PRODUCT DESIGN, MECHANICAL ENGINEERING
Vibration Plate Project
Background
The concept of the vibration plate as an aid to enhance the effects of physical exercise has been adopted in gym’s across the world.
The principle behind the vibration plate is to subject muscles to additional repeated momentary loading (& unloading) during an exercise regime.
By adding a vertical oscillation the muscles are momentarily loaded with 3-20G (3-20 x gravitational pull) and momentarily allowed to relax.
Using an effective vibration plate makes muscles feel like they are doing considerably more work, and they are.
Manufacturers claim significantly increased benefits to exercise conducted on a vibration plate compared to the same exercises performed on a solid surface.
This additional micro-exercising of muscles can have the effect of doubling the effectiveness of certain exercises and reduce the time required to obtain the same benefits.
Initial research revealed that there are two parts to the vibration plate market; professional gym equipment (£2,000- £10,000) and the domestic market (£80- £2,000).
The units in both sectors work in one of two basic ways; 1. Oscillation of a foot plate suspended on rubber or steel springs. 2. A plate with a rocking action around a central axle driven back and forth by a reciprocating drive mechanism.
Typically the claims for these units are often outlandish and real evidence of their effectiveness is scarce.
We obtained three examples of vibration plates for assessment and soon found that there is massive scope to develop a more effective, practical exercise tool.
One professional gym plate claimed operational parameters only possible when no load is applied. The vibration amplitude reduced to one eighth of that claimed when someone of average weight stands on it.
Several domestic plates overstate their performance by up to 1,000%, so their effect on exercise efficiency is negligible.
Crucially, to achieve market penetration it has to be supported by thorough research.
We set out to establish how and why micro-oscillation can enhance muscular exercise routines.
The market for these vibration devices has grown steadily, leading us to find out if there were merits in developing a truly effective, cost effective vibration device.
Our objective is to use our research, analysis, innovation and engineering abilities to develop a vibration plate capable of serving the professional and domestic markets.
It must also cost less than and show significant headline advantages over any similar, available product.
Weight and size:
The units that get close to providing effective vibration cannot contain that vibration without the addition of significant steel ballast. This takes the overall weight beyond the acceptable threshold for carrying and transporting economically (without significant damage returns). They are generally much larger than is required for their function.
Solving this engineering problem would provide a much more effective, practical product and important IP to protect its’ advantages.
What we did
Phase One
Define objectives.
Research - market, competitors, vibration and oscillation technologies, existing IP. Benchmarking strategy.
Brainstorm events; physiological and lifestyle benefits, technological & mechanical innovations, search for USP’sover competition.
Investigations using rig’s and prototypes.
CAD engineering development: system modelling; oscillation, acceleration and ‘G’ measurement simulations.
Testing capabilities to benchmark: How effective, safe, viable?
Mechanical development & FEA analysis: Engineering parts to build test system.
Prototyping and assembly first build.
Testing and evaluation.
With the successful development and testing of new solutions, we began planning for the mechanical development of the new product.
At this time we established functional parameters for the start of the mechanical development and testing.
Phase 1 Detail.
Our research has identified that there are benefits to be gained from augmenting certain types of muscular exercise with medium/high frequency mechanical oscillation.
Research into the different vibration technologies on the market has identified a number of different mechanical actions. These actions vary massively in amplitude, frequency, acceleration/deceleration (‘xG’ factor).
Taking existing products, we will use three axis accelerometers to understand the characteristics of different mechanical actions.
We will then consult with physiotherapist’s, orthopaedic and sports injury specialists to better understand the implications of the different actions on bone, cartilage, tendon and muscle health.
Phase 1 Testing:
For the purposes of testing we purchased five different vibration units. This allowed us to test and measure the effect of different mechanism’s. The initial aim was to establish the type and level of effective exercise enhancing vibration.
We decided that the ideal testing sequence for the sample units and our functional prototypes would be:
Vital statistics: recording action direction, speed, amplitude, frequency & acceleration / deceleration (? +/- G).
Comparison of quoted to actual performance: Accuracy of product data. Benchmarking our prototypes against existing product performance.
User tests: comparative feedback based on perceived additional exertion / muscle work between sample units and non-augmented control work-out. Subsequent feedback on whether there are any perceived performance improvements after a short program of augmented exercise.
Measurable physiological changes: Oxygen consumption in muscles, Lactic acid peaks etc. *This may not be possible until we get into Phase 2.
Functional parameters: Weight v vibration - walking product.
Phase 1 : Conclusions Summary.
There are two basic action types; 1. the suspended vibration plate and 2. the rocking plate type, the latter demonstrating a much greater ability to work muscles effectively.
The main reason for this is that a spring/rubber suspended oscillating plates’ movement varies wildly according to the weight and position of the user. Also, without a massive reciprocating weight the loaded oscillation is reduced to an amplitude too small to induce a useful cycle of intermittent muscle loading and relaxation.
Rocking has the advantage of enabling precise control of the vibration frequency and, by shifting position, the ability to change the amplitude of the oscillation.
The quoted operational parameters for most of the sample units were disappointingly inaccurate and misleading.
Our calculations and prototypes showed that to achieve optimum levels of ‘G’ in oscillation, rocking plate mechanics were far superior to suspended spring vibrators or electro-magnetic oscillation (like an audio speaker).
User testing of the rocking prototypes indicated increased muscle fatigue/work during workouts and improved results after a sequence of workouts.
The consensus from testing the new unit is that some workouts could be reduced by as much as 50% while achieving the same benefits. Further tests are required to consolidate what appears to be a significant advantage.
Phase 2 blood tests will provide more detailed evidence of how effective the unit is at enhancing a physical workout.
Weight and size:
The units that get close to providing effective vibration cannot contain that vibration without the addition of significant steel ballast. This takes the overall weight beyond the acceptable threshold for carrying and transporting economically. They are also generally much larger than is required for their function.
**Solving this engineering problem would provide a much more effective, practical product and important IP to protect its’ advantages.
Phase 2
Activities:
Define objectives.
Market, technological and IP re-appraisal.
Brainstorm technological & mechanical innovations, f, USP’s over competition.
Investigations using rig’s and prototypes.
CAD development, mechanism’s and simulations.
Testing to benchmarks.
Development & prototyping.
Mechanical development & prototyping.
Assembly & Testing
Conclusions.
Phase 2 Detail:
We researched for some time to find experts on the effects of exercise who might be a knowledge resource we could contract in to do this specialist work.
We found papers by experts in exercise physiology, musculoskeletal biomechanics and physiological functioning, but very little to shed light on the likely effects of significant vibration during exercise.
Many inventive steps were required to understand and marry the different requirements and elements of this new system to realise a ground-breaking new product.
Weight and size:
The units that get close to providing effective vibration cannot contain that vibration without the addition of significant steel ballast. This takes the overall weight beyond the acceptable threshold for carrying and transporting economically. They are also generally much larger than is required for their function.
Solving this engineering problem would provide a much more effective, practical product and important IP to protect its’ advantages.
Effect
Vibration without shock:
Using a specialist vibration data-logger, we were able to measure acceleration and deceleration in all three axis: x, y, z. This gave us a ‘G’ value for the arresting value in each cycle.
Comparing data from our prototypes with the available samples told us that we were generating suitably high ‘G’ values in an effective range for user testing.
This also confirmed that our novel cam mechanism generates high ‘G’ values while minimising percussive arresting at the end of each stroke; very important in protecting joints, cartilage and tendons.
Weight and size:
The units that get close to providing effective vibration cannot contain that vibration without the addition of significant steel ballast. This takes the overall weight beyond the acceptable threshold for carrying and transporting economically. They are also generally much larger than is required for their function.
Solving this engineering problem would provide a much more effective, practical product and important IP to protect its’ advantages.
We solved the weight and size problem in a number of steps:
Reducing the unit to the minimum footprint for viable function.
Refining the drive train to smooth the reciprocating cycle.
Minimising the rocking platform weight with innovative engineering and FEA simulation. Concentrating the structural platform weight closer to the centre of rotation.
Developing a suspension system for each of the four feet, allowing full operation without additional ballast.
These measures make it possible to reduce the total weight from 25-30kg to 14-17kg. A massive advantage for manufacture, mailing, handling and use!
Financial benefits of undertaking the project.
Research revealed a commercial opportunity for an innovative exercise enhancing vibration plate, if we solve certain technical problems.
Market intelligence research confirmed that this is an area of opportunity not currently fulfilled.
With this knowledge we have invested significant time and resources in developing a new product with massive benefits to the end user, manufacturer and reseller.
The main objective of this work was to create a unique, innovative, cost effective exercise enhancing system to be the first and core product of a new range of similar equipment.
Crucial in this was the creation of protectable IP to give us real market advantage and help us secure funding for production and growth.
*We have submitted a patent application to protect this novel arrangement.
There are few companies active in this growing market, but none with a product of these capabilities and benefits.
Our innovative approach to the product and the business model make a strong commercial proposition.
We have found a company interested in investing in the final development, manufacture, marketing and sales of the new product.
ALL MEDICAL CONSUMER INDUSTRIAL SCIENTIFIC BABY POWER TOOL TRANSPORT