Development of a Low-Cost Wearable Prevention System for Msds Using Imu Systems And
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DEVELOPMENT OF A LOW-COST WEARABLE PREVENTION SYSTEM FOR MSDS USING IMU SYSTEMS AND ELECTRICALLY CONDUCTIVE MATERIALS MANUFACTURING COST WEARABLE PREVENTION WEARABLE FORSYSTEM MSDS COST VIA ADDITIVE MANUFACTURING - MEMORY submitted for the Degree of Doctor of Philosophy of the University of Navarra by Chuan Cao DEVELOPMENT DEVELOPMENT OF LOW A under the supervision of USING IMU SYSTEMS USING IMU SYSTEMS AND ELECTRICALLY CONDUCTIVE VIA ADDITIVE MATERIALS María Isabel Rodríguez and Aitor Cazón Martín Donostia-San Sebastián, May 2020 Chuan Cao Chuan UNIVERSITY OF NAVARRA SCHOOL OF ENGINEERING DONOSTIA-SAN SEBASTIÁN DEVELOPMENT OF A LOW-COST WEARABLE PREVENTION SYSTEM FOR MSDS USING IMU SYSTEMS AND ELECTRICALLY CONDUCTIVE MATERIALS VIA ADDITIVE MANUFACTURING DISSERTATION submitted for the Degree of Doctor of Philosophy of the University of Navarra by CHUAN CAO under the supervision of MARÍA ISABEL RODRÍGUEZ and AITOR CAZÓN MARTÍN Donostia-San Sebastián, May 2020 Acknowledgement There is an ancient poem in China: "Hai nei cun zhi ji, tian ya ruo bi lin.", which means "A bosom friend afar brings distance near." During the three years of studying here, I have met many kind and lovely people and received countless help. Your meticulous care has made me feel like a hometown in this strange land, and also helped me to learn and experience a lot in this brand-new cultural environment. Here I want to express my gratitude with a little space. First of all, I appreciate that the University of Navarra - Tecnun gave me this opportunity to do my PhD here in such a beautiful city. Thanks to all the people who work here, your hard work has made each of us extraordinary. Secondly, I would like to thank my mentors, Aitor and Mabel. You are the most patient and selfless professors I have ever encountered. When I was in a low state and evaded reality, it was your effort, tolerance, and kindness that gave me enough courage to face the difficulties again. You have not only taught me the knowledge and way of thinking but also brought me the shining point of humanity. Thank you for everything you have done for me. Also I would like to thank my colleagues: Sergio, Leire, Amaia, Mikel, Iñigo, Juan, and guys who have left school, Angél and Wilmer. You also gave me a lot of help and suggestions after work, I will not forget those happy hours with you. And people at Tecnun and Ceit: i ii Acknowledgement Desmond, Izaro, Elena, and another Sergio, I am glad to meet you. In addition, Josecho's coffee is the best I have ever tasted, because it carries the memories of my talk with you during the coffee break here. Far away in a foreign country, loneliness and incomprehension are the most unbearable burdens. Fortunately, there are several close friends here with me: Eric, Cristina, Zubi, Itu, Roby, and Juan. You have given me a taste of real western life, and I am also very happy to be able to show you the charm of Eastern culture through me. Finally, I want to thank my parents: Guanghan and Zuomei. Thank you for giving me life. It is the love that across the time zone all last long. It makes me realize once again that even when the world's end is coming, when I turn back, I am extremely convinced that you are always there. I understand that these three years have made countless white hairs to your heads, and your cheeks are no longer rosy. Thank you for your silent effort, please let me use my remaining life to repay you well. Chuan Cao Table of contents Acknowledgement .............................................................................. i Table of contents .............................................................................. iii List of figures .................................................................................. vii List of tables ................................................................................... xiii Abstract ........................................................................................... xv 1 Introduction .................................................................................... 1 1.1 Motivation ............................................................................... 1 1.2 Main contributions of this thesis............................................ 3 1.3 Contents and structure of this thesis ..................................... 4 2 State of the art ............................................................................... 7 2.1 Introduction ............................................................................ 7 2.2 Musculoskeletal disorders ...................................................... 7 2.2.1 Risk factors ..................................................................................... 7 2.2.2 Prevalence rate on body region ...................................................... 9 2.2.3 Assessment methods .................................................................... 15 2.2.4 Direct measurements for the human hand ................................. 24 2.3 Additive Manufacturing ....................................................... 29 iii iv Table of contents 2.3.1 Introduction................................................................................... 29 2.3.2 AM printing technologies ............................................................. 30 2.3.3 Functional materials for AM in wearables ................................. 35 2.4 Conclusions .......................................................................... 39 3 Assessment of ergonomic methods ................................................ 41 3.1 Introduction .......................................................................... 41 3.2 Selection of the ergonomic methods ..................................... 42 3.2.1 Assessment of Repetitive Tasks (ART)........................................ 42 3.2.2 Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA) .................................................................................. 44 3.2.3 Biomechanical Assessment (BA).................................................. 46 3.2.4 Optoelectronic Systems (OES) ..................................................... 47 3.2.5 Electro Goniometer (EG) .............................................................. 49 3.2.6 Accelerometry (ACC) .................................................................... 50 3.2.7 Inertial Measurement Unit (IMU) .............................................. 52 3.3 Questionnaire: criteria ......................................................... 53 3.3.1 Before measuring .......................................................................... 55 3.3.2 While measuring ........................................................................... 56 3.3.3 After measuring ............................................................................ 57 3.4 Expert interview .................................................................. 58 3.5 Results from experts ............................................................ 59 3.6 Conclusions .......................................................................... 61 4 Developing finger motion capture device ...................................... 63 4.1 Introduction .......................................................................... 63 4.2 Hardware .............................................................................. 64 4.2.1 Microcontroller .............................................................................. 65 4.2.2 Inertial Measurement Unit .......................................................... 67 4.2.3 Multiplexer .................................................................................... 69 4.2.4 SD module ..................................................................................... 69 4.3 Electrical connection layout ................................................. 70 4.4 Assembling prototype ........................................................... 73 4.5 Software ............................................................................... 73 4.5.1 System framework ........................................................................ 73 4.5.2 Orientation format ........................................................................ 74 Table of contents v 4.5.3 Algorithm ...................................................................................... 80 4.6 Accuracy verification ............................................................ 86 4.7 Conclusions ........................................................................... 89 5 Developing 3D printed conductive trace board ............................. 91 5.1 Introduction .......................................................................... 91 5.2 Cross-contamination factors ................................................. 93 5.3 Fabrication process ............................................................... 97 5.4 Design of experiments .......................................................... 99 5.4.1 Step 1. Maximum allowable resistance ....................................... 99 5.4.2 Step 2. Conductive thermoplastic composites........................... 101 5.4.3 Step 3. Printing settings: infill .................................................. 101 5.4.4 Step 4. Printing settings: temperature, speed and layer height 102 5.4.5 Step 5. Cross-sectional shape of conductive paths ................... 103 5.5 Results of experiments ....................................................... 105 5.5.1 Determination of Maximum allowable