Chapter 3

METHODOLOGY

This chapter discusses if what is supposed to be done in order to

accomplish the stated objectives. It explains the research methods and

procedures adopted by the study. It outlines the performance of the test,

simulations and calibrations needed to attain the best possible result. It defines

the instruments and equipment, and specifies the conditions needed in the study.

It summarizes the routine of tasks, simulations and specifications needed to

attain the best possible results and also to carry out stated objectives. In

summary, this chapter includes conceptualizing, designing, fabricating, material

assigning, testing and evaluating the prototype.

Project/Research Design

This research project is a developmental study which seeks to create

knowledge grounded in data systematically derived from practice. It is a

pragmatic type of research that offers a way to test "theory" that has been only

hypothesized and to validate practice that has been perpetuated essentially

through unchallenged tradition. Hence, the project of this study is patterned to be

a developmental study. And as defined, it requires certain ways and techniques

in accomplishing this study. One of these ways is prototyping.

Prototyping is a great way to communicate the intent of a design both

clearly and effectively. Prototypes help you to flesh out design ideas, test
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assumptions, and gather real-time feedback from users. As it was compared to a

website prototyping, It is much cheaper to change a product early in the

development process than to make change after you develop the site. Thus,

prototyping is a good way in accomplishing this study. There are several types of

prototyping such as Basic prototyping, Advance prototyping, Manufacturing

prototyping and Virtual prototyping. Basic prototyping is a prototyping that is often

made from things lying around the house, but will prove the theory and it is the

first step in making the distinction between innovating and inventing. Advance

prototyping, on the other hand is generally done with the help of professional

trade. That is, you have taken your basic prototype to a machine shop.

Manufacturing prototype is one that is EXACTLY like the final manufactured

product. What sets this apart from other prototyping is that it can be used to

create the machine tooling actually used to create tooling actually used in the

manufacturing process. That is, it’s the exact shape, size and function of the final

product. Lastly, Virtual prototyping is created in a computer; this relatively new

form of prototyping represents both good and bad to the inventor. From these

four types, this study uses manufacture prototyping. A final product is produce in

this study. And this final product is going to be tested and to be evaluated.

As mentioned, theories and ideas are to be tested by making a prototype.

Hence, Experimental Research Method and Evaluative Research Method must

be applied as a part of methodology. Experimental Research Method is a

methodology relies on random assignment and laboratory controls to ensure the

most valid, reliable results. Experimental is most scientifically sophisticated

research method. It is defined as ‘observation under controlled conditions’.

Experimental research design are concerned with examination of the effect of

independent variable n the dependent variable, where the independent variable

is manipulated through treatment or invention(s), and the effect of those

interventions is observed on the dependent variable. Evaluative research seeks

to assess or judge in some way, providing useful information about something

other than might be gleaned in mere observation or investigation of relationships.

Project Development

 Preliminary Investigation

Preliminary investigation is conducted through observation in numerous

gymnasiums located on the respective vicinities of the proponents. The main

concern of this study is to utilize waste energy produced by humans. Via

observation a person goes to a gym to lose extra calories, he exerts effort thus

creating work. With the work produced, the force involved goes nowhere but unto

the equipment. The energy would be more useful if it can be converted into

another workable energy.

 Conceptualization

Due to the aim of converting human energy, a review of literatures and

studies has been conducted. The idea of converting mechanical energy to

electrical energy is based on the idea of a simple hand crank flashlight. This
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simple kind of machine, that converts energy, could be maximized by making the

machine compound; also making the transformed energy maximum.

Maximization could be done, as an assumption, if multiple works are done by

humans.

This compound machine will have an input of mechanical energy which is

done by human, since human is the perfect medium to perform different motions.

This different motions will be exhibited or be performed by the aid of known

mechanism. Motion is a key to exert mechanical energy. For a generator,

rotational motion is the most significant type of motion to turn the shaft of a

generator. Rotational motion can be resulted from other types of motion such as

linear, oscillating and others.

Since these motions would be the product of human efforts, and a

machine can receive such efforts and would be reproducing these efforts into

workable energy, the study comes up to an idea of multi-work-gym equipment.

 Preliminary Assembly Modeling

Using the idea at hand and data gathered, a number of models have been

formed. These models have been compared and the one that emerged was

decided upon its attainable fabrication and of course its quality is at its best.

 Design Phase

Design detail may have been the most complicated phase in this project

study, below is the design process followed:

1. Identifying the strength, details of the specimen and design of the

overall structure of the project.

2. Necessary values computation - forces, stresses, speeds, and others.

3. Dimensioning and design of the overall structure of the project.

4. Specifications of machine parts, etc.

Pulley

Handle

Folding Bench

Plate holder

Frame
Rope
Plates (weights)

 Fabrication

The following activities involved in the fabrication phase:

1. Purchase of required materials appropriate for fabrication of the

prototype/machine.
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2. Selection of an appropriate and convenient machine shop to

fabricate the prototype.

3. Fabrication of the following parts:

 Frame

 Generator holder

 Folding bench

 Handles for lifting weights and pulling ropes

4. Assembly of the parts using bolts and nuts, screws, and welds.

5. Troubleshooting plus additional modifications.

6. Painting and buffing

7. Finishing

 Materials

a) 2 by 1-1/2 inch ASTM A-513 gage 10, 16ft. rectangular steel tube

b) ¾ inch ASTM A-513 gage 10 steel tube

c) ¼ inch stranded wire rope

d) 3 inch pulley

e) Foam

f) Rubber

g) Crank generator

h) Metal plates

i) Fasteners

j) Bearing
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On the researchers’ part, the detachable crank generator is the only

custom part and has reasonably short lead time of one week. One of the most

expensive parts is the crank generator, the cost is approximately Php 2,000.00

per unit. And the most expensive part is the steel tubes costing about Php 125

per foot of a length.

Properties of A513 Steel

High Carbon Content

High Strength: Su = 87,000 psi

Sy = 72,000 psi

Foam cushions is about Php 500.00 including upholstery. Rubber

handles ranging from Php 100.00 to Php 150.00 per pair

 Operation and Testing Procedure

The operation and testing of the prototype is simple. All handles for

different types of exercise are connected to ropes and pulleys.

1. Choose a system for your preferred exercise (i.e. back, abs, chest,

etc.)

2. If chest exercise is chosen, put the specific number of plates (weights)

on the late holder

3. Push the handle bar for the chest exercise.

4. The plates held by the rope and pulley will move up and down. Upon

this movement the L-shaped arm or lever of the generator will be activated
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and thus rotating the magnet inside the generator – producing

energy/power.

5. The rest of the exercise routines (pull for the back, biceps, abs,

triceps; push for the legs, etc.) will produce the same output – plates

ascend and descend.

Operation of the Generator

The L-shaped handle has a gear rack, which spins the white step-up gear,

which in turn spins the flywheel on which is mounted the dark grey magnet, seen

on the lower left. The magnet induces an electrical current in the red copper

winding. The current from the copper winding flows through the battery (not

shown) giving off stored energy. A spring and ratchet returns the handle to its

original position after each engagement.

One of the DC motors was gear headed with the ratio of 1:10 (the

input cycle was increased from one to ten before the generator produced

electricity). The second one was a typical brushless DC motor; the last one was a

typical motor. As a test process of the generators, the generator was initially

either mounted on or connected to the appropriate plate above the front shaft

with the aid of a bolted flat plate.

During the test process of the fitness equipment, the generator output

voltage and current were tested in order to build a proper energy. A person

initially tested the system during a 15 minute continues workout; a 1 Ohm resistor

was placed between a multi-meter and the generator to measure and calculate
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an AC and DC open circuit voltage and current that was produced by the

generator. It was determined that the generator produced sufficient voltage/

current levels to drive the fitness equipment. The output power of the generator

may be changed when higher gear ratio or more human power is applied.

To calculate the power output of the generator, Ohm's Law is used and the

power is added under tested generator specifications; P=V*I, (P=Power,

I=Current; and V= Voltage)

 Standards

The proponents ensured the user’s safety upon using the equipment

by increasing the design’s factor of safety. This is done to meet the standards

stated on PSME code and for the machine’s reliability.

 Evaluation

 Evaluation Process

Probably, the best evaluator of a fitness gym equipment are the fitness

savvy themselves, or the athletes. It will give them an idea if the gym equipment

is suitable and comfortable for usage. In this study, an evaluation sheet are to be

used to evaluate the final product. First, the evaluators - preferably fitness

experts and enthusiasts - will be asked to use the equipment. An evaluation

sheet is going to be handed down to the evaluators afterwards. The evaluation

sheet is presented in the "Instruments and Techniques Used” part of this study. If
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the evaluators wish to reuse the equipment for further evaluation, they may be

able to re-examine the equipment. After gathering data from preferably 30

evaluators, statistical data are going to be presented as a basis for an overall

evaluation of the gym equipment.

 Evaluation Criteria

The criteria of evaluating the equipment is as follows:

1.) Simplicity or Complexity

This factor is much easier to evaluate for the home fitness

purchaser. Comfort can be assessed with simplicity and complexity of the

equipment. Many people might use the equipment. Simplicity or complexity must

be evaluated through how adjustable the equipment is when it comes to variety

of use. Any adjustments required of the user should be few and easy to make.

You also want to make sure the equipment is simple to learn.

2.) Safety

Safety is also a major consideration for both the facility purchaser

and the home purchaser. In regard to safety, variety of questions must be asked

such as "How stable is the equipment?", "Can it accommodate all users

regardless of size?", "Are moving parts enclosed to protect users?", "Are there

any pinch points?" and etc. Getting on the equipment and imagining all possible

scenarios that may be hazardous for the future users. In a weight machine- like

the ones in this study, favor equipment designed to place the body in appropriate
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body alignment. Following initial instruction, this allows participants to train

safely by themselves.

3.) Appeal

An equipment's look and features are should be appealing so that the

user will want to continue to use it. A machine with lots of gadgetry may scare

some apprehensive exercisers. The gadgetry can also serve as an attraction to

young children, which can be a safety concern. Position, grip, angles, smooth

action and contoured body supports all contribute to appeal. But not to

overemphasize the appeal factor.

4.) Space

Space is an important factor for evaluation. Certain questions must be

asked such as "Is is space consuming?", "Is it easy to move when cleaning the

place where it is placed?" "Can the floor handle the weight of the equipment and

a user(s)?"

Evaluation sheet is presented.

Evaluation Sheet

Instruction: Please put a check in the row that best describes the equipment.
Legend:
1- Not at All 2-Least of the time 3- Sometimes 4- Most of the time 5- Very
Much
Characteristics 1 2 3 4 5

Simplicity or Complexity
Adjustability to different variety of usage
Is the equipment easy to learn
Are instructions on use displayed
Safety
Do the joints appear strong
Does it stand steady on its base even
when in use?
Do the parts appear sturdy?
Is the safety measures included in the
user’s guide?
Do the welded joints look safe?
Are there any pinch points?
Is there no any imaginable cause of
hazards and/or accidents?
Appeal
Is the machine equipment appealing?
Is there no gadgetry?
Does the design motivate the user to
continue the usage?
Is the design quiet to use?
Space
Is the equipment space saving?
Is it easy to reposition?
Is it easy to be disassembled?
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Instruments and Techniques Used

A collection of different machine shop instruments, tools, and

equipment were significantly used in the production of the Multi-Work Gym

Equipment Energy Converting Machine. The following are the machines and

tools used in the production

1. Lathe machine – is used to fabricate the threads on the shafts.

2. Shearing machine – used to cut metal sheets to its desired sizes

3. Welding machine – used to connect or join the edges of the

chamber

4. Wrench – used to tighten the nuts on the round bar that is used

as reinforcement

5. Square rule – used to check if the adjacent plate of the chamber is

perpendicular to each other

6. Steel rule – used to layout the dimensions in the steel plates before

cutting

7. Vernier caliper – used to determine the depth of the thread

8. C-clamp – temporarily connects the machine parts to be welded

9. Grinding machine – used to chamfer sharp edges of the plates