 187 249 133 187 57 80 80 89 67 89 36 67
π
6
2 151 137 116 98 160 76 107 93 116 89 98 67
π
3
1 142 165 98 160 76 89 93 116 71 80 45 71
π
2

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 Chapter Five

1 116 107 96 151 67 89 80 89 76 89 53 76

π
3

5.5.1 DESIGN OF HANDLEBAR

Consider the free body diagram (FBD) for the Handlebar as taken from the selected alternatives.
Now let’s find the reaction force (RC and RB ) acting on the handlebar to be designed.

Applied force

Pin reaction (RC) Pin reaction (RB)

29
Chapter Five

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 Chapter Five

Since the machine involves Pulling and Pushing at 180° (π)

Then for pulling with right hand is 231N for Pushing is 222N and for Pulling with left hand is
222 for pushing 187N.

Now let consider right hand 231+222 = 453N

Then the average is 453/2 = 226.5N

And for left hand is 187+222 =409N

Then the average is 409/2 = 204.5N

So the average for Right force and Left force is:

226.5+204.5
=
2

=215.5N
From sum of upward forces and downward forces equal to zero.

∑f = 0……………………………………………………………………………… (5.1)

Now,

215.5-Rc+RB = 0,

Taking moment about B.

∑MB = 0

0.6RC – 215.5 × 0.9 = 0

RC = 323.25N

From ∑f = 0,

RB = 323.25 – 215.5

RB = 107.75N

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

For Shear Force

FB = 107.75N

FC = 107.75-323.25 = -215.5N

FA = -215 + 215 = 0

Bending moment

At B, MB = 0

C, MC = -107.75 × 0.6 = -64.65Nm

A, MA = (-107.75 ×0.9) + (323.25 × 0.3) = 0

Therefore the Maximum bending moment is -64.65Nm

5.5.2 DESIGN OF STRIDER

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From ∑f = 0

0.785KN-RA-RB=0

0.785KN=RA+RB

Taking moment about B

∑MB=0

0.6RA-0.785KN×0.3=0

RA=0.3924KN

From 0.785KN=RA+RB

RB=0.785-0.3924

RB=0.3924KN

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

5.5.2.1 SHEAR FORCE

FB= -0.3924

FC= -0.3924+0.785

FC=0.3924

FA= - 0.3924

5.5.2.2 BENDING MOMENT

Bending Moment at B, MB =0

At C, MC=0.3924×0.3

MC=0.1176KNm

At A, MA=0.6×0.3924-0.785×0.3

MA=0

5.5.3 DESIGN OF SHAFT.

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

From ∑f=0

0.3925+0.3925-RC-RD=0

Take moment about D

∑MD=0

0.3925×0.085-0.14RC+0.3925×0.225=0

RC=0.869KN

From

0.3925+0.3925-RC-RD=0

RD=0.0841KN

5.5.3.1 SHEAR FORCE

FB=0.3925KN

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

FD=0.3925-0.0841

FD=0.3084KN

FC=0.3084-0.869

FC=0561KN

FA=-0.561KN

5.5.3.2 BENDING MOMENT

At B,

MB=0

At D,

MD=-0.3925×0.085

=-0.0334KNm

At C

MC=(-0.3925×0.225)+(0.14×0.0841)

=-0.07654KNm

At A,

MA= (-0.3925×0.31)+(0.0869×0.225)+(0.084×0.085)=0

5.5.3.3 DESIGN OF SHAFT DIAMETER

From Torque

T=F×D………………………………………………………………………………. (5.2)

=F×R

Where

F=Force

D=Diameter

Now let’s consider the Radius of the Flywheel that is R0.15m

T=392.4×0.15

=58.86Nm

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 Project Work for Bachelor of Mechanical Engineering Student, DIT

Torque = 58.86Nm

5.5.3.4 EQUIVALENT TWISTING MOMENT

From

Te=√ (Km+ Mb )2+( Kt +T )2……………………………………………………. (5.3)

=√ (1.5+76.54)2 +(1.0+58.9)2

Te = 98.4Nm= (98.4×103) Nmm

Then From

π
Te= × τ ×d 3
16

π
(98.4×103)Nmm = × 96.6 ×d 3
16

D=25.6mm

5.5.3.5 EQUIVALENT BENDING MOMENT

By using Equivalent bending moment (Me)

1
Me= [ ( Km × Mb ) +Te]…………………………………………………………… (5.4)
2

1
Me= [ ( 1.5 ×76.54 )+ 98.4]
2

Me= 426.42Nm

π
Me= × τ ×d 3
16

π
426420 = ×96.6 × d 3
2

D = 20.7mm

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 Chapter Five

Table 5.6 Operation Sequence

S/N MACHINE PARTS OPERATION SEQUENCE TOOLS/MACHINE

USED

1 FRAME i.)Marking and cutting of rectangular mild -Scriber

steel of 50×50×2mm size according to the
dimension as specified in detail drawing. -Hand hacksaw
ii.)Joining by welding the pieces of -Steel tape measure
rectangular pipes to make the frame as
-Arc welding machine
shown in detail drawing.
-Hand grinder

2 HANDLEBAR i.)Marking and cutting of round pipe of -Scriber

internal Ø24mm according to the
dimension as specified in detail drawing. -Hand hacksaw

ii.)Drilling the handlebar by drill bit of -Steel tape measure

Ø18.
-Arc welding machine
iii.)Welding the handlebar with small
-Drill machine
piece of pipe of Ø18×40mm.

3 STRIDER i.)Marking and cutting of round pipe of -Scriber

internal Ø24mm according to the
dimension as specified in detail drawing. -Hand hacksaw

ii.) Drilling the handlebar by drill bit of -Steel tape measure

Ø18.
-Drill machine

4 SHAFT i) Clamp and cut a piece of mild steel rod -Steel tape measure
of Ø25×330mm on the power hacksaw
machine. -Power hacksaw
machine.
ii.)Clamp the work piece on the lathe
machine, face and turn it according to -Lathe machine
dimension on the detail drawing.
-Clamp
iii.)Remove the work piece and clean the
machine.
See Appendix

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 Chapter Six

CHAPTER SIX

CONCLUSION AND RECOMMENDATION

6.1 CONCLUSION
The Modification of stationary elliptical trainer is completed. During the the modification
different factors such as compatibility,machine portability,efficiency and cost of manufacturing
the machine were properly analyzed from which the optimum design was selected. Base on
optimum design selected, all parts of the machine were designed to contribute on making
Stational Elliptical trainer. Different parts were designed involving calculations and other parts
were designed on basis of shape nad size of machine so as to reachthe optimal design of the
machine. Also some of the parts such as Bearing were selected as per table of standards;hence
such parts were mathematically proved in accordance of specification of engineering displine.
The technical drawing for each part were prepared to help in manufacturing of the stational
elliptical trainer. The protoype of the stational elliptical trainer was manufactured and tested by
riding it for half of a hour.

6.2 RECOMMENDATION
The machine is designed for maximum weight of 80kg and it will be running with speed of
4.83km/h to 11.83km/h. And inorder to ensure good perfomance the machine should be kept
away form moisture so as to prevent it from rusting and away from sunlight so as to prevent the
colour of the machne.The machine can be used either inside the house or outside depending on
how confortabe the operator will fill during the exercice.

38
Chapter Six

39
 References

REFERENCES

Amazon. (2017). Retrieved january 20, 2017, from www.amazon.com

Bryant, S. (1996). Cross training:Giving yourself a whole-body workout. The Physician and
Sportsmedicine.

Fitness, L. (2016). Retrieved january 26, 2017, from www.lifefitness.com

Fitness, O. (2017). Retrieved january 20, 2017, from www.optimumfitness.com

Indoor, E. (2016). Retrieved january 20, 2017, from www.indoorellipticals.com:

http://indoorellipticals.com/elliptical-drives/

Leaf, G. (2014). Retrieved 12 12, 2016, from www.livestrong.com:

http://www.livestrong.com/article/15559-elliptical-machine-benefits

Lisa. (2000). Overcoming exercise autoplot. Fitness Management.

Pecplanet. (2012). Retrieved 12 20, 2016, from www.peclapnet.com

williams . (2000). Guidelines for Exercise Testing and Prescription. American college of Sports
Medicine.

39
 Appendices

APPENDICES

Appendix A

PPROJECT COST ESTIMATION

The cost estimation for this Project has been divided into categories as described below:-

i. Material cost
ii. Machining cost
iii. Overhead cost
1. MATERIAL COST

The considered cost in this design is roughly estimated based on the construction of the whole
machine. The part like bolt and nuts, rectangular pipes, pillow bearing, round pipes mild steel
sheet and shaft should be purchased from dealers and manufacturers according to the design
specifications. The material cost is approximately based on the cost of the material from the local
markets.

Table 1: Project cost estimation

No DESCRIPTION QUANTITY PRICE AMOUNT IN TSHS

1 Rectangular pipe 1 @40,000 40,000
(50×50×3mm) 20 feet
2 Round pipe(Ø25mm) 20 feet 1 @30,000 30,000

3 Pillow bearing 2 @15,000 30,000

4 Shaft (Ø25mm×440mm) 2 @32,000 64,000

5 Sheet metal 1 @65,000 65,000

6 Cutting disk 2 @5,000 10,000

7 Grinding disk 1 @10,000 10,000

8 Welding disk 2kg @3,000 6,000

Total cost 255,000/=

Therefore the total material cost is Tshs 255,000/=

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 Appendices

2. THE LABOUR COST

The labour payment is calculated as;

Labour cost = 10% of material cost

10× 255,000
Labour cost =
100

Labour cost = 25,500/=

Therefore the labour cost is Tshs 25,500/=

3. THE FABRICATION AND MACHINING COST

Fabrication and machining cost as taken, payment estimates is calculated as:

Fabrication and cost is = 10% of material cost

10× 255,000
Fabrication cost =
100

Therefore the fabrication cost is Tshs 25,500/=

4. THE OVERALL COST

The overall cost is taken as 40% of the labour cost plus machining and fabrication cost.

Overall cost = 40% × (Labour +fabrication and machining cost)

40 ×(25,500+25,500)
= = 20,400/=
100

Therefore the overall cost is Tshs 20,400/=

5. TOTAL COST

The total cost of the Stationary Elliptical trainer is taken as the summation of material cost,
labour cost, fabrication and machining cost plus overall cost.

Total cost = (material cost + labour cost + fabrication and labour cost + Overall cost)

= 255,000 + 25,500 + 25,500 + 20,400

= 326,400/=

Therefore the total cost is Tshs 326,400/=

41
Appendices

Appendix B

42