New Brake System Retrofit for a Wheelchair

New Brake System Retrofit for a Wheelchair

WPI ME3506 Rehabilitation Engineering, Jan 2023 - Mar 2023

The goal of this project is to create a better braking system for a manual wheelchair. The current brakes on a wheelchair are less of "brakes" but wheel-locking mechanisms. This means they are not super helpful when a wheelchair user tries to slow down when going down a sloped area.

In this project, we are working with a famous Worcester local and wheelchair user/tinkerer, Charles Croteau. He has engineered and modified many wheelchairs for himself, others, and for organizations, so his input and guidance on this project are going to be beneficial. From Charlie, our team conducted a thorough client/customer analysis to get an idea of design specifications for our project development.

Design Specifications

Of our 11 design specs, the following are a few of the needs:

Allow for slowing or stopping while the wheelchair is in motion
The key here is that the goal focuses on a wheelchair while in motion. The most common type of wheel lock, the push-to-lock mechanism, is not recommended to be used while the wheel is moving; rather it acts as a stabilizer when the chair is stopped.

Require minimal maintenance
Wheelchair wheels are recommended to be replaced every 3-4 years and if, with a new braking system, the user hopes to be more active on these wheels, the team estimates at least yearly maintenance on the system (Reasons, 2021).
Introducing a new braking system can bring maintenance considerations. Different braking systems have different life spans for various friction linings or component materials. For example, it is recommended that bike disc brake pads be replaced around 500-700 miles from a resin pad, and 1000-1250 miles from a sintered metal pad (How, 2012).

Not interfere with the motion of using the wheels
For a manual wheelchair, in order to propel oneself, the user must grip and push off of the side wheel handlebars. The most common technique, when needing to repeat this, is to move your arms in a smooth circular motion between the starting and push-off positions (How, 2023). The reason this technique is common is because it is what feels most comfortable and natural. It would be impractical to change this motion. That being said, the new braking system needs to not interfere with this motion. This also applies to the method of activating the brakes.

Not hinder the wheel being modular
The wheels on a traditional wheelchair are considered modular because they have the ability to be easily removed from the frame. Many wheels have a push-button quick-release axle that makes this removal easy (Wheelchair Caster, n.d.). Charlie would want to keep this modular ability for the wheels because this makes it easier and more efficient to service the frame and wheels separately.

Ideation

In the ideation process, our team researched and considered multiple types of brakes and activation methods. The table on the right shows our morphological chart depicting this.

Final Prototype

The final prototype consisted of a modified band brake attached to a pull mechanism. The wheel stays modular with a modified wheel hub that also has the band brakes drum attached. In the picture, the activation mechanism has 3D printed prototype components which were later machined in order to be stronger. This mechanism also utilizes existing components of the handbrake which makes it easier to not "fully" redesign a new mechanism that would alter the user's interaction with it. If it ain't broke...

Wheel hub bracket

Drum (bronze) mounted to bracket

Modular side view

Final prototype video (I'm the user)

IMG_9782.MOV
IMG_9717.MOV

Final Report

ME3506 Team Brakes Final Design Report