Final Project Post: Safe Sleeve

  1. Safe Sleeve
  2. Jacob Cordover
  3. Safe Sleeve is a soft, functional sleeve that conveys biomechanics that have been historically confined to clinical settings and cost prohibitive motion capture equipment.

 

  1. Video:

 

  1. Poster:

  1. Safe Sleeveis a soft knee sleeveintegrated with two inertial measurement units. Safe Sleevecalculates the angle of the knee joint— a task traditionally completed with a goniometer— by utilizing the two inertial measurement units which calculate each sensor’s angle relative to the gravity vector. These two values are subtracted from each other and streamed wirelessly to a computer via Bluetooth. The user can interact with the custom-built application in order to set bounds for flexion or extension. If the bounds are breached, the application will flash red, otherwise it will remain green. Additionally, the user can examine flexion and extension from entire streaming session with a line graph.

 

  1. Overall, I am very pleased with the outcome of this project. From the beginning, I wanted to work on a project catered towards sports and/or healthcare as this is what I am most interested in. With zero background in any design related fields, I tried to tailor my project towards what I was more comfortable with. I could have tried to construct the knee sleeve myself, however I don’t think I would have been as pleased with the final result as I am. Because I worked on this project solo, I invested time into getting the best data from the sensors as possible, along with creating a more seamless user experience, rather than focus on trying to achieve something I know I am not as strong in, which could have led to more frustrations and less to show for my efforts. Thus, I am left feeling pleased and optimistic about what I was able to achieve with my project, from ideation, to each milestone, to the final product, to the future of the sleeve.

 

  1. The original intent of this project was to create a soft, functional knee sleeve that would convey flexion and extension data in situations where traditional means of collecting this data were too costly and/or impractical. When I started the ideation process, I had a few ideas of how to accomplish this goal: one, I could integrate either conductive fabric, stretch sensors, or flex sensors onto the sleeve and wire them to a Bluetooth microcontroller, or I could go the route I ended up using, implementing IMU’s with Bluetooth to achieve my goal. Ultimately, I decided that using IMU’s would be more conducive to achieving the overall goal of this project— to create a sleeve as functional as possible. Each additional piece of hardware introduced into the sleeve created another possible failure point and took away from the overall functionality of the sleeve. However, I still was looking for a solution to contain two batteries, two IMUs, a Bluetooth module, and a microcontroller in my sleeve in a way that would achieve the intent of my project. Thus, when I came across the Yost sensors that, it just about solved every issue in creating as functional of a sleeve as possible in an extraordinarily elegant way.

The sleeve has no wires, it did not need to be soldered, its footprint is significantly smaller than having to source each part individually, and the sensors are able to be anchored to the sleeve with virtually zero extra bulk on the outside of the sleeve.

While I did pay a premium for the sensors, I am very confident that this was the best solution in attaining my goal of creating a functional sleeve that conveys flexion and extension data. At each step of the process, every decision was made with this goal in mind, and as a result, I believe I have surpassed my goal of creating this functional sleeve that conveys flexion and extension in ways that turned out even better than I had envisioned.

As for the actual data, I have gotten the sleeve to the point where it looks to be outputting acceptable data. From eyeballing angles, it looks to return an angle around 3-5 degrees from which one would expect, however, I would like to see the sleeve compared and potentially calibrated against a goniometer.

  1. There were two main challenges that I faced in creating the final product, the first of which was what methodology I should employ to get my intended data. A large issue in calculating flexion angles with both goniometers and wirelessly is that the human body is one, soft, and two, not flat. Thus, when using a goniometer, there are specific bodily landmarks to determine placement for an accurate measurement. Likewise, when using IMU’s, the sensors will never be flat, and additionally, it is not practical to ensure precise placement every time the sleeve is worn. As a result, I had three possible implementation plans: quaternions, Euler angles, and taking angles with respect to gravity.

Quaternions are an extension of the complex number system, and while they are the most complex approach to solving the problem, they offer an extremely robust solution, while avoiding known problems of Euler angles, like gimbal lock. Essentially, quaternions would create rotational offsets that could be accounted for when calculating the final angle of interest, no matter the orientation. Theoretically, this works well, however after I implemented this approach, the data would just not cooperate. I could get somewhat accurate results for around twenty seconds or so, however the angle would start to drift until the angle became completely nonsensical.

Taking angles with respect to gravity and subtracting them was the simplest approach, however it seemed to give the best angle. While this solution may not be as robust as quaternions, it was not plagued by the issues the quaternion approach presented. This method was so satisfactory, that I decided that any improvement Euler angles could potentially provide was not worth it, rather I spent the rest of my time working with the second major problem, Bluetooth connectivity.

Getting the sensors to talk to my computer hard wired was not much of a problem at all, however unplugging the sensors and communicating via Bluetooth proved to be the biggest challenge of this project. For some reason, the sensors would work fine for a few seconds and then there would be an unresolvable communication error resulting in a crash. I tried both windows machines and macs to no avail. I tried all sorts of error handling in the backend to no avail. I also made sure low battery wasn’t affecting the Bluetooth communications. Nonetheless, I noticed a few things, the first of which is that the sleeve works better when I’m around fewer devices. At the showcase, Bluetooth didn’t work for longer than a second or two. During class time, the sensors sometimes work for 10-15 seconds before crashing, however at home, the sensors will work for minutes at a time, which makes me think that the sensors are susceptible to some kind of interference.

The other thing I noticed is that the longer the sensor has been on and connected and reconnected to Bluetooth, it works longer before crashing. I am still not sure as to why this is the case.

Unfortunately, I didn’t solve the Bluetooth issue. As mentioned, error handling in the backend cast the sensors into an infinite loop of reading back nonsensical values. Thus, to work around the issue of communication error, there is a button in the user application that terminates and reconnects the streaming session. The process only takes a second or two, so until the Bluetooth issue is solved, this will have to suffice.

  1. Given more time, besides working more on the Bluetooth issue, I would harness more functionality from the IMUs. There are many different measurements that can be taken from these sensors with the accelerometer, gyroscope, and compass. While perhaps the scope of this project focused on the rehab aspect on trying to emulate a goniometer, given more time I would like to implement more performance-based features. For example, measuring a vertical leap, or measuring force produced by the leg. Performance asymmetries between the legs is a flag for increased injury risk, so this could also help further Safe Sleeveas an injury prevention tool.

Otherwise, the technology in safe sleeve can easily be ported into an arm sleeve. I’d have to do some more research into what mechanics are used in upper extremity recovery protocols as well as what performance metrics are used, but I believe the difficult part has been done.

  1. Materials:

2 Yost Labs mini Bluetooth IMUs

2 back plates with 4 anchoring screws

1 knee sleeve

Project Post #7

Safe Sleeve

Jake Cordover

One Sentence: Safe Sleeve is a soft, functional sleeve that conveys biomechanics that have historically been confined to clinical settings or cost prohibitive motion capture equipment.

Weekly accomplishments: This past week, I implemented Professor Ponto’s recommended implementation. This was a much simpler approach, without quaternions or Euler angles, but the data looks pretty good so this will probably be the chosen implementation for the final project.

Otherwise, I spent some time trying to get Bluetooth working— one sensor connects, but the other doesn’t so I’m trying to figure out why that’s the case. Additionally, I have begun work on a simple app for data visualization.

Images:

Below is the simple visualization app. I would like to add a line graph plotting knee angle vs time in the bottom right of the tracking screen. When the current angle of the knee crosses the threshold set the screen turns red, otherwise it is green.

 

Materials (no change):

Part/Material Price ($) Quantity Link
IMU 117 with discount secured 2 https://yostlabs.com/product/bluetooth-mini/
Knee Sleeve 1 16.97 1 https://www.amazon.com/PowerLix-Compression-Knee-Sleeve-Basketball/dp/B01MQYADOT/ref=sr_1_5?keywords=powerlix+knee+sleeve&qid=1552264456&s=gateway&sr=8-5
Knee Sleeve 2 20 1 https://www.amazon.com/Zensah-Knee-Compression-Sleeve/dp/B00GPU7QRO/ref=sr_1_6?keywords=zensah+knee+sleeve&qid=1552264496&s=gateway&sr=8-6#customerReviews
3D printing and associated costs TBD TBD TBD

 

Areas of concern: Now that the data looks much better, my biggest concern is getting the second Bluetooth sensor working.

Project Post #6

Safe Sleeve

Jake Cordover

One sentence: Safe sleeve is a functional knee sleeve that conveys knee data that has historically been confined to either clinical settings or prohibitively expensive motion capture equipment.

Weekly accomplishments: This past week I focused on trying to smooth out the flexion and extension data. It has improved to a much more consistent level that seems to better reflect the rough angle, however I think there is still room for improvement. One area in particular that I’m interested in looking into is using Euler angles rather than the quaternion approach I’m using now. While Euler angles may have some limitations and are not as robust as quaternions, this may be ok in my use case. Nonetheless I am planning on implementing this approach so I can compare the two approaches.

Images:

Below is the brace on a knee with sensors attached.

Below is the data readout of the brace on a knee flexed around 90 degrees.

Materials:

Materials (no change):

Part/Material Price ($) Quantity Link
Potential IMU 1 117 with discount secured 1 https://yostlabs.com/product/bluetooth-mini/
Knee Sleeve 1 16.97 1 https://www.amazon.com/PowerLix-Compression-Knee-Sleeve-Basketball/dp/B01MQYADOT/ref=sr_1_5?keywords=powerlix+knee+sleeve&qid=1552264456&s=gateway&sr=8-5
Knee Sleeve 2 20 1 https://www.amazon.com/Zensah-Knee-Compression-Sleeve/dp/B00GPU7QRO/ref=sr_1_6?keywords=zensah+knee+sleeve&qid=1552264496&s=gateway&sr=8-6#customerReviews
3D printing and associated costs TBD TBD TBD

 

Areas of concern: Getting the data as accurate as possible is my main goal as well as concern right now. Hopefully using Euler angles proves provide better data. If I can achieve this, I’d like to focus on creating my custom enclosure so the sensors don’t have to be screwed down at all times.

Project Post #5

Safe Sleeve

Jake Cordover

Weekly Accomplishments:

I have finally received the two sensors this week, thus I have begun implementing the program to measure the actual knee data. Bluetooth seems to be a little finicky, so I have focused on developing the code on a wired basis at this point. I have gotten it to the point where the accuracy seems to be within 5-10 degrees of the desired value, however, there seems to be a lot of noise and/or drift. I plan on hopefully implementing some techniques or researching what can be done to reduce the drift or noise.

Otherwise, I have printed a prototype of the enclosure that I will be using to secure the sensors. Since I have the sensors, I can adjust the prototype’s dimensions and design, and hopefully have the enclosure pretty close to the final version.

Images:

The images are of the 3D printed enclosure prototype.

Materials (no change):

Part/Material Price ($) Quantity Link
Potential IMU 1 117 with discount secured 1 https://yostlabs.com/product/bluetooth-mini/
Knee Sleeve 1 16.97 1 https://www.amazon.com/PowerLix-Compression-Knee-Sleeve-Basketball/dp/B01MQYADOT/ref=sr_1_5?keywords=powerlix+knee+sleeve&qid=1552264456&s=gateway&sr=8-5
Knee Sleeve 2 20 1 https://www.amazon.com/Zensah-Knee-Compression-Sleeve/dp/B00GPU7QRO/ref=sr_1_6?keywords=zensah+knee+sleeve&qid=1552264496&s=gateway&sr=8-6#customerReviews
3D printing and associated costs TBD TBD TBD

Areas of concern:

I’m a little concerned about the reliability and functionality of the Bluetooth, but at this point I am focusing on getting the best measurements using a wired approach.

Otherwise, the drift/noise issue is potentially very problematic. This may require a significant effort to smooth, otherwise I might need to start looking for a workaround.

 

 

 

Project Post #4

Safe Sleeve

Jake Cordover

Weekly Accomplishments:

Unfortunately, the shipment of the sensors continue to cause delay into the programming aspect of the project. I have been in touch with Yost Labs (the supplier), and the reason for the delay was that they ran out of casings for the sensor, so supposedly they were shipped midweek. This is frustrating, especially considering how much was spent, nonetheless hopefully they will be here soon.

Otherwise, I have begun to prototype the 3D printed enclosures in CAD. My enclosure includes sew tabs on the bottom and a top that “snaps” into the bottom, therefore the sensor into place. I am attempting to emulate the annular cantilever snap fits as seen here: https://www.sculpteo.com/blog/2018/04/25/how-to-connect-two-parts-with-3d-printed-joints-and-snap-fits/.

The next step in the process is to print the prototype and make sure the design works, before trying it on the real sensors, and then finally sewing it down to the sleeve. I have included images of the design below.

Images:

The first three images represent the bottom of the enclosure. This sensor will be placed into this sewn down piece( see sew tabs in the bottom). Additionally, the cutouts will be where the top piece “snaps” into place

The next piece is the top that snaps into the bottom, securing the sensor into place.

And the two pieces fitted together:

 

Materials (no change):

Part/Material Price ($) Quantity Link
Potential IMU 1 117 with discount secured 1 https://yostlabs.com/product/bluetooth-mini/
Knee Sleeve 1 16.97 1 https://www.amazon.com/PowerLix-Compression-Knee-Sleeve-Basketball/dp/B01MQYADOT/ref=sr_1_5?keywords=powerlix+knee+sleeve&qid=1552264456&s=gateway&sr=8-5
Knee Sleeve 2 20 1 https://www.amazon.com/Zensah-Knee-Compression-Sleeve/dp/B00GPU7QRO/ref=sr_1_6?keywords=zensah+knee+sleeve&qid=1552264496&s=gateway&sr=8-6#customerReviews
3D printingand associated costs TBD TBD TBD

Areas of concern:

At this point, I would like to be able to start work on the sensor, theres not too much to do without it. Hopefully this issue resolves itself soon…

Otherwise, I’m still undecided on the method of attachment of the enclosure to the sleeve. I talked with Professor Fairbanks about potentially cutting a hole in the sleeve, which I think may look the best, however, I’m not sure if that will degrade the integrity of the sleeve too much.

I have never 3D printed before, so if I go this route, I’m not sure if the material will flex enough (without breaking) for my design. Additionally, I’m not sure of the type of margins I need to build in for the print to be successful.

Project Post #3

Safe Sleeve

Jake Cordover

Weekly Accomplishments:

All materials have been sourced and ordered. I have received the knee sleeves, just waiting on the sensors. I had been debating on whether to go with the all in one Yost sensors, or to go with less expensive IMU’s with microcontrollers, batteries, and wires, and I have decided to go with the Yost integrated sensors. While significantly more expensive, I believe they will be much more conducive in realizing the vision of this project, to create a seamless, functional knee sleeve.

While I don’t have the sensors on hand yet (hopefully early this week), I have looked at the manuals and read up on how I will interface with the sensors. It looks to be a fairly straight forward process and there is some source code available for this that I have located.

Additionally, I have continued to study vector mathematics. While there is a straight forward way to calculate the flexion/extension angle from the vectors the sensors return, quaternions potentially provide a means of more accurate data, thus I have continued to look at using these.

Images:

Below is some source code I found that will be of use when it comes to connecting to the sensors and reading/writing.

Materials:

Part/Material Price ($) Quantity Link
Potential IMU 1 117 with discount secured 1 https://yostlabs.com/product/bluetooth-mini/
Potential IMU 2 76 1 https://mbientlab.com/store/metamotionc/
Knee Sleeve 1 16.97 1 https://www.amazon.com/PowerLix-Compression-Knee-Sleeve-Basketball/dp/B01MQYADOT/ref=sr_1_5?keywords=powerlix+knee+sleeve&qid=1552264456&s=gateway&sr=8-5
Knee Sleeve 2 20 1 https://www.amazon.com/Zensah-Knee-Compression-Sleeve/dp/B00GPU7QRO/ref=sr_1_6?keywords=zensah+knee+sleeve&qid=1552264496&s=gateway&sr=8-6#customerReviews
3D printing

and associated costs

TBD TBD TBD

Areas of concern:

An area of concern regards anchoring the 3d printed housing to the sleeve. As the sleeves are compression and stretchy, I’m not sure how this will affect the anchoring stitching when the sleeve is being worn and stretched out. I need to make sure it will still be structurally sound enough, or I will need to start pursuing other methods of attachment, like a pocket. I have two sleeves to choose from, so hopefully one will offer a viable solution.

Otherwise, my understanding of quaternions is not sufficient if I choose to go this route, however I will continue to study up on this matter.

Project Post #2

SAFE Sleeve

Smart Active Flexion Extension Sleeve

Jake Cordover

 

Accomplishments

 

From project post 1’s timeline the goal for this week was: decide implementation plan and order materials needed.

 

I have decided to implement the wireless approach or utilizing IMUs in order to measure flexion/extension angles with a stretch goal of measuring lateral translation. There were a few deciding factors that went into this decision: one, and perhaps most importantly, if the wired approach, or using materials to measure the change in resistance were utilized to extrapolate to joint angles, the sleeve would need to be recalibrated and mapped to a set of goniometer values for every use, or else run the risk of inaccurate data. Measuring knee angles with a goniometer every time the sleeve is to be used is impractical and defeats the purpose of the sleeve. The second major deciding factor was the longevity of the device, as a knee sleeve is subjected to frequent forces. Thus, any change in characteristics of conductive materials or loose connections could render the sleeve useless. Thus, the wireless approach was selected.

 

There were a few drawbacks with this implementation plan, namely price and learning curve. For the price aspect, I have reached out to one of the companies I’m considering sourcing for IMU sensors and secured a 10% discount. While the price remains expensive, I really like these sensors because they are essentially ready to go with the IMU data, Bluetooth connection, and a rechargeable battery, enclosed in a small package. The other option is to secure an IMU, a Bluetooth module, a battery, and a development board, which may prove to be less expensive, however the task of integrating everything into an active knee sleeve becomes harder.

 

Additionally, I have decided on two knee sleeves to order. They are both relatively inexpensive and get high reviews on amazon. I did some preliminary research on 3D printing, and I would like to print a snap fit enclosure with sew tabs to anchor the electronics onto the sleeve.

 

Finally, as I’m going with the wireless approach, I will need to learn about IMUs and how to extrapolate this data into angular measurements. I spent time this week reading about accelerometers and gyroscopes, how they work, and how their data can be used to calculate angles.

 

Images

 

Knee sleeve 1

 

 

Knee sleeve 2

 

 

Changes to approach

 

At this point, there have not been any changes to my approach, however I have selected the wirelessimplementation as outlined in this weeks accomplishments.

 

Material List

 

Part/Material Price ($) Quantity Link
Potential IMU 1 117 with discount secured 1 https://yostlabs.com/product/bluetooth-mini/
Potential IMU 2 76 1 https://mbientlab.com/store/metamotionc/
Knee Sleeve 1 16.97 1 https://www.amazon.com/PowerLix-Compression-Knee-Sleeve-Basketball/dp/B01MQYADOT/ref=sr_1_5?keywords=powerlix+knee+sleeve&qid=1552264456&s=gateway&sr=8-5
Knee Sleeve 2 20 1 https://www.amazon.com/Zensah-Knee-Compression-Sleeve/dp/B00GPU7QRO/ref=sr_1_6?keywords=zensah+knee+sleeve&qid=1552264496&s=gateway&sr=8-6#customerReviews
3D printing

and associated costs

TBD TBD TBD

 

 

 

 

 

Project Post #1

SafeSleeve

Smart Active Flexion Extension Sleeve

By Jake Cordover

 Description

The goal of SafeSleeve is to create a soft, functional knee sleeve that interfaces with a mobile device, reading back live data about knee motion, including flexion, extension, and hopefully excessive lateral translation. This type of device could benefit numerous individuals including, but not limited to: healthy athletes, rehabbing athletes, and rehabbing patients. Data about knee motions are readily available in a clinical setting, however most patients and athletes do not spend the majority of their recovery or activity in a clinical setting— by providing access to this data anywhere, patients can complete range of motion exercises within bounds set by their recovery team, coaches can assess positioning or form on movements, improving performance or enhancing safety, and motion extrema can be flagged, allowing for earlier injury detection. Additionally, providing a mechanism of injury could potentially lead to more accurate diagnoses.

To use SafeSleeve, a user would first put on the sleeve and turn it on with a switch or button. Depending on design implementation, the sleeve will require either consistent and precise positioning on the knee, or it will require a short calibration period. After the device has been positioned or calibrated, the user will open a companion application to select the mode of usage: either continuous live feedback, or sport mode. Live feedback would continuously display current knee metrics on a mobile device, while sport mode would keep all data on the sleeve, flag any data extrema, and transfer the data to a device at a later time. Finally, the data on the companion application can be analyzed in a number of ways like max extension/flexion/lateral translation, whether a set motion boundary was breached, and potentially how many reps of flexion/extension were performed in non-sport mode. The ability to track motion data over longer lengths of time may also be useful.

Similar Products

After perusing over similar, existing products, it was concluded that there is no other readily available functional knee sleeve that tracks positioning. However, two somewhat similar products were found, one of which was the Donjoy X4. This product differs in that it is a hard knee brace meant for post-operative knee arthroplasty. Hence, this product would not be suitable for athletes looking to track during activity— not to mention price. One of the benefits of the design of this project is if the planned design can be executed, sleeves can potentially fit under a number of braces, combining the benefits of the bracing stability, compression, and data. The other somewhat similar product is the Smart Knee, which is essentially two sensors connected by a bend sensor that attaches directly to the skin with adhesive pads. One, like the Donjoy, two sensors attached directly to the skin would not be optimal for athletes wanting a functional solution, and two the product does not appear to be sold to directly to consumers, and the cost for developer kits start at $2500. See below for images of the Donjoy X4 and the Smart Knee.

The smart knee is pictured above.

 

DonJoy X4 pictured above.

 

Sketches of Sleeve

Implementation and Materials

At this point, there are two potential implementations to make this product a reality. The first implementation involves using IMUs (inertial measurement units) or other wireless sensors. These sensors would be utilized with mathematics in order to provide the desired data. The benefits of going this route would nullify the necessity of precise and consistent sleeve placement. The disadvantages of going this route includes price, reliability and accuracy of sensors, and fairly sophisticated mathematical prerequisite knowledge required to achieve the data. For simplicity, this will be called the wireless implementation.

The other implementation involves utilizing a material that changes resistance, such as a flex senor, stretch sensor, stretchy conductive fabric, or conductive thread, and mapping the data to a known set of values to achieve the knee data. The benefits of this implementation include less involved knowledge of mathematics and a less expensive approach. However, there is concern about the durability of such materials holding up in strenuous activity and achieving and maintaining the exact fit of the sleeve from which the mapped values were accrued. Additionally, while maybe not a concern for this project, any future sleeves produced will need to be calibrated with a goniometer to each particular user. This implementation will be called the wired implementation.

The following materials will be required regardless of implementation:

  • A knee sleeve ($15.48, amazon)
  • Thread to stich down electronics
  • Mobile device to capture data

The following materials would be necessary for the wireless implementation:

The following materials would be necessary for the wired implementation:

  • Small microcontroller like ($8.95) Trinket M0
  • Batteries
  • Either stretch conductive fabric/flex sensors/stretch sensors/conductive thread
  • Either excess material to make a pocket or 3D printing to make housing for electronics to be sewn down to sleeve

Skills to be mastered

  • Mathematical knowledge for wireless implementation
  • Neat, elegant sewing
  • 3D printing to house electronics
  • If mini Bluetooth sensors not used, electrical/physical componentry and component communication protocols like I2C
  • Measuring knee angles with goniometer for calibration/comparison

Timeline

  • By March 11th: decide implementation plan and order materials needed
  • By March 18th: have all materials on hand (pending shipping) and be able to collect some type of data on mobile device
  • By March 25th: demonstrate that sensors provide a means of accurate knee data
  • By April 1st: complete final design plan and produce 3d componentry if that route used
  • By April 8th: demonstrate that sensor suite, perhaps temporarily integrated, produces accurate knee data
  • By April 15th: push to complete integration and mobile app
  • By April 22nd: Debug, finish app, demonstrate integrated knee sleeve works

Fallback Plan

If it is deemed too difficult to gather accurate, consistent knee data, strategic placement of soft switches on the knee sleeve could provide tactile feedback (vibration) if undesirable knee positions are realized.

Bare Minimal Outcome

The bare minimum for this project is to create a functional knee sleeve that provides some sort of feedback (data or tactile feedback) to a user. For how big of a field medical technology is, there are surprisingly few solutions to provide feedback on knee movement outside of a clinical setting. Thus, the inspiration of this project, and what will determine the success of the project is creating a functional knee sleeve, granting insights into knee metrics that are traditionally restricted to a clinical setting.