Design and Investigation of a low-cost elbow rehabilitation tool

The research content of this paper is to design a push system for an Aluminium tube to be cut on the cutting machine. The system consists of one driving pulley, one idler pulley, and a timing belt. The stepper motor will drive the pulley and the stopper attached to a timing belt will push the Aluminium tube further. This paper describes the process of developing a push system using a stepper motor driver, membrane keypad, Nokia LCD, and a microcontroller board. Different types of stepping mode and the formula for the number of pulses to be sent to a stepper motor are derived and tested. The result of the paper shows that a stepper motor along with the electronic components improves accuracy for a push application and can be used.

Step motors are widely used in motion control systems. The step motor controller must perform high-precision positioning and smooth movement operation. In motion systems applying velocity profile control, the velocity of the motor gradually increases or decreases, to avoid the negative effect caused by the sudden change in velocity. Previous research proposes several step motor controller designs, that contain several modules, including a velocity profile generator, step motor driver, and feedback counter. These controllers are able to perform precise positioning and provide smooth motion operation. However, because these controllers operate in an open-loop control so the synchronous condition can be lost when disturbances in load torque exist. This paper presents the application of closed-loop control in the step motor controller. The control algorithm is based on two mode operations: open-loop and closed-loop. The controller operates in open-loop mode when it remains synchronized, and switches to closed-loop mode when it loses synchronization. This paper presents an algorithm for generating various velocity profiles and closed-loop control algorithms. The experiment is performed on a 16-b DSP, to verify the performance of the design. The experimental results show a velocity profile of unsymmetrical shape and demonstrate effective closed-loop control in an actual step motor system

An inverted microscope is designed to have a stage in which the specimens can be placed for microscopy. Most of the biological microscope is built in with static or manual adjustable stage which cannot provide consistent and precise adjustment to move the specimen during microscopy. As an add-on to the microscope stage, the existing motorized 2-axis linear stage in the market is bulky and heavy. Therefore, a lightweight and joystick controllable bipolar stepper motor X-Y translational stage was proposed to solve the problem. In our design, the joystick functions to provide input signals to the Arduino Mega microcontroller in order to control the position of the X-Y translational stage. For the X-Y translational stage, the stepper motors of a pair of the linear slides were driven by a micro stepping motor driver with full scale drive signal to provide controllable stepping movement. It was found that full scale drive signals could support higher resolution of movement at 99 + 13 µm. The overall X-Y translational stage weighted approximately 700 g. As a conclusion, the light weight stepper motor based X-Y translational stage allows the user to move the specimen in a small stepping size during microscopy.

Three-dimensional (3D) scanning technology is pivotal in manufacturing, product design, and architecture, enabling precise digital reconstructions of real-world objects. However, existing 3D scanners are often costly and complex, hindering accessibility. To address this, our study presents a cost-effective 3D scanning system using Arduino technology. Utilizing an Arduino Nano, GP2Y0A21YK0F IR Sensor, stepper motors, motor drivers, and an SD card module, our system offers a simple solution for scanning small objects and creating 3D models. The scanner measures object distance, rotates a work table, and captures scan data, processed with MeshLab software. Successful scanning demonstrates affordability and automation. Future work will focus on optimizing accuracy and scanning speed.

The object of this study is a large-scale Cartesian 3D printer with a build volume of 2 × 2 × 2 meters, equipped with BLDC servo motors on the X and Y axes, a NEMA 34 stepper motor on the Z axis, and a NEMA 17 stepper motor for filament extrusion. The main problem addressed is the limitation of existing firmware, which only supports bipolar stepper motors (NEMA standard), making it unsuitable for achieving the higher extruder speeds required in large-format printing. To overcome this issue, a new firmware was designed to support brushless direct current (BLDC) servo motors, enabling faster, more stable, and more precise motion control. The developed firmware, based on the ESP32 microcontroller, processes G-code instructions step by step, calculates motor commands, and communicates them to BLDC motor drivers (FSESC 4.12 on the VESC platform) with encoder feedback for accurate positioning. Experimental results demonstrated reliable synchronization of the X and Y axes across different speeds and distances, with average positioning errors of 0.9% on the X-axis and 1.03% on the Y-axis. The system operated stably within a rotational speed range of F8000–F54000 (1000–7000 RPM) and a printing speed range of 92–800 mm/s, confirming the firmware’s capability to handle both low- and high-speed operations. The interpretation of the results provides superior acceleration, precision, and stability compared to stepper-motor-based systems. A distinctive feature of this work lies in adapting G-Code step execution for BLDC motors, which has not been widely implemented in existing 3D printing firmware. The practical significance of the results is the potential application of this firmware in large-scale and high-speed 3D printers. This makes the approach highly relevant for advanced manufacturing industries where precision, scalability, and efficiency are critical

The development of technology today has emerged the latest technology in three-dimensional (3D) printer machines. Problems faced by 3D printers include the position of the printer bed that is not horizontal. The position of the printer bed that is not horizontal will cause the 3D print to be skewed. To overcome the problem of tilting the bed of a 3D printer, the auto-level system is needed, which is a system that can correct the position of the base so that it becomes horizontal. In this study, an auto-leveling system was designed and made for four 3D printing base support positions. The drive for the printing press uses a stepper motor with a worm gear transmission. The controller uses an Arduino board and tested various position sensors to determine the slope of the base. The sensor tested is a 3D touch probe sensor. From the test results, the 3D touch probe sensor has a height value difference of not more than 0.05mm from each measurement position. The print base slope reference point is at the center point of the print base. The position of the other corner of the base will be adjusted in height with a stepper motor drive.

Additive manufacturing or 3D printing slowly and steadily replaces traditional subtractive manufacturing, where parts are manufactured by sequentially removing pieces of the workpiece material. In 3D printing, the material is added in layers, which enables producing parts of complex geometric shapes made from expensive metals with higher productivity and economic efficiency. In order to perform 3D printing on an industrial scale, it is necessary to combine robotics with 3D printing software. This article presents the results of the process design for 3D printing of a compressor impeller prototype. A detailed methodology of customization of the KUKA industrial robot for the 3D printing process is given. Once the impeller model was created in the CAD environment, it was cut into layers in the slicer program. Special software for offline programming of industrial robots was used to translate the program into the robot language and perform 3D printing using an experimental robotic complex. As a result, a prototype of a low-carbon steel compressor impeller was printed using a welding machine and steel wire. The developed technological process was successful and proved that an industrial robot combined with a welding machine can be used as an industrial 3D printer for printing real machine parts.

Most times in engineering and other fields, engines need to be transformed from one form to another, in circuits and most components we are familiar with, electrical engines, impulses, digital information, etc need to be changed from one level to another, a motor does this, be it in any kind, pending on the desired function. This literature review examines various research studies that have been done using the PIC 16F84 microcontroller to control stepper motors. The PIC 16F84 is a popular choice for stepper motor control applications due to its simplicity, low cost, and ease of programmability. This review highlights several key control techniques implemented using the PIC 16F84, including full-step mode, half-step mode, closed-loop control with position feedback, and speed control. The peripheral interfacing aspects are also discussed, covering the integration of stepper motor driver circuits, rotary encoders, and user interface components. The firmware development approaches for the PIC 16F84 are explored, demonstrating how researchers have programmed the microcontroller’s digital I/O, timers, and interrupts to precisely control the stepper motor windings and respond to feedback signals. While the PIC 16F84 has proven to be a capable platform for stepper motor control, the review also identifies some limitations, such as the microcontroller’s restricted resources and potential scalability challenges as the complexity of the control system increases. Suggestions for future research include exploring more advanced microcontrollers, integrating the PIC 16F84 with additional hardware, and developing more sophisticated control algorithms to enhance the performance and robustness of the stepper motor control systems. The CMOS circuit stands as the drive circuit between the PIC IC and the stepper motor which provides precision in advanced control methods of design and production. Keywords: Stepper motor, Controlled, PIC 116F84, Microcontroller

This paper presents the results of research on a new schematic generator load controller simulation, namely an electronic load controller based on a dimmer circuit and a stepper motor for a small-scale 5 kW micro-hydro. The load controller is built from a dimmer circuit and a stepper motor with program control using Matlab software, and the PPI 8255 interface device. Using a dimmer circuit built from diac, triac, a variable resistor (pot), and capacitor components. As well as using a 28BYJ-48 stepper motor. Simulation is made to determine the performance of the load controller in controlling the distribution of power to the ballast load when the generator supplies power to consumers less than the full load of the generator. By using the simulation data of 45 variations of the consumer load sample, the result is that there are only 4 samples where the load controller is not working well. For the 4 samples, the generator was loaded beyond its full load tolerance limit (full load tolerance of 5kW ± 5 %). Overall, based on the simulation results, it can be said that the generator load controllers tested in this study have good performance.
 HIGHLIGHTS
 
 Methods and power electronic configurations used in electronic load controllers for micro-hydropower plants from 1980 until now. In the future, the use of low-power micro hydro and pico hydro power plants is also in great demand, especially for rural areas
 The utilization of micro-hydro in Indonesia, especially low-power micro-hydro, has been utilized by the community in Bulukumba Regency, South Sulawesi Province. A 5 kW generator has been operated in Katimbang Village, Borong Rappoa District, Kindang Regency, Bulukumba Regency, South Sulawesi Province to distribute electrical energy to 15 households
 This research proposes a new electronic load control scheme for a simple and inexpensive 5 kW micro-hydro power plant, namely a dimmer circuit and stepper motor-based generator load controller. With the consideration that the main components that make up this controller are not expensive
 
 GRAPHICAL ABSTRACT

This session is designed so that the learning objectives are practical. The intent is that the attendee may take home an understanding of not just the technology, but also the logistical steps necessary to execute these 3D printing techniques in the clinic. Four practical 3D printing topics will be discussed: (i) Creating bolus and compensators for photon machines; (ii) tools for proton therapy; (iii) clinical applications in imaging; (iv) custom phantom design for clinic and research use. The use of 3D printers within the radiation oncology setting is proving to be a useful tool for creating patient specific bolus and compensators with the added benefit of cost savings. Creating the proper protocol is essential to ensuring that the desired effect is achieved and modeled in the treatment planning system. The critical choice of printer material (since it determines the interaction with the radiation) will be discussed. Selection of 3D printer type, design methods, verification of dose calculation, and the printing process will be detailed to give the basis for establishing your own protocol for electron and photon fields. A practical discussion of likely obstacles that may be encountered will be included. The diversity of systems and techniques in proton facilities leads to different facilities having very different requirements for beam modifying hardware and quality assurance devices. Many departments find the need to design and fabricate facility‐specific equipment, making 3D printing an attractive technology. 3D printer applications in proton therapy will be discussed, including beam filters and compensators, and the design of proton therapy specific quality assurance tools. Quality control specific to 3D printing in proton therapy will be addressed. Advantages and disadvantages of different printing technology for these applications will also be discussed. 3D printing applications using high‐resolution radiology‐based imaging data will be presented. This data is used to 3D print individualized physical models of patient's unique anatomy for aid in planning complex and challenging surgical procedures. Methods, techniques and imaging requirements for 3D printing anatomic models from imaging data will be discussed. Specific applications currently being used in the radiology clinic will be detailed. Standardized phantoms for radiation therapy are abundant. However, custom phantom designs can be advantageous for both clinical tasks and research. 3D printing is a useful method of custom fabrication that allows one to construct custom objects relatively quickly. Possibilities for custom radiotherapy phantoms range from 3D printing a hollow shell and filling the shell with tissue equivalent materials to fully printing the entire phantom with materials that are tissue equivalent as well as suitable for 3D printing. A range of materials available for use in radiotherapy phantoms and in the case of phantoms for dosimetric measurements, this choice is critical. The necessary steps required will be discussed including: modalities of 3D model generation, 3D model requirements for 3D printing, generation of machine instructions from the 3D model, and 3D printing techniques, choice of phantoms material, and troubleshooting techniques for each step in the process. Case examples of 3D printed phantoms will be shown. Learning Objectives: Understand the types of 3D modeling software required to design your device, the file formats required for data transfer from design software to 3D printer, and general troubleshooting techniques for each step of the process. Learn the differences between materials and design for photons vs. electrons vs. protons. Understand the importance of material choice and design geometries for your custom phantoms. Learn specific steps of quality assurance and quality control for 3D printed beam filters and compensators for proton therapy. Learn of special 3D printing applications for imaging. Cunha: Research support from Phillips Healthcare.

The dimensional accuracy of three-dimensional (3D) printed anatomical models is essential to correctly understand spatial relationships and enable safe presurgical planning. Most recent accuracy studies focused on 3D printing of a single pathology for surgical planning. This study evaluated the accuracy of medical models across multiple pathologies, using desktop inverted vat photopolymerization (VP) to 3D print anatomic models using both rigid and elastic materials. In the primary study, we 3D printed seven models (six anatomic models and one reference cube) with volumes ranging from ~2 to ~209cc. The anatomic models spanned multiple pathologies (neurological, cardiovascular, abdominal, musculoskeletal). Two solid measurement landing blocks were strategically created around the pathology to allow high-resolution measurement using a digital micrometer and/or caliper. The physical measurements were compared to the designed dimensions, and further analysis was conducted regarding the observed patterns in accuracy. All of the models were printed in three resins: Elastic, Clear, and Grey Pro in the primary experiments. A full factorial block experimental design was employed and a total of 42 models were 3D printed in 21 print runs. In the secondary study, we 3D printed two of the anatomic models in triplicates selected from the previous six to evaluate the effect of 0.1mm vs 0.05mm layer height on the accuracy. In the primary experiment, all dimensional errors were less than 1mm. The average dimensional error across the 42 models was 0.238 0.219mm and the relative error was 1.10 1.13%. Results from the secondary experiments were similar with an average dimensional error of 0.252 0.213mm and relative error of 1.52% 1.28% across 18 models. There was a statistically significant difference in the relative errors between the Elastic resin and Clear resin groups. We explained this difference by evaluating inverted VP 3D printing peel forces. There was a significant difference between the Solid and Hollow group of models. There was a significant difference between measurement landing blocks oriented Horizontally and Vertically. In the secondary experiments, there was no difference in accuracy between the 0.10 and 0.05mm layer heights. The maximum measured error was less than 1mm across all models, and the mean error was less than 0.26mm. Therefore, inverted VP 3D printing technology is suitable for medical 3D printing if 1mm is considered the cutoff for clinical use cases. The 0.1mm layer height is suitable for 3D printing accurate anatomical models for presurgical planning in a majority of cases. Elastic models, models oriented horizontally, and models that are hollow tend to have relatively higher deviation as seen from experimental results and mathematical model predictions. While clinically insignificant using a 1mm cutoff, further research is needed to better understand the complex physical interactions in VP 3D printing which influence model accuracy.

A Study of Development of a Dedicated Control IC for a Five Phase Stepper Motor Driver

This paper represents a design of an automatic ironing machine, whose motion is controlled by two stepper motors and two servo motors. The computer-aided design figure will be introduced first, to express the basic structure and show the movement process of the automatic ironing machine to achieve the goal of ironing a cloth. Next, the control methods of servo motors and stepper motors are represented as well as the way to optimize the algorithm, where the objective is to make the motion adapt to the structure of the machine. Then, since some parts of the machine are made by 3D printing, there are some problems in the actual production process, and some solutions to those problems are going to be introduced. Finally, the results are discussed, with a focus on both the advantages and disadvantages of this machine and further improvement.

The world population is aging. Age-related disorders such as stroke and spinal cord injury are increasing rapidly, and such patients often suffer from mobility impairments. Wearable robotic exoskeletons are developed that serve as rehabilitation devices for these patients. An assistive knee brace is a simple wearable exoskeleton which is used to help people with mobility issues. This device provides partial assistance to the user and also helps in providing locomotion. Many exoskeletons are currently available in the market that have different functions and use. It is believed that, to date, no voice-controlled knee brace exists in an orthotic application, and that this project debuts a unique approach. This project presents the design of an assistive bionic knee joint with a motor-based actuator. The new exoskeletal mechanism uses the serial elastic actuator concept and mainly consists of a stepper motor, a ball screw, a set of spur gears, and a set of linear springs. The ball screw provides a linear movement to mimic the stretching and retracting action of a human knee. To create a proof-of-concept of the design, 3D printing is used. A voice recognition system has been developed in-house to control the exoskeleton using very simple voice commands. The motor is controlled using a motor driver and powered using an external power source. The 3D printed prototype with integrated voice-control module is tested for its essential functions. The test setup is loaded on the leg of a mannequin and tested under both no-load and full-load operation. The concept is proven to be successful in providing assistance to the human knee. However, the 3D printed material is observed to be bending, causing disruptions in the device’s operation. The reaction times are expected to be significantly larger compared to the theoretically calculated values.

The design and realization of a PC-based continuous passive motion device (CPM) for shoulder joint recovery was done. This machine can be used after performing an operation, or for patients suffering from joint motion limitation due to early stage of frozen shoulder. The system consists of a PC, a 8255, a motor driver and stepper motor, an application software, a mechanical module and a forearm orthotic. The experimental results showed that pulse signals are able to control the motor driver which in turn controls the stepper motor according to the predetermined parameters. The stepper motor is also able to provide bi-directional motions at the predetermined durations and velocities (low, medium, and high). By adjusting the delay time in the software, the PC-Based CPM can produce smooth motion.