ADVANCE EXERCISE MACHINE MECHANISAM Engi

ADVANCE EXERCISE MACHINE MECHANISAM Engineering Design & CAD
ISTANBUL TECHNICAL UNIVERSITY

Engineering Design and CAD
Term Project
Final Report
Submitted By: Shahroz Khan

911320006
Time Table of the Project
Activity November December

Week Week Week Week Week
3 4 1 2 3
Project Selectin
Background Research
Conceptual Design
Solutions for Design
Embodiment Design
Final Project Report
Project Presentation
Contents
1. Introduction
1.1 The Engineering Design Process
1.1.1 Recognition of need
1.1.2 Conceptualization and Creativity
1.1.3 Establishing Design Requirements
1.1.4 Preliminary Design
1.1.5 Detailed Design
2. Identification of need
2.1 The Need for Exercise
2.2 Background Research in Exercise Technology
2.2.1 Existing Machines and trends
2.3 Home Exercise Market
2.4 The Defined Need
3. Conceptualization Design
3.1 Initial Concepts
3.2.1 Evolution of Prismatic Mechanisms to Revolute Mechanisms
3.2 Refined Concepts
3.3 Feasibility Assessment
4. Embodiment Design Decision

4.1 Establishing Design Requirements
4.2 Design Requirements for the Home Exercise Machine
5. Preliminary Design
5.1 Decision Matrix for Design Selection
6. Second Preliminary Design
6.1 New Idea
7. Detailed Design
7.1 CAD Model
7.1.1 Parts of Mechanism
8. Working
9. Benchmarking
9.1 Benchmarking Table
10. Conclusion
1. Introduction
This report uses the engineering design process applied to advance exercise machine. This
uses a person own weight as a source of resistance. The design process is used to take idea
from concept to computer aided design modeling.
The design process can be used to devise a system, component or process to meet desired
needs. Another definition of the design process is “The pro ess of appl i g the various
techniques and scientific principles for the purpose of defining a devise, a process or a
system in sufficient detail to permit its realization."
1.1 The Engineering Design Process

The engineering design process is generalized for large projects done by large organizations
or companies. For small organizations or student projects, some of the steps can be
simplified or ignored. It is important to first know about synthesis and analysis in the design
process. This is not a discrete step, but is continuously ongoing. To synthesize means to
combine parts into a complex whole. To analyze means to separate the whole into
elements. They are interrelated during the design process. This usually happens right after
an initial statement of need.
1.1.1 Recognition of need
The first step in the engineering design process is the recognition of need. When a need is
given, it is usually brief and lacking detail. The design engineer must structure the problem
statement. There are different categories for each of the five different types of needs. The
first type of need is a formal request, also called a request for proposals. The second type is
an informal request, this is a suggestion or an implication from a potential customer. The
third type is when a need is felt to exist. The forth type of need is an assignment from a
supervisor. Finally, the fifth type is the need for a product for which market could be
developed.
1.1.2 Conceptualization and Creativity
Once a need is recognized, concepts immediately follow. A design engineer will start to
crudely synthesize and analyze the problem. This step is fun and frustrating and potentially
the most satisfying. Few facts exist about the phenomenon of creativity. Some believe it can
be taught, and others believe that it is inherited.
1.1.3 Establishing Design Requirements
This step follows the feasibility assessment and will provide detailed task specifications for
the design. I feel that this step should follow the recognition of need since this will also help
determine the best concept. The list of requirements or specifications is important for
communicating ideas to other engineering groups. It helps to save time and cost by
minimizing wasted pursuits.
1.1.4 Preliminary Design
This stage is the bridge between design concept and detailed design. If there is more than
one acceptable concept, an evaluation will be conducted. The cost will now become more
realistic and schematics, diagrams and layouts will be used. Also at this stage, some
computation and analysis will be done. A component-level literature search can also be
conducted.
1.1.5 Detailed Design
The detailed design stage is an extension of the preliminary design stage. There is still some
synthesis and analysis occurring. Each part is evaluated to see if it meets the overall
requirements. Specifications are given for each component, this is usually done in detail
drawings.
2. Identification of Need
2.1 The Need for Exercise
The need for strength training is the first issue to consider. The surgeon general states that
daily activity for 35 to 40 minutes will improve overall health and quality of life. Some
examples of such aerobic activity include biking, walking, even working around the house or
yard work.
The effects of strength training go beyond just increasing strength. Several weeks of
strength training will reduce resting blood pressure, a 2 month program can reduce it by 4
mm Hg. It also causes fat reduction in two ways. First, strength training will burn calories
during the work out. Secondly, the after burn effect will burn more calories for hours after a
workout.
2.2 Background Research in Exercise Technology

It is important to understand the trends and facts of exercise to know the needs in the
home exercise market. There are many different opinions from muscle magazines and the
field or sports medicine on the best methods of strength training. A wide variety of different
workout routines are readily available. These routines specify how weights should be lifted,
and how many sets and repetitions should be done.
2.2.1 Existing Machines and Trends
It is important to look specifically at the products available in the market. This will help save
time in the design process by not repeating work that has already been done. This can also
give ideas to improve and change existing designs.
Some of the different types of existing machines like:
- Resistance Machines
 Weight Machines
A weight machine is an exercise machine used for weight training
that uses gravity as the primary source of resistance and a
combination of simple machines to convey that resistance to the
person using the machine. Each of the simple machines (pulley,
lever, wheel, incline) changes the mechanical advantage of the
overall machine relative to the weight.
 Stack Machines
A stack machine also called a stack or rack has a set of massive
rectangular plates that are pierced by a vertical bar which has
holes drilled in it to accept a pin. Each of the plates has a
channel on its underside (or a hole through the middle, as
shown in the diagram) that aligns with one of the holes. When
the pin is inserted through the channel into the hole, all of the
plates above the pin rest upon it, and are lifted when the bar
rises. The plates below do not rise. This allows the same
machine to provide several levels of resistance over the same
range of motion with an adjustment that requires very little
force to accomplish in itself.
 Plate-loaded machines
Plate-loaded machines (such as the Smith machine) use
standard barbell plates instead of captive stacks of plates.
They combine a bar-end on which to hang the plates with a
number of simple machines to convey the force to the user.
The plate-loaded machines will often have a very high
mechanical advantage, due to the need to make room for
large plates over a large range of motion following a path that
causes them to converge at one end or the other.
- Other kinds of resistance machines
 Friction machines
 Spring-loaded machines
 Fan-loaded machines
 Fluid-loaded machines
 Bull worker
 Hydraulic Equipment
 Whole body vibration
 Outdoor gym
 Pneumatic exercise equipment
 Solo flex
 Stretch Trainer
- Endless-path machines
 Stationary bicycles
A stationary bicycle (also known as exercise bicycle, exercise bike,
or exercycle) is a device with saddle, pedals, and some form of
handlebars arranged as on a bicycle, but used as exercise
equipment rather than transportation.
 Elliptical machines
Elliptical (elliptical machines) are a combination of stair-climbing
and a treadmill. Generally it contains two tracks upon which the user
stands; when he or she moves his or her legs, they describe an elliptical
motion (hence the machine name). Some elliptical have magnetic
resistance controls that add difficulty to doing the motion.
 Glider machines
This machine allows the user to stand on two separate foot pedals and
use their own muscles to create the movement. The stabilized movement can be likened to
that of a "swing set" for each leg.
 Climbing machines
Also named stair-climbing machines, they work the user's legs as he/she pumps pedals up
and down, much like climbing stairs. Some climbing machines have handles to push and pull
to exercise the whole body.
2.3 Home Exercise Market

The home exercise market is replete with various types of cardiovascular and strength
training equipment. Advertisements continually show new ideas for cardiovascular workout
or abdominal workout machines. There is also an ever-increasing range of strength training

equipment. The attraction of home exercise equipment is the convenience of not going to a
gym. There also may be a cost savings over a long period of time. The concept of using a
perso ’s od eight for a cardiovascular workout is very common now. I feel that one
reason that the idea is successful is because the exercise appears to be fun.
2.4 The Define Need

The need is not a specific request, but a sensing of a need. There is a need for strength
training to improve overall health. Home exercise machines are attractive to people who
would rather save time, money and avoid the inconvenience of a gym. The retail cost should
be under $300 to compete with similar exercise equipment. The eed for usi g a perso ’s
weight exists because it is fun and attractive. It also saves cost for materials and
manufacturing.
Another way to define the need is to make a Goal Statement.
"A ho e exercise achi e that uses a perso ’s ow weight as the source of resista ce.
This resistance must be variable for people of different strengths. This machine needs to
include eccentric exercises and the resistance of each exercise should be designed with the
strength curve in mind. The machine should be competitively priced for less than $300 and
offer a complete range of exercises."
3. Conceptualization Design
(Conceptualization of solutions)
The "Conceptualization of Solutions" Stage in the engineer design process. This Stage
Immediately follows the "identifications of need". This phase initiates the synthesis of the
solution.
3.1 Initial Concepts

The general concept developed from the need statement of the project is to develop
"Advance Exercise Machine Mechanism" that will lift the person vertically. This mechanism
needed to allow adjustments in the mechanical advantage without lifting the user's weight.
Additionally, the motion of an exercise of machine mechanism stroke is linear; the required
input motion is also linear. A linkage is conceived with only prismatic joints causing linear
motion of each joint. The idea is also appears in Fig. CAD-1. The platform link is used to
support a platform for the user. Therefore, the output motion will raise the user. The
adjustment link is used to vary the resistance by varying how high the user is raised. Since
prismatic joints are expensive and difficult to implement, this linkage is modified by
replacing prismatic joints with revolute joints
Figure CAD-1, Fully Prismatic Linkage
3.1.1 Evolution of Prismatic Mechanisms to Revolute Mechanisms
While prismatic joints produce the desired motion in a conceptually simple way, these joints
have several drawbacks in application. They are relatively expensive to produce, and they
are prone to higher frictional forces and stick-slip motion. This led to a systematic attempt
to replace all prismatic joints with revolute joints. A prismatic joint can be replaced by
straight li e li kages su h as Watt’s four ar li kage. Ea h Watt’s linkage adds four more
re olute joi ts. The Watt’s mechanism is shown in Fig. CAD-2. The two rockers in this
linkage are of equal length and the midpoint of the coupler forms an approximately linear
coupler curve.
Figure CAD-2, Watt’s Straight Li e Mecha is
Figure CAD-1 shows a schematic of a fully prismatic linkage. This linkage has 1 revolute joint
a d pris ati joi ts. There are a total of li ks i ludi g the grou d li k. Grue ler’s
equation for planar linkages shows that there is 1 degree of freedom.
m: Mobility or degrees of freedom

n: Number of links not including ground
: Number of one degree of freedom joints
: Number of two degree of freedom joints
The vertical prismatic joint is replaced usi g t o Watt’s four ar li kages, as sho i Fig.
CAD-3. This linkage has 11 revolute joints, 2 prismatic joints and 10 total links including
ground. This linkage does have a mobility of one.
Figure CAD-3, One Replace Prismatic
Next, the adjustable prismatic joint is replaced with a single Watt linkage. One linkage is
used since this does not require keeping another link in constant orientation. This schematic
is shown in Fig. CAD-4. This linkage contains 1 prismatic joint and 15 revolute joints. There
are a total of 12 links including ground. The mobility of this linkage is also one.
Figure CAD-4 Two Replaced Prismatic

The most complex straight-line-equivalent mechanism is created by replacing the last

horizo tal pris ati joi t ith a other Watt’s four ar. This is shown in Fig. 3-5. This linkage
has 19 revolute joints and no prismatic joints. There are a total of 14 links. The mobility of
this linkage is still one.
Figure CAD-5, Fully Revolute Linkage
Each one of these linkages has one degree of freedom. Since, the platform link should
maintain a constant orientation. A prismatic joint would most likely be a linear bearing. This
would be more expensive to implement tha a li kage. Ho e er, t o Watt’s li kages are
complicated and add 10 revolute joints to the system. Other concepts of creating a vertical
motion for the platform must be considered. The horizontal prismatic joint can still be
created with a simple roller.
3.2 Refined Concepts

Concepts are generated to create linear, vertical motion without using a prismatic joint or
t o Watt’s li kages. Linkages are considered first. One linkage idea used a scissors-type
linkage as shown in Fig. CAD-6.
Figure CAD-6 Scissors Linkage

This concept also gives a linear vertical lift motion. The linkage is based on rotating a bevel
gear set to compress the scissors links and lift the platform. The input shaft must remain
vertically fixed relative to ground to maintain gear contact. Also, a method of adjusting the
resistance is not determined.
The second linkage concept is a four bar with two parallel rockers. A parallel four bar would
be a good choice to eliminate links and joints. The arced motion is not ideal for the feel of
the user, since the motion is not vertically linear. The radius of the arc depends on the
length of the rockers. This compromise is worth investigating. A schematic is shown in Fig.
CAD-7. In this concept, the four-bar linkage is used to elevate the person. The input is a
cable with a roller under the bottom link. As the cable is pulled, the linkage is forced to
move upwards.
Figure CAD-7, Parallel Linkage

Another version of this idea uses a cam under the linkage to replace the roller on an inclined
surface. As the cam rotates from the cable tension, the change in radius lifts the linkage.
This concept is shown in Fig. CAD-8.
Figure CAD-8, Parallel Linkage with a Cam

Another linear motion linkage is found from "Mechanisms and Mechanical Devices
Sourcebook by Chironis". This eight-bar linkage not only causes linear motion but
also keeps the link in a constant orientation. This linkage is shown in Fig. CAD-9.
Figure CAD-9, Constant orientation linear linkage

Another idea is also considered that is not based on a linkage mechanism. This idea is a
hydraulically actuated machine. Resistance can be created by lifting a perso ’s eight
hydraulically. A simple schematic of a hydraulic mechanism is shown in Fig. CAD-10. This
mechanism has an input lever that compresses one cylinder. The fluid is then forced into
the cylinder below the support platform. As a result, the user is lifting his body weight.
Figure CAD-10, Hydraulic Mechanism
The process of conceptualization led the first concepts toward a parallel linkage with a roller
to create two revolute joints. Clearly, during this step of the engineering design process,
there is synthesis and some analysis. Each time a problem is found or a new idea comes to
mind, the design engineer iterates on the concept.
3.3 Feasibility Assessment

The feasibility assessment is the next step in the design process.
The hydraulic lift concept will likely be higher in cost and the required maintenance of
hydraulic cylinders is a disadvantage. Another problem with hydraulic cylinders is the
potential leaking of fluid. This type of may also have noticeable friction.
Therefore, the focus turned to linkage concepts. In general, radial plate cams are more
expensive to manufacture than linkages. Since a roller on a ramp, as shown in Fig. CAD-7,
will accomplish the same task as a radial plate cam, as shown in Fig CAD-8, the linkage with
rollers were further considered. One advantage of a radial cam is that its surface can be
shaped to control the mechanical advantage. This could be an advantage for designing a
resistance curve. There is still another potential problem with a linkage that uses a roller. As
the angle of the inclined surface that the roller follows is adjusted, the length of cable may
change. The cable length may need to be adjusted for different adjustments in the
resistance. Therefore, a new design consideration is that the roller must always start at the
same position.
4. Embodiment Design Decision

4.1 Establishing Design Requirements
After developing some conceptualization and feasibility analysis, some design requirements
become more apparent. Most of these requirements are known after the need is defined
and some background research is done.
4.2 Design Requirements for the Exercise Machine

At this point of the engineering design process, a list can be made of specific design
requirements. This list should be as exhaustive as possible as the design process continues.
The following list is made for the home exercise machine.

I. The machine must use the perso ’s eight as a sour e of resista e.
II. The resistance must be variable for strengths of different people.
III. The resistance should be reasonably constant.
IV. The machine must include concentric and eccentric resistance.
V. The retail price should be between 300$ to 400$.
VI. The machine should be light enough for two people to carry.
VII. The machine must fit through a door opening of 83 in (210.82 cm) by 35 in (88.9 cm).
VIII. The operating height should be less than 7 ft. (213.36 cm).
IX. The machine should include one major exercise for each muscle group, alterations of
these exercises will add to list of exercises. These major exercises include a chest
press or fly, a biceps curl, a row, a lateral pull-down, a triceps extension, a leg-press,
a leg curl, a calf exercise, and a military press.
X. There should be no more than 2 adjustments to operate the machine.
XI. The machine must be safe.
XII. The design should have as few parts to assemble as possible
XIII. The manufacturing processes should be efficient.
5. Primarily Design
After a reasonable design concept has been developed, it must be analyzed to determine
more specific design issues. These can include coat, accuracy, and ease of handling, ease of
use, Manufacturing, motion, forces, and stresses. This step includes additional synthesis and
more extensive analysis. It is an iterative process that will refine the design. This step may
also reveal that a concept is too difficult to implement if, for example, the motion is
unacceptable, or internal forces are too extreme. In this case, the process will have to
return to the conceptualization stage. The concept that has been selected for further
development is a hydraulic cylinder linkage, four-bar linkage with a roller and an inclined
link to adjust the linkage movement.
5.1 Decision Matrix for Design Selection
CONCEPTS
Hydraulic Cylinder Four Bar Linkage Four Bar Linkage with
Linkage with Roller simple Lever Bar
SELECTION CRITERIA WEIGHT Rating Weighted Rating Weighted Rating Weighted
Score Score Score
I. Cost 20 2 0.40 3 0.60 5 0.10
II. Accuracy 15 3 0.45 2 0.30 4 0.60
III. Ease of handling 25 4 0.1 4 0.60 3 0.75
IV. Ease of use 20 3 0.60 3 0.60 3 0.60
V. Manufacturing 20 2 0.40 2 0.40 4 0.80
VI. Durability 15 2 0.30 3 0.45 3 0.45
VII. Portability 10 3 0.30 2 0.20 2 0.20
TOTAL
SCORE 2.55 3.15 3.50
Continue? NO NO YES
Fig. CAD-11 Fig. CAD-12 Fig. CAD-13

Hydraulic Cylinder Four Bar Linkage Four Bar Linkage with simple
Linkage with Roller Lever Bar
6. Secondary Design
By decision matrix we came to know that our first selection of mechanism for our project,
the four bar linkage with rollers would not be feasible for use. So by keeping in mind this the
additional brainstorming focused on overcoming these problems and on solving problems
with minimum number of parts.
6.1 New Ideas

Additional brainstorming resulted in the simple lever shown in Fig. CAD-14 This gave birth
to a new approach in actuating the parallel four-bar linkage.
L1 L2
lever
C
F o
n
n
ec
F+W to
r
Platform
Figure CAD-14 Leaver Concept
The force (F) is applied by the user pushing up on the leverage bar. The equal and opposite
force is applied down on the platform. The weight of the person is also included in the
downward force. The motion of the platform as a result of the input force may seem
counter-intuitive. However, a simple summation of forces on the lever and platform proves
this to be a worthy idea. Figure CAD-15 displays the free-body diagrams.
L1 L2
Pivot
Lever
F T F
F+W T
Platform
Figure CD-15 Free body diagram of lever

concept
Summing moments of lever bar and solving for T gives the following expression.
The vertical forces of the platform can now be found by summing forces in the vertical
direction.
As L1 approaches zero, the input force becomes infinitely large. Also, as L2 approaches
zero, the force becomes zero. In order for the input force to be equivalent to the weight,
L1 would be equal to L2.
A schematic of this new hybrid concept is shown in Fig. CAD-16
Figure CAD-16 Four-Bar Lever Concept

In this concept, the input lever bar moves relative to ground rather than the platform. Such
relative motion feels awkward to the user because the motion of the platform relative to
the ground changes as the mechanical advantage is changed. In the next iteration, the input
leverage link was attached to the platform link as shown in Fig. CAD-17 . A mobility analysis
shows that this 6-bar linkage has one degree of freedom.
Figure CAD-17 Modified four Bar Lever Concept

7. Detailed Design
After a preliminary design has been completed and accepted, detailed design must be
completed. This stage of the design process ultimately results in detailed drawings of a
tested design for manufacturing. This is inevitably an iterative process of design, testing and
redesign. The first iteration of this step is demonstrated with a modeling design and initial
test results.
7.1 CAD Model
Figure CAD-18 Final Design
7.1.1 Parts of Mechanism
Figure CAD-19 Side view

The design consists of following links:
- Link 1:
The link is the T shape main base frame link on which the whole weight of the machine will
act. It is basically consist of two members joint to form T shape link.
Figure CAD-20 link 1

This is the longitudinal member of link 1 support the link 6 on the specific point. Length of
this member is 46in with cross-section height = 2in and the width = 1.50in
This is the transverse member of link 1 providing the horizontal support to the whole
system. Length of this member is 33.5in with cross-section height = 2in and width = 3in

Rubber pad provided on the link to avoid the
jerks produced by link 6 when it comes down
- Link 2:
The vertical link providing rotating support to the link 3 and 4 by two revolute joints.

This is the vertical link attached to link 1 by an angle bracket support at 45. The vertical
length of this link is 14.5in having two holes for revolute joint of 1in diameter. The cross-
section height of this link is 2in and width is 1.50in.
Figure CAD-23
- Link 3:
Provides the connection between link 2 and 6 connected by two revolute joints.
Figure CAD-24 Link 3
Figure CAD-25
This horizontal link connected between the link 2 and 6 to provide the degree of motion.
Length link is 38in having two holes of 1in diameter at 36in center to center distance. The
cross-section height and width of this link is 1.50x1.50in.
Figure CAD-26
- Link 4:
The main link it help to push the weight of whole system by pulling down link 9.

This horizontal link connected between the link 2 and 6 to provide the degree of motion .
This link pust the whole system in the upword direction by pushing the link 9 in the
downword direction, it also helps to connect the link 7 and 8 to the system. The length of
this link is 47in with three holes for the revolute joints, two holes on the left side has
diameter of 1.50in and hole at left has diameter of 1in. The distance between the first two
hole is 36in. Cross-section hieight of the link is 2in and width is 1.50in.
Figure CAD-28
- Link 5:
The link for carring the weigth of the person and push it upwords and downwords according
to the position of link 9.

Figure CAD-30
This link has seat attached to it for carrying the load of the person laying on it. The length of
the link is 39in having cross-section height = 1.50in and with =3in.
Figure CAD-31
- Link 6:
The main frame of the system providing the connection between the other links.

This is main frame providing the support for link 5 which is welded to it. The length of this
link is 42.16in having three holes on to provide the joint for link 9,3 and 4. The cross-section
heigth of link is 2in and width is 1.50in.
Figure CAD-33
Figure CAD-34
- Link: 7
Helps to provide the degree of motion to link 4 by moving the link 9.

Two pairs of ball bearing rollers attached to this link at one end so that this link easily move
between link 4 and 9.
Figure CAD-36 Linear Bearings

Basically the roller moves in the link 9 which is a C channal, by moving the link 9 downwords the
rollers moves in the left direction and to pulle up the link 4 which is attached to it.
Figure CAD-37 Internal Structure of Bearings

Figure CAD-38 Bearings used in Mechanism

The length of this link is 27.2in having holes of 0.6in diameter at the ends. The cross-section heigth
and width of this link is 1.50x1.50in.
Figure CAD-39
- Link 8:
The connecting link providing the connection between the link 7 and link 4.

This the smallest link of whole providing the rotating movement between the link 4 and 7.
Figure CAD-41
The length of the link is 8in having one hole at left side of 1in diameter and two holes on
right side of 0.75in diameter. The cross-section height of this link is 1.50in and width is 1in.
- Link 9:
The C channel shaped input link of the system in which two pairs of rollers mover to provide
the degree of motion.
The input handles for

pushing up and down

This link is C channel shaped link to prvide the input, the C shape hepls to move the rollers
samoothly while movining up and down.
.
Figure CAD-43
This link is povited at the little reight to center to the link 6 to create the moment in the
both directions.
Figure CAD-44
There is a plastic handle is attached to the left end of the link to provide the ease to the
user, so that it can easily graped for providing the input. When this link moves up the roller
set moves to right and when this link moves down then roller set moves to left.
Figure CAD-45 Detailed Design

8. Working
This machine use the person's own weight as a source of resistance. Person lay down on the
seat with hands in the up direction graping the plastic attached to the input link, by pulling
the input link in downword direction. Then input lever will apply the force on link 7 in
upword direction, this llink will pull up the link 4 and 8. When the upword force acts on the
link 4 it will also apply the force on the link 6 in the up direction, then this force will transfer
to the link 6 and will push the person up against his own weight acht downwords.
As demonstrated in figure below,
B
A
E
C
Figure CAD-46 Working

When the person push the input link in the upword direction, the roller moves to right by
pushing down the link 7. When the link 7 moves down it apply the downword force on the
link 8 and 4. The link 4 and the weigth of the person apply downword force on the link 5 and
6. This up and down movement of the input link helps the person to get continous to and
fro motion and to get good resistance to develop muscles of arms and cheast.
This eliminates the need of extra weight resistance and reduced the cost of system. As
demonstrated in the figure below,
F
G
H
J
Figure CAD-47 Working

9. Benchmarking
Some other types of machines are also available in the market they can do the job like this
but they are very expensive, much more compexity, difficult to use, heavy and use the exter
sour e of resista e. That’s h the a ot e used i the ho es, it is ore ti e a d
consuming to go to gyms and use these machines.
Some machines available in the market are:
HOME FITNESS MULTI GYM V-Fit Herculean LFG2 Multi home gym system
WEIGHT BENCH PRESS Lay Flat Home Gym With Price Tag of 800$
INCLINE ARM CURL TRICEPS With Price Tag of 700$
CHEST LEG
With Price tag of 600$
Multi Gym equipment HEAVY DUTY MUTLI GYM WEIGHT

BH Fitness Global WEIDER PRO 7500 BENCH - PREACHER CURL TRICEPS
Home Multi Gym CHEST FLY LEG CURL ABS
With Price Tag of 850$
With Price tag of 1800$ With Price Tag of 700$
9.1 Benchmarking Table

Consumer Expectations Advance Exercise Machine Other Products Available in
(Fratures) (Out Product) Market
Cost Cost of our product is about Cost of products available in the

300-400$ market is about 500-2000$
Approximate Weight Approximate weight of our Weight of other products is
machine is about 30-40 kg about 50-150 kg
Handling This machine is easy to handle Difficult to handle
Balance Simple to operate Difficult to operate
Overall Appearance Very simple structure Complex structure
Manufacturing Simple because of less number Difficult because of incerase
of parts number of parts
Engineering Requirements
(Competitor)
Ruggedness
Benchmark
Operation
Weight
Ease of
Shape
Cost
Size
Portable X X Weak
Requirements
Customer
Reliable x Moderate
Appealing x Weak
Inexpensive X x Strong
300-400$
Engineering Targets
The table filled according to the Benchmark work

10. Conclusion
This project has demonstrated the engineering design process as applied to the design of
e er ise a hi e that uses the perso ’s eight as a source of resistance. This mechanism is
designed to allow the user to adjust the mechanical advantage without resistance during
the adjustment. Also, the motion of the input link is relative to the user. This allows for
correct motion for the exercise. The design also implements techniques that simplify
manufacturing processes and assembly. For example, parallelogram linkage and linear
bearings which are relatively simple to fabricate and inexpensive are used.

ADVANCE EXERCISE MACHINE MECHANISAM Engi

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ADVANCE EXERCISE MACHINE MECHANISAM Engi

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ADVANCE EXERCISE MACHINE MECHANISAM Engineering Design & CAD

ISTANBUL TECHNICAL UNIVERSITY

Submitted By: Shahroz Khan

Time Table of the Project

Activity November December

4. Embodiment Design Decision

1.1 The Engineering Design Process

1.1.1 Recognition of need

1.1.2 Conceptualization and Creativity

1.1.3 Establishing Design Requirements

1.1.4 Preliminary Design

1.1.5 Detailed Design

2.2 Background Research in Exercise Technology

2.2.1 Existing Machines and Trends

Some of the different types of existing machines like:

- Other kinds of resistance machines

2.3 Home Exercise Market

or abdominal workout machines. There is also an ever-increasing range of strength training

2.4 The Define Need

3.1 Initial Concepts

Figure CAD-1, Fully Prismatic Linkage

3.1.1 Evolution of Prismatic Mechanisms to Revolute Mechanisms

Figure CAD-2, Watt’s Straight Li e Mecha is

m: Mobility or degrees of freedom

Figure CAD-3, One Replace Prismatic

Figure CAD-4 Two Replaced Prismatic

The most complex straight-line-equivalent mechanism is created by replacing the last

Figure CAD-5, Fully Revolute Linkage

3.2 Refined Concepts

Figure CAD-6 Scissors Linkage

Figure CAD-7, Parallel Linkage

Figure CAD-8, Parallel Linkage with a Cam

Figure CAD-9, Constant orientation linear linkage

Figure CAD-10, Hydraulic Mechanism

3.3 Feasibility Assessment

4. Embodiment Design Decision

4.2 Design Requirements for the Exercise Machine

The following list is made for the home exercise machine.

5.1 Decision Matrix for Design Selection

Fig. CAD-11 Fig. CAD-12 Fig. CAD-13

6.1 New Ideas

Figure CAD-14 Leaver Concept

Figure CD-15 Free body diagram of lever

A schematic of this new hybrid concept is shown in Fig. CAD-16

Figure CAD-16 Four-Bar Lever Concept

Figure CAD-17 Modified four Bar Lever Concept

7.1 CAD Model

Figure CAD-18 Final Design

7.1.1 Parts of Mechanism

Figure CAD-19 Side view

The design consists of following links:

Figure CAD-20 link 1

Figure CAD-21 link 1

Figure CAD-22 link 2

Figure CAD-24 Link 3

Figure CAD-27 Link 4

Figure CAD-29 Link 5

Figure CAD-32 link 6

Figure CAD-35 link 7

Figure CAD-36 Linear Bearings

Figure CAD-37 Internal Structure of Bearings

Figure CAD-38 Bearings used in Mechanism

Figure CAD-40 link 8