Team 8 Milwaukee Bucks Final Report

Milwaukee Bucks Chair
Project
Spring Semester Report

April 6th, 2017
Connor Swanson Project Manager

Kailee Cox Communications Director
Emily OKelley Pearson Financial Manager
Haley Smith Test Engineer
Garrett Cook Test Engineer
Summer Nicks Systems Engineer
Kyle Russell Systems Engineer
Ellis LaGrone Manufacturing Engineer
Kylie Copenhagen CAD Engineer
Cole Moore CAD Engineer
Client Dr. Troy Flanagan, Director of Performance Milwaukee Bucks
Director Dr. Jack Zable, Professor Emeritus of Mechanical Engineering - University of Colorado Boulder
Table of Contents
Table of Figures ............................................................................................................................... 3
Table of Figures ............................................................................................................................... 4
1 Executive Summary .................................................................................................................. 5
2 Background .............................................................................................................................. 6
3 Problem Statement ................................................................................................................... 7
4 Requirements and Specifications ............................................................................................... 7
5 Fall Semester Accomplishments................................................................................................ 9
5.1 Summary of Important Research ....................................................................................... 9
5.2 Current Bucks Chair ........................................................................................................ 11
5.3 Brainstorming and Prototyping........................................................................................ 12
5.3.1 Initial Ideas .............................................................................................................. 12
5.3.2 First Prototype ......................................................................................................... 13
5.3.3 Second Prototype ..................................................................................................... 14
5.3.4 Third Prototype ....................................................................................................... 15
5.3.5 Fourth Prototype ..................................................................................................... 17
5.4 Milwaukee Visit ............................................................................................................... 19
6 Spring Semester ...................................................................................................................... 20
6.1 Final Design Overview .................................................................................................... 20
6.2 Heating............................................................................................................................ 25
6.3 Manufacturing ................................................................................................................. 30
6.3.1 Outsources Components.......................................................................................... 30
6.3.2 Cushion Construction .............................................................................................. 30
6.3.3 Frame....................................................................................................................... 33
6.3.4 5-Chair Base ............................................................................................................. 34
7 Testing .................................................................................................................................... 35
7.1 Heating Effect on Foam .................................................................................................. 35
7.2 Tipping ............................................................................................................................ 35
7.3 Tear Out Testing ............................................................................................................. 36
7.4 Performance Testing ....................................................................................................... 37
7.4.1 Test Procedure ......................................................................................................... 37
7.4.2 Test Results .............................................................................................................. 38
8 Handoff with New Zealand .................................................................................................... 40
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8.1 Overview ......................................................................................................................... 40
8.2 Future Expectations ........................................................................................................ 40
Appendices .................................................................................................................................... 43
Appendix A: Preliminary Ideas ................................................................................................... 43
Appendix B: Adjustability Kepner-Tregoe .................................................................................. 47
Appendix C: Seat Cushion Assembly .......................................................................................... 48
Bottom Cushion ..................................................................................................................... 48
Seat Back Cushion .................................................................................................................. 50
Appendix D: Manufacturing Procedure ...................................................................................... 59
Appendix F: Inkbird ITC-1000 Digital Temperature Controller User Manual ............................ 60
Visual Representation of Important Keys ............................................................................... 60
Menu Instruction .................................................................................................................... 61
Inkbird ITC-1000 Instruction Manual ..................................................................................... 61
Appendix G: Engineering Drawings ........................................................................................... 62
Table of Figures
Figure 1: Dallas Walton on Standard Bench Chair ............................................................................ 6
Figure 2: Changes in Blood Flow Velocity with Variations in Seating Position and Breathing .......... 9
Figure 3: Popliteal Height ............................................................................................................... 10
Figure 4: Bucks Chair Front View .................................................................................................. 11
Figure 5: Bucks Chair Side View..................................................................................................... 11
Figure 6: CAD Model of Initial Piston Idea .................................................................................... 12
Figure 7: First Prototype Iteration .................................................................................................. 13
Figure 8: Second Iteration with Mesh Back .................................................................................... 14
Figure 9: CAD Model of New Back Attachment System ................................................................ 15
Figure 10: New Back Attachment System ....................................................................................... 15
Figure 11: CAD model of Prototype with Adjustable Back System ................................................ 16
Figure 12: Interface of piston mechanism, steel plate, and back frame ............................................ 17
Figure 13: Back frame and steel plate interface ............................................................................... 17
Figure 14: CAD model of Assembled End-of-Semester Prototype ................................................. 17
Figure 15: High-Resolution Prototype of the Fall Semester ............................................................ 18
Figure 16: Data from Load Cell Testing ......................................................................................... 19
Figure 17: Player Opinion Testing Results ...................................................................................... 19
Figure 18: Schematic of bottom cushion ........................................................................................ 20
Figure 19: Schematic of seat back cushion...................................................................................... 20
Figure 20: CAD model of the frame ............................................................................................... 21
Figure 21: Side schematic of the locations of the frame, heating pads, wood, foam, and vinyl on the
final design ..................................................................................................................................... 21
Figure 22: CAD model of the 5-Chair Base .................................................................................... 22
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Figure 23: FEA for Base with von Mises Stress .............................................................................. 22
Figure 24: CAD model of water bottle holder ................................................................................ 23
Figure 25: CAD model of circuit box ............................................................................................. 23
Figure 26: Water bottle holder on the back on the chair assembly .................................................. 24
Figure 27: 5-chair base assembly..................................................................................................... 24
Figure 28: Simple layout of heating pads in chair ............................................................................ 25
Figure 29: Wiring schematic of heating pad wires after they exit the upholstery but before they enter
the Circuit box ............................................................................................................................... 26
Figure 30: Back and Bottom Inkbird ITC-1000 Digital Controllers in 3D printed Circuit Box ....... 27
Figure 31: Feedback Loop Graph using Inkbird ITC-1000 Digital Temperature Controllers set to
109.4 Degrees Fahrenheit ............................................................................................................... 28
Figure 32: Digital Temperature Controller Wiring Diagram............................................................ 28
Figure 33: Foam pieces necessary for seat back creation ................................................................. 30
Figure 34: Top view of poplar pieces attached to plywood piece .................................................... 31
Figure 35: Front view of poplar pieces attached to plywood piece .................................................. 31
Figure 36: Back view of the seat back and bottom cushions on the frame ...................................... 32
Figure 37: Welded, ground-down frame ......................................................................................... 33
Figure 38: Base drying after being primed and painted ................................................................... 34
Figure 39: Force gage displaying tensile force of 120.7 lbs. without T-nut failure ........................... 36
Figure 40: Percent changes in individual performance measures ..................................................... 38
Figure 41: Averages and standard deviations for all four performance measures ............................ 39
Figure 42: Simple Piston CAD Model ............................................................................................ 43
Figure 43: Raised Position of Piston and Scissor Lift ...................................................................... 43
Figure 44: Lowered Position of Piston and Scissor Lift .................................................................. 43
Figure 45: Power Pedestal CAD Model .......................................................................................... 43
Figure 46: Cybex Prestige Strength VRS ......................................................................................... 44
Figure 47: Cable-Actuated Spring Pin CAD Model ........................................................................ 44
Figure 48: Ribbed Back CAD Model .............................................................................................. 44
Figure 49: Rack and Pinion ............................................................................................................ 45
Figure 50: Motorized Rack and Pinion In a Chair System ............................................................... 45
Figure 51: Counterbalance Diagram ............................................................................................... 45
Figure 52: Pin in Slot CAD Model ................................................................................................. 45
Figure 53: Four Way Piston CAD Model ....................................................................................... 46
Figure 54: Pillar Chair CAD Model ................................................................................................ 46
Table of Figures
Table 1: Force needed to tip 5-chair base and chairs with varying number of players sitting ........... 35
Table 2: Results of MANOVA and ANOVA tests of performance testing data ............................. 39
Table 3: Kepner Tregoe Requirements for Adjustability ................................................................. 47
Table 4: Kepner Tregoe Matrix For Adjustability Methods ............................................................ 47
4
1 Executive Summary
The National Basketball Association as an enterprise had a 2015-2016 revenue of $5.87 billion, with the
average franchise being worth $1.36 billion and allotting $90.93 million a year for their athletes payroll.1 AS
the numbers clearly show, our society awards a lot of time and money to professional sports and the elite
athletes that compete in them. It is therefore of the highest priority for these franchises to protect their most
valuable assets: their players. Teams dedicate massive amounts of their capital to sports medicine, nutrition,
and sports performance causes in order to ensure that their players are always at peak performance. However,
until the beginning of this project, one key aspect of this model was being overlooked. The current sideline
chairs in the NBA are not properly designed for the large frames and often unusual proportions of the
population playing in the NBA, and this has negative impacts on the performance, recovery, and comfort
levels of players on the bench. A sideline bench chair specifically designed to be used by this unique
population of people is necessary to ensuring that these highly-compensated athletes are able to perform to
the best of their ability every night of the season.
After this project was contracted out by Dr. Troy Flanagan, the Performance Director of the Milwaukee
Bucks Franchise, the project team explored numerous design options to improve the ergonomic design of a
sideline chair. This included determining and modeling many possibilities for height actuation and
dimensioning, as well as prototyping the most promising solutions. With these prototypes, the team was able
to collect data on the proper sizing of the different subsystems of the design, as well as opinions on the
comfort of different models. This allowed for a culminating prototype to be manufactured in December of
2016. This design incorporated height adjustment through the use of a non-rotating, pneumatic piston, well
as a heated seat. This prototype was taken to the headquarters of the Milwaukee Bucks franchise to be
demonstrated to Dr. Flanagan and executive members of the franchise, as well as be tested by the players,
yielding positive results.
Through the use of this data and observations made by Dr. Flanagan and the players, the chair frame was
updated and a larger that could house multiple chairs was designed. This allowed for the chairs to be
positioned closer together on the sideline, using the allotted space more efficiently, as well as providing a
channel to hide all the wiring relevant to the heating circuits embedded in each chair. The team spent the
semester manufacturing this final two-part design, and then completed a testing plan to ensure all
specifications were met. Notably, a performance test was performed, allowing us to say with 90% confidence
that the final design maintains metabolic homeostasis better than the chair currently being used on the
Milwaukee Bucks sideline.
Uniquely, this project has been completed in collaboration with a design team at the University of Canterbury
in New Zealand. They were updated by the team on relevant information and current progress, and will be
extending the project until early fall before delivering final specifications and a manufacturing process to the
client. Their main focuses are to: redesign the current base to reduce weight, allow for better wire integration,
increase stability, and design handles to ease in maneuverability; redesign the chair frame to reduce weight and
create a channel to run wires through the frame; explore other possibilities for heating the cushions of the
chair and integrate the heating circuits from both chair cushions into a single circuit; research the possibility
and reliability of electromechanical actuation for height adjustment; and engineer a system for electronic
advertisements on the base. After these improvements are made, the final specifications will be sent to the
client and the bench will be integrated into the stadium, ideally before the start of the 2017-2018 NBA
season.
1 Statista, n.d.
5
2 Background
In the NCAA basketball league, there are 351 Division I teams, 64 Division II teams, and 62 Division III
teams. That equates to well over 18,000 players, many of which are viable options for the NBA. However,
with only 30 teams, 6 conferences, and around 480 players for the 2016 season, you can be assured that only
the most elite college players are making it to the next level. The odds of making it from the NCAA to the
NBA are only about 1.2%. Even tougher is making it all the way from high school through college to the
NBA, weighing in at about 0.03% odds. That is about 3 out of every 10,000 high school players. 2
While several of the players in the NBA come from the college pool, the teams are made up of athletes from
all different demographics. In addition to NCAA feeder players, there are also many international players that
join the sport. While these players can vary greatly in key athletic demographics such as age and weight, the
most astounding is their range in height. These players stand anywhere from 59 to 73 tall, and even taller
on occasion, and weigh between 161 lbs. and 307 lbs. for the 2016 season.
Out of the 30 total teams, only 16 make it to the playoffs with one eventual champion at the end of the
tournament. With such similar talent spread across the league, teams look for any small advantage to set them
apart from the rest. Team owners seek to hire the most qualified athletic trainers, team doctors, chiropractors,
and nutritionists to help make sure their team is running at its best. Coaches have their teams watch film of
their opponents and study statistics and probability of plays. A small edge can possibly mean the difference
between a winning and losing record. However, nearly every team is overlooking a hidden variable.
NBA players currently sit on non-adjustable, normal-sized fold up chairs when they are on the sideline. Being
taller than the average person, the players long legs rest at an unnatural position, requiring their knees to be
bent at angles less than 90. Dallas Walton, a player on the University of Colorado basketball team, is 70.
With his height, he is an excellent representation of the problems experienced by the taller players in the
NBA. As shown in Figure 1, when sitting in an average bench chair, the angle between his lower leg and thigh
are much less than the desired 90.
FIGURE 1: DALLAS WALTON ON STANDARD BENCH CHAIR
After sitting on the bench for extended periods of time, this constricted position often causes below average
performance when re-entering the game. This notion is backed by studies stating that knee angles of less than
90 can restrict blood flow to the legs. As even smallest decline in performance can influence a teams
chances at the playoffs, the period of lowered performance after sitting on the bench is unacceptable.
2
NCAA, 2013
6
3 Problem Statement
The objective of this project is to design a chair that can be adjusted to fit the wide range of heights seen in
the NBA, particularly the Milwaukee Bucks. Several methods of adjustability will be analyzed and evaluated
for their ease of operation and ability to remain inconspicuous. The chosen design must encourage the
desired knee-to-thigh angle of greater or equal to 90 to help increase blood flow to the lower extremities.
Giving the players the ability to adjust the bench chair to their appropriate sitting height will help decrease the
warm-up period for players coming off the bench. To further promote increased performance, heating
elements will be integrated into the chair design. The chair will need to keep the players muscle temperatures
in an optimal range for performance via a safe and non-restricting method. Lastly, the project will include
collaboration with four students at the University of Canterbury, and conclude in a hand-off to these students
at the end of the spring semester. The Canterbury students will work primarily on optimization of the base,
heating systems, advertising, and actuation method.
4 Requirements and Specifications

The requirements and specifications are listed below and given a ranking of either High, Medium, or Low
in terms of priority:
Quick and Easy Adjustability of the Seat Height The chosen design must be quickly and easily
adjustable to the wide range of player heights High
o Chosen method of adjustment must have a stroke of at least 10 to accommodate the player
height range of 53 77
o No assigned chairs
o Must be able to be adjusted in under 10 seconds with little to no effort from the user
Comfort The chosen design must be comfortable for the players and promote improved
performance of players coming off the bench High
o Greater than an average 7.5/10 rating of comfort by opinion data test subjects, where 10 is
Extremely Comfortable and 0 is Extremely Uncomfortable
The main test subjects will be basketball players and students at the University of
Colorado, with higher regard given to the players opinions
o Back of chair tilted back at a 110-120 angle from the thighs
o Minimal, fixed lumbar support, able to accommodate range of lumbar heights
o Knees at a +90 angle
Electrically Powered The chosen design must incorporate electrical components Medium
o 120 V outlet
o No batteries
o Electronically adjustable height, if the reliability is sufficient in comparison to a simpler
method, and client approves (Canterbury team)
Durable and Maintainable The chosen design must be durable enough to endure the wear and
tear of supporting NBA basketball players and all hazards of an NBA bench Medium
o Water/sweat-proof
o Any additional covers will be washable
o Lasts at least 1 full season
o Less than 3 failures a season for an entire set of chairs
o Bobby Knight test - able to be kicked/dropped with no critical damage
o Must accommodate players as tall as 76 and as heavy as 340 lbs.
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Sleek Profile The chosen design must maintain a sleek, compact design while maintaining safety
and advertising standards High
o Cannot protrude into walking space in front of or behind players, coaches, and spectators
o Cannot pose any detriment to the safety of players, coaches, and spectators
o Minimize any technology that draws excessive attention to the chair
Mobility and Storage The chosen design must be easy to transport and store Medium
o Individual chair must weigh less than 30 lbs. or have supplemental infrastructure that makes
the chair easier to move i.e. wheels, removable pieces, etc.
o Multiple chair base must be able to be moved easily by the facility manager and his crew
o Bases and chair must fit in existing storage infrastructure, or have an easily implementable
modification
Cost The chosen design must not exceed the combined budget of the University of Colorado and
the Milwaukee Bucks Low
o Total cost must be less than $10,000
Heating The chosen design must incorporate heating elements High

o Seat cushion and back will both have heating coils
o Must be able to reach the optimal temperature of 43C
o Adjustable heat settings that can be customized by each player
o Separate controls for the seat back and seat cushion heating coils
o Must work in conjunction with the University of Canterbury to optimize heating elements
Footprint The chosen design must fit within the designated space on the sidelines High
o Must not take away prime advertising space for the team or NBA, including the floor
beneath the chair
o Multiple chair base must fit within designated 8 3 x 2 5 space and hold 5 player chairs
o Must leave room for 5, smaller coaches chairs
o Must not protrude into walking space for the trainers, referees, and other personnel
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5 Fall Semester Accomplishments
5.1 Summary of Important Research
At the start of this project, various aspects of chair ergonomics were researched in depth. The most
important topics were the angles of the seat back, seat cushion, and the angle between a persons lower leg
and thighs.
By varying the backrest angle and seat angle, there is a drastic change on the amount of blood flow to the
lower limbs. A study by the Graduate School of Human Sciences in Japan and the Gifu Prefectural Human
Life Technology Research Institute in Japan researched the effects of various backrest angles on the muscle
oxygenation in the right calf. It was found that when sitting in a slight reclining position of 105 from
horizontal there was a significant (p-value <0.05) increase in blood flow to the lower extremities.3 A graph
showing the difference venous blood flow velocity to the lower extremities when sitting position and
breathing is varied is shown below in Figure 2. As the position is switched from upright (90) to a more
reclined position, the blood flow velocity increase significantly.
FIGURE 2: CHANGES IN BLOOD FLOW VELOCITY WITH VARIATIONS IN SEATING POSITION

AND BREATHING
Another study by the Laboratory of Posture and Movement Physiology, University Champollion in France
studied the effects of a forward sloping seat when compared to a tradition horizontal seat. A seat with a
forward slope of 15 increased the leg activity of thigh and lower limb muscles by a factor of 2.5 when
compared to a 0 seat.4 In addition, a positively inclined seat pan positions the spine more naturally than a flat
seat pan, per the Ergonomics Center of North Carolina.5
It is not the position of the seat or back individually that creates the positive effects. Rather, the angle
between the torso and legs, and that of the knees that makes the difference. Both the Ergonomics Center and
other research conducted by Cornell show that both the knees and the trunk must be at angles greater than
90, where 93-120 is recommended for the trunk to thighs. It is important that this position is maintained
regardless of the chair reclining or leaning forward. Both lumbar disc pressure and back muscle activity are
lowest with a supported recline angle of 110-130. In addition, the lumbar support from the backrest is
3
H. Oyama, n.d.
4
A. Hamaoui, n.d.
5
Marion, n.d.
9
optimal at 0.6-2 depth with a backrest height of at least 5 inches of lumbar support and 17-22 inches in
total. Lumbar support is also enhanced by the ability of the seat pan to slide forwards and backwards as the
backrest position changes. This seat pan should be sized so that the back is up against the backrest and there
is no compression at the back of the knee.6
Seat height is a very important aspect of the chair as well, as too low of a seat height will not achieve the
desired angle between the lower leg and thigh. Popliteal height is a critical point of interest for chair designers
because it is the vertical distance between the floor and crease behind the knee.7 This height is labeled below
in Figure 3.
FIGURE 3: POPLITEAL HEIGHT
It is important that a method with a large range of seat height adjustment is chosen to cater to the wide range
of player heights. To determine the necessary stroke, anthropometric data, as well as measurements from
male college basketball players, was analyzed. It was found that the distance from the floor to a mans knee
joint is approximately 30% of his total height. This height was estimated as the necessary chair height. The
height range of 63 to 91 thus translates to a chair height range of 18.9 to 27.3. Therefore, any chosen
adjustment method should have about 10 of stroke to ensure proper joint angles for the athletes.
After discussing this research further with Dr. Rodger Kram, it was determined that while the seat back
should be reclined, an altered seat cushion angle would not be explored with the teams prototypes.
Furthermore, the client expressed he did not want to have an adjustable lumbar support. Thus, to avoid
damage due to an incorrect fixed lumbar, or the hassle of having removable lumbar supports for each player,
an extended seat back no more than 4 away from the top of the seat cushion will provide maximum support
without a designated lumbar region.
6
Cornell University, n.d.
7
Herman Miller, n.d.
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5.2 Current Bucks Chair
The bench seat currently being used by the Milwaukee Bucks NBA team can be seen in Figure 4 and Figure 5
below. Several measurements of the chair are included on the figures. The chair has approximately 4 of
padding in the seat cushion and back. It also has a wide base of 18.5, though the width of the bottom
cushion is smaller than the base at 17. This shows there is room to increase the seat cushion size without
increasing the footprint on the sideline. Another interesting aspect of the Bucks chair is the angle of the seat
back, which is 115. This type of reclining position further supports the ideas seen in the initial research.
These measurements are important to see not only what can be adjusted but also similarities that should be
implemented into future prototypes.
FIGURE 4: BUCKS CHAIR FRONT VIEW FIGURE 5: BUCKS CHAIR SIDE VIEW
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5.3 Brainstorming and Prototyping
5.3.1 Initial Ideas
To meet the requirement of adjustability, 13 unique methods to adjust chair height were examined at the
beginning of the fall semester. The designs were then explored for their pros and cons and compared using
the Kepner-Tregoe method. It was determined that each design would be ranked on its cost, probability of
success, ease of use, weight of the system, aesthetics, and reliability. Each of these criteria were then ranked
on a scale from 0 to 10, with 0 being Not Important and 10 being Crucial. In line with the specification and
requirements, reliability and ease of use were weighted most highly with a 9 out of 10. The probability of
success considered the likelihood that the team could create and successfully integrate the idea into a
functional system, and thus was also weighted heavily at an 8. Due to the desire for an inconspicuous but
elegant system, the aesthetics was given a weight of 7. Lastly, as the weight of the system and cost have more
loose specifications, they were rated at a 4 and a 3 respectively. Each idea was then ranked out of 10 on how
it met each criterion. These values were then multiplied by the corresponding weight of the criteria and then
summed to give an overall score. A table of all the brainstormed possibilities, as well as the corresponding
rationale for each, is included in Appendix A and B. After ranking all ideas, it was determined that a simple
piston design was the best for this application. The preliminary model incorporating this technology is shown
below in Figure 6. While not shown, a lever would be included on the underside of the seat to actuate the
piston. Initial concerns about the rotation of the piston were addressed in later iterations, and an entirely new
base was designed for improved manufacturability.
Frame
Piston
Base
FIGURE 6: CAD MODEL OF INITIAL PISTON IDEA
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5.3.2 First Prototype
For the first prototype, the focus was on testing the base and the lifting mechanism. This prototype was
designed with an H-frame base because it was a simple and elegant design that could be incorporated into all
future prototypes. The lifting piston, salvaged from an office chair, had 12 of stroke, which allowed the
height to be adjusted to accommodate the determined height range. This stroke was later determined to be
too large, and a change to a piston with only 10 of stroke was made. The prototype allowed for the ability to
change the back and seat for testing purposes. The prototype was compared to the Bucks chair to gain
valuable user opinion data regarding comfort and ease of adjustability. All test participants could adjust the
prototype in under the set time limit. On a scale from 0-10 on comfort, the prototype earned an average of
7.2, compared to the current Bucks chair average of 6.5. From comments from test subjects, it was
determined that stability and seat back and cushion comfort needed to be improved. Stability of this iteration
was also something to be improved upon. Lastly, though not an issue with an individual chair, having the
actuation lever on the side of the chair in a sideline setting would be very inconvenient. The first prototype is
shown in Figure 7.
Piston
Actuation Lever
H-frame Base
FIGURE 7: FIRST PROTOTYPE ITERATION
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5.3.3 Second Prototype
For the second prototype, a cylindrical sleeve was welded to the base to provide additional support to the
piston and diminish the wobbling experienced in the first iteration. The actuation handle was moved to the
front of the chair for ease of use, as well as to remove the inconvenience and safety issue of having to adjust
the lever in between seats. Another major change is seen in the seat back. The manufacturing engineer
designed a back-attachment sleeve that allowed for simple exchanging of different seatbacks. This sleeve was
compatible with the CU seat back utilized in the previous prototype and a mesh-based office chair back. The
completed prototype iteration with the mesh-base office chair back is shown in Figure 8.
Mesh Back
Actuation Lever
H-frame Base
Piston
Sleeve
FIGURE 8: SECOND ITERATION WITH MESH BACK
Overall comfort received an average score of 6.8 out of 10, while ease of adjustment was given an 8.5. This
prototype led to the examination of the weight distribution and distances between the seat back and cushion,
both vertically and horizontally. It was determined that the seat back was too far away from the edge of the
cushion, leading to uncomfortable sitting positions, and the lumbar support sat too high up the back.
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5.3.4 Third Prototype
For the third iteration, the same overall design was kept. However, the base footprint was reduced from 20
by 24 to 18 by 18 and the system and manufacturing engineers redesigned the back of the frame to be
adjustable for seat back position testing. Three slots were created to adjust seat back depth to accommodate
thicker back seat cushions. There were also ten slots 1 apart to adjust seat back height, which helped
determine an appropriate height and size for the seat cushion and back. The back mount also could swivel
from a vertical to angled position. The CAD model of this system is shown Figure 9, while the manufactured
system is in Figure 10.
Seat Back
Interface
Back
Attachment
System
New Piston
Mechanism
w/Lever
FIGURE 9: CAD MODEL OF NEW BACK FIGURE 10: NEW BACK ATTACHMENT SYSTEM
ATTACHMENT SYSTEM
Within this iteration, a brand-new piston and mechanism were utilized. The mechanism handle provided
better access and positioning, and the piston was more powerful, decreasing the time required to adjust the
height. As far as seat cushion material, FoamSource suggested that 3 of high-density foam would provide
more support and last longer than 4 of medium density. Since the seat back would not see the same forces
as the cushions, it was deemed appropriate to stay with medium-density foam. After opinion testing, it was
determined that preference for the vertical and horizontal position of the seat back did not vary significantly
with test subject height, with the 4th vertical position and 3rd horizontal position as the preferred settings. A
CAD model of the assembled system can be seen in Figure 11 on the following page.
15
Frame Attachment
to Seat Back
Position 4 Vertically
Adjustment
Lever Position 3 Horizontally
FIGURE 11: CAD MODEL OF PROTOTYPE WITH ADJUSTABLE BACK SYSTEM
Furthermore, extensive testing for heating elements was completed. Initially, five different methods of
heating were explored and ranked using the Kepner-Tregoe method, including gel heating pads, infrared
heating pads, and carbon fiber tape. Upon further investigation and several rounds of opinion testing, it was
determined that just simple heating coils, like ones seen in heated car seats, would be the best method to use.
The thin profile, evenly distributed heating profile, and ability to reach the determined target temperature
made it easy to integrate into seat cushions. This method also had three different settings: Off, Low, and
High.
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5.3.5 Fourth Prototype
The fourth iteration was manufactured with all new materials in preparation to be sent to Milwaukee for
testing in mid-January. These new materials included a non-rotating piston, non-tilting piston mechanism,
heating elements and updated seat and back cushions. The piston connected to the base of the chair cushion
via the piston mechanism, a steel plate and four bolts through the wood for mounting, which can be seen in
Figure 12. The steel plate was welded to the back frame which attached the entire back of the chair to the seat
assembly, as shown in Figure 13. The entire assembly can be seen in Figure 14.
Wood interface
of Seat
Non-tilting
Mechanism
- 20 Bolt (4x) Back Frame
Steel Plate
FIGURE 12: INTERFACE OF PISTON MECHANISM, FIGURE 13: BACK FRAME AND STEEL PLATE
STEEL PLATE, AND BACK FRAME INTERFACE
- 20 Bolt (4x)
Back Frame
Non-tilting
Mechanism
FIGURE 14: CAD MODEL OF ASSEMBLED END-OF-SEMESTER PROTOTYPE

Three inches of medium-density polyurethane foam was used for the seat cushion, while the back cushion
used medium-density polyurethane foam with a 40 radius curvature for optimal contact area and comfort.
These updates were made based on the results of various opinion tests, as well as ergonomics research,
completed in the fall. Due to the grievances of some of the taller test subjects, and the fact that foam
degenerates relatively quickly, it was brainstormed that a thin layer of high-density foam underneath the
medium density foam could help provide more structure. However, after talking to Foam Source, a local
17
foam and mattress company, it was determined that multiple layers of different foam densities are utilized
more with thicknesses greater than 6, such as in mattresses or couch cushions. For this project, one layer of
3 thick high-density foam is sufficient, with water-falling of the front edge to decrease pressure behind the
knees. It has more support than medium density to prevent the bottoming out of some of the bigger players,
and will be more durable. Further testing showed that test subjects indeed preferred the high-density foam
over the medium-density of the same thickness of 3. The simple heating coils chosen in the previous
iteration were installed in the seat cushion 1 below the surface. Both the seat and back cushion were then
outsourced to Gonzalez Upholstery for covering in black vinyl. A picture of the prototype that was sent to
Milwaukee can be seen in Figure 15.
Cushion
w/Heating Pads
Piston
Sleeve
Actuation
Lever
Smaller
Base
Heating
Pad Wires
FIGURE 15: HIGH-RESOLUTION PROTOTYPE OF THE FALL SEMESTER
18
5.4 Milwaukee Visit
During the visit to Milwaukee, testing was completed to ensure the robustness of the design. This testing was
conducted by placing the chair on a large load cell pad, which is normally used for player performance testing.
The weight of each participant was recorded as the static load and then a dynamic load test was performed.
This dynamic load was obtained by having each participant fall or sit on the chair with as much force as
possible. This motion would mimic the max force that might be applied to the chair during a game. The
results can be seen in Figure 16 below.
FIGURE 16: DATA FROM LOAD CELL TESTING
As shown in the figure, three participants were used. The chair functioned well even when subjected to these
severe loads.
During the visit to Milwaukee, opinion data from six Bucks players was also taken to determine how
comfortable the prototype was. Players were asked to rate the comfort of the prototype against that of their
current sideline chairs. These results are shown in Figure 17.
FIGURE 17: PLAYER OPINION TESTING RESULTS
The data shows that the prototype chair brought to Milwaukee, which is labeled CU is superior in each of
the categories; seat cushion, seat back, and aesthetics. A fourth category for which data was recorded was ease
of adjustability. This was not included in the previous image as the current chair is not adjustable whatsoever.
On average, the ease of adjustability of the prototype was a 9.2 out of 10. All 4 of these categories meet the
requirements outlined in the project requirements.
19
6 Spring Semester
6.1 Final Design Overview
For the final design, the seat cushion utilizes 18 by 18 high-density polyurethane foam that is 3 thick. The
corners have a 3 radius, and the front edge was rounded using Dacron insulation and tight upholstery to
avoid excessive pressure behind the knees. The seat back cushion is composed of a medium density of the
same type of foam, and is 19 tall and 17 wide with the same 40-inch radius of curvature. Elaboration on the
specifications and assembly procedures of the cushions can be found in the Section 6.3.2. Schematics of these
cushions can be seen below in Figure 18 and Figure 19.
FIGURE 18: SCHEMATIC OF BOTTOM CUSHION
FIGURE 19: SCHEMATIC OF SEAT BACK CUSHION
Heating was implemented into the back cushion in addition to the seat cushion heating. The pads cover the
entirety of the surface area, and are installed just below the upholstery on the surface of the foam. Additional
details and schematics can be found in Section 6.2.
The frame for the chair has steel plate below the seat cushion, which is in between the wood support of the
bottom cushion and the piston mechanism. The plate supports 1 square tubing on both sides that extend to
20
support the seat back. The tubing for the back is attached via welds at a 105 angle. A CAD model of this
frame is shown in Figure 20. Further details on the frame can be found in Section 6.3.3.
Square
Tubing
Steel Plate
Welded to
Frame
Holes for -
20 Bolts (4x)
FIGURE 20: CAD MODEL OF THE FRAME
This back part of the frame, as discussed previously, is between the wood support of the seat back cushion
and some additional support foam, all of which will be upholstered and anchored to the added wood piece at
the bottom. A schematic of one chair can be seen below in Figure 21.
FIGURE 21: SIDE SCHEMATIC OF THE LOCATIONS OF THE FRAME, HEATING PADS, WOOD, FOAM, AND
VINYL ON THE FINAL DESIGN
21
Instead of chairs with individual bases, a 100 long base that holds 5 chairs was manufactured. There would
be two of these bases on the sideline, such that 10 players can be seated simultaneously. The base is made
from steel square tubing so that the wiring from the heating can be hidden within, allowing for a more
aesthetic design. The base itself weighs 48 lb., while the total weight with 5 bench chairs is 192 lbs. The CAD
model for this base is shown in Figure 22. Further details on the base can be found in Section 6.3.4.
Piston
Sleeves
Holes for
Wires
FIGURE 22: CAD MODEL OF THE 5-CHAIR BASE
To ensure the stability of the base design, finite element analysis, or FEA, was completed in SolidWorks. The
resulting image is shown in Figure 23. No stress above the minimum yield strength of 36,000 psi for A36
ASTM steel was experienced.
FIGURE 23: FEA FOR BASE WITH VON MISES STRESS
22
Another element requested by the client was a water bottle holder. One was designed to have a double
cantilever press fit that would fit on the back of the frame. It was created with a 3D printer using black PLA.
A CAD model of this design is shown below in Figure 24.
Double
Cantilever
Press-fit
FIGURE 24: CAD MODEL OF WATER BOTTLE HOLDER
A final component of the final design was a circuit box to hide and protect the heating circuits. Like the water
bottle holder, it was 3D printed in black PLA. A CAD model of the circuit box itself is shown in Figure 21. It
is attached to the underside of the chair via L-brackets, allowing discrete access to the temperature controls.
This is discussed in more detail in Section 6.2.
Holes for
Hole for Heating
Transformer Control Boxes
Power Cords
Holes for
Sensor Cords
FIGURE 25: CAD MODEL OF CIRCUIT BOX
23
An assembly of the chair with the water bottle holder and circuit box can be seen in Figure 26.
Seat
Cushions
Water Bottle
Holder
Actuation
Lever
Circuit Box
Piston
Piston
Sleeve
Base
FIGURE 26: WATER BOTTLE HOLDER ON THE BACK ON THE CHAIR ASSEMBLY
A CAD assembly of an entire 5-chair base, complete with water bottle holders, wires, and circuit boxes is
shown in Figure 27. The final design utilizes a non-rotating piston and non-tilting mechanism.
FIGURE 27: 5-CHAIR BASE ASSEMBLY
24
6.2 Heating
After showcasing the heating option on the third prototype to the Milwaukee Bucks after the first semester, it
was determined that heating would be added to the back cushion of the chair in addition to the seat cushion.
The pads being integrated are 12-volt DC Crimestopper HSK150 heating pads that are sized at 18 long and
9 wide (see Bill of Materials). Each five-chair base will now utilize ten sets heating pads: two on the surface
of each seat and back. Figure 28 shows a simple layout of heating pad placement in one chair on the 5-chair
base.
Bottom
Heating Pads
Heating
Pad Wires
Bottom
Heating Pads Base
FIGURE 28: SIMPLE LAYOUT OF HEATING PADS IN CHAIR
25
The wires from the seat back heating pad feed through the top 1 tubing frame via a hole in the left back
support piece and into the circuit box. Figure 29 shows this wiring diagram in addition to the placement of
the bottom heating pad wires before they enter the 3D printed circuit box. For the purpose of this diagram,
the wires are shown in red.
Heating Pad
Wires from Back
Cushion (go
through frame)
3D-Printed
Circuit Box
FIGURE 29: WIRING SCHEMATIC OF HEATING PAD WIRES AFTER THEY EXIT THE UPHOLSTERY BUT
BEFORE THEY ENTER THE CIRCUIT BOX
26
The heating pads connect to an AC/DC converter through the female adaptors soldered to the leads where
they exit the upholstery. These ultimately feed into the user control system where the converter boxes are
housed. Two Inkbird ITC-1000 Digital Temperature Controllers are used for this user interface. One
controller is used to control the back cushion heating pad temperature while the other is used to control the
bottom cushion temperature. A picture of the Digital Temperature Controllers in the 3D printed circuit box
can be seen in Figure 30.
FIGURE 30: BACK AND BOTTOM INKBIRD ITC-1000 DIGITAL CONTROLLERS IN 3D PRINTED CIRCUIT BOX
These controllers also integrate the temperature sensors, which are installed within the upholstery. The sensor
in contact with the surface of the heating pad, furthest to the rear of the seat as possible. These sensors are
essential because they provide the feedback for the controllers to regulate the temperature of the heating
pads. If the desired temperature is set to our ideal temperature of 110 degrees Fahrenheit (which is
approximately 43 degrees Celsius) and the sensors measure a value below the set temperature, the controller
box turns on power to the pad to heat it up. Once 110 degrees Fahrenheit is reached, the controller cuts off
power to the pad. The temperature allowance can be adjusted within the controller settings, but is set at 1
degree for the most ideal feedback. A graph that shows how this feedback looks over time can be seen in
Figure 31 on the following page. Notice that when we gathered this data, we were testing using the highest
temperature setting of 110 degrees Fahrenheit which is approximately 43 degrees Celsius.
27
FIGURE 31: FEEDBACK LOOP GRAPH USING INKBIRD ITC-1000 DIGITAL TEMPERATURE CONTROLLERS
SET TO 109.4 DEGREES FAHRENHEIT
With the sensors in the cushions and the wires from the heating pads connected to the Digital Temperature
Controller, the assembly can be connected to any outlet that supplies 120-volt AC power, the power that will
be supplied by the Bucks generator. The power cords feed through the interior of the base tubing, and
extend upwards to the circuit box within a wire housing. The ends of these wires have male and female wire
connectors on the ends, and the opposite connectors come out of the rear of the box. A final wiring diagram,
to assist when setting up these boxes, can be seen in Figure 32 with wires color coded for reference. Note
that one cord has all male connectors while the other has all female; this is to ensure that cross wiring of the
boxes is not possible.
FIGURE 32: DIGITAL TEMPERATURE CONTROLLER WIRING DIAGRAM
28
To ensure the electrical system is safe, a 10-amp fuse is connected before the controller box in case of a
power surge. The control boxes have a 10-amp limit so the fuse protects the control system adequately. In
addition, the Digital Temperature Controller boxes have a safety feature for ensuring a safe temperature level
on the pads. If the sensors read a value over a preset maximum temperature, an alarm will sound to warning
the trainers. The temperature cannot be changed accidentally either. To change any temperature, push down
the S button for three seconds, then select the desired temperature, then push the Power button to set it.
Knowledge of this process can be reserved to the training staff to ensure that they are in sole control of the
pads. Again, further information and a step-by-step guide on how to use the InkBird ITC-1000 Digital
Temperature Controller can be found in Appendix F
Finally, the heating pads will be supplied with power from a pre-existing power generator provided to the
Bucks during home games. This generator can provide 120 volts with a 2000-watt maximum capacity.
Theoretically, all 10 chairs heated all at once will not reach this threshold. To determine if the system met the
requirements of the generator, an AC/DC Clamp Meter with Non-Contact Voltage Detector was used to
measure the current flowing through the live wire that would be connected to an outlet. It was determined
that the total amperage for one chair was approximately .324 amps. Given that 120-volt AC was being
supplied, we were then able to determine that the total wattage per chair is 38.88 watts and for a ten-chair
system, the heating would draw 194.4 watts. This is well below the requirement of 2000 watts, leaving the
remaining capacity for additional electronic components such as an LED advertising board.
29
6.3 Manufacturing
6.3.1 Outsources Components
While several of the components are custom made, others had to be purchased. Below is a list of components
for the final design that were outsourced.
1. Piston: The piston allows us to adjust the height of the chair. It was chosen based on stroke length,
weight, cost, and the non-rotating aspect.
2. Mechanism: The mechanism connects the piston to the frame of the chair. This mechanism fits to
the frame and piston, and is simple in design for easy incorporation and sure reliability.
3. Heating Pads: Heating pads are incorporated into both the seat and back cushions of each chair. The
pads were selected based on their power capabilities, size, and cost.
4. Cushion: The back cushion is currently being upholstered by Gonzalez Upholstery. It includes
heating and the frame, mounted all together within the foam.
6.3.2 Cushion Construction
For the seat back, medium-density polyurethane foam is utilized. The specs were derived from both
ergonomics research and testing. All pieces were first cut using an electric serrated knife to the sizes shown in
Figure 33.
FIGURE 33: FOAM PIECES NECESSARY FOR SEAT BACK CREATION
The wood support also needed to be cut and assembled. This support is made of a 17 by 19 by thick
piece of plywood with the top corners rounded to a 3 radius, and a smaller 15 by 1 by thick piece of
poplar, with the edges rounded to radius to avoid sharp corner cutting through vinyl. The poplar piece is
attached at the bottom of the plywood piece, as shown on the following page in Figure 34 and Figure 35. This
piece was utilized in upholstery as a surface for stapling. A complete procedure for attaching these two pieces
is found in the Appendix C.
30
Plywood
Seat Back
Poplar
Upholstery
Support Piece
FIGURE 34: TOP VIEW OF POPLAR PIECES ATTACHED TO

PLYWOOD PIECE
Plywood
Seat Back
Poplar
Upholstery
Support Piece
FIGURE 35: FRONT VIEW OF POPLAR PIECES ATTACHED TO

PLYWOOD PIECE
The first step in assembly was attaching the 18 by 3 by 1 foam rectangles to the outer sides of the
plywood. The best method for attachment is to use a spray adhesive that works for both wood and glue,
applying to both the top of the wood and the bottom of the foam. After these pieces were glued together,
weights were placed on top of the foam to provide pressure and ensure a secure connection. Once this dried,
the large 17 by 15 piece and the 17 by 4 piece were attached, using the same gluing method as above. It
was found that these foam pieces stuck better when the middle section of was glued to the wood first, and
the side sections connected to the rectangle foam were glued second.
31
High-density polyurethane foam was used for the bottom seat cushion. The specs were again derived from
ergonomics research and testing. The seat cushion is 18 by 18 of 3 thick foam. Each corner is rounded to
achieve a 3 radius. The front edge of the foam is rounded as well to provide a waterfall effect for added
comfort. The effect was achieved using Dacron, an upholstery insulation material. The foam was glued to a
18 by 18 plywood board. This plywood board is thick and has 3 rounded corners. To assemble, the
top of the plywood and the bottom of the foam were sprayed with adhesive and pressed together. Additional
weights can be placed on top of the foam to add consistent pressure and ensure a better connection while the
glue dries.
A CAD model of the cushions on the frame is shown in Figure 36. As discussed earlier in the report, the
frame is upholstered to the seat back cushion and wood support with vinyl.
FIGURE 36: BACK VIEW OF THE SEAT BACK AND BOTTOM CUSHIONS ON THE FRAME
32
6.3.3 Frame
The frame is composed of segments of 1 x 1 square, steel tubing and a 7 x 16 steel plate. Small holes had
to be milled into the plate and 2 of the tube segments. An additional hole is added to the inside of the right
tube segment to allow for wiring to be threaded through. After sandblasting each piece, all the segments were
welded together. Due to the relatively small tubes, the number of welds, and the unique angle of the frame
back, extra precautions were taken with the welds to minimize warping. Once welding was finished, any
rough spots were ground down. The frame was then primed and painted. The welded, ground-down frame is
shown in Figure 37.
Central Support Piece
Welded to Back Frame
Pieces
Back Frame
Pieces
Welded at
115
Plate
Welded to
Frame
FIGURE 37: WELDED, GROUND-DOWN FRAME
33
6.3.4 5-Chair Base
The base is composed of five 1/16 circular steel tube pieces, four 1/16 square steel tube pieces, and one
steel strip. Aside from cutting each tube piece to their specified lengths, the only piece that required
milling was the long 2 by 3 by 98 square tube cornerstone piece. A CNC mill was used to cut five 2
diameter holes in the top surface to fit the pistons into and the piston sleeves. Five diameter holes were
also milled 4 to the left of each larger hole to allow the wires from each seat to flow into the base. An
additional hole was milled on the front face for the input wire to flow out. Once the machining of the
cornerstone piece was completed, the surface of each piece was cleaned and prepped for welding. The smaller
pieces were sandblasted and a hand grinder was used to grind down the weld spots for the 2 larger pieces. No
finishing was needed for painting. Once all the pieces were prepared, they were welded together accordingly
then primed and painted. Finally, several self-adhesive felt buffers were placed on the bottom of the base to
eliminate wobbling and to protect both the surface of the floor and base from scratching. The painted base is
shown below in Figure 38.
FIGURE 38: BASE DRYING AFTER BEING PRIMED AND PAINTED
34
7 Testing
7.1 Heating Effect on Foam
The purpose of this test was to determine if the high temperatures of the heating coils had any negative
effects on the high-density foam used in the seat back and cushion. This could include charring, melting, or
ignition of the foam. The following is the test procedure used for the heating safety test:
1. Turn on heating coils at highest setting and leave on for two and a half hours (higher end of average
NBA game duration)
2. Use thermal imaging camera to measure surface temperature of upholstered seat
3. Place additional set of heating coils within foam and measure temperature with thermal imaging
camera
4. Document any effects of heat on foam
From the testing completed, there does not appear to be any noticeable signs of distress on the fabric or
foam after prolonged exposure to heating. When experimenting with other heating pads, there appeared to be
some singeing of the polyurethane and Dacron insulation, so those methods were ruled out. Testing was also
completed on the appropriate heating pads with the addition of a test subject sitting to simulate the heat
transfer in a game situation. No damage to the chair materials was seen.
7.2 Tipping
Tipping is one of primary concerns for this chair. Because these chairs will be much taller and larger than the
average chair, it will be easier to tip due to the larger moment arm in the back, which can cause larger torque
when someone leans back. From calculations made earlier in the semester, it was determined that elongating
the supports of the base backwards would increase the force needed to tip the chair, provided nobody is
sitting in the chair. With the creation of the 5-chair base, and considering the weights of the players, the force
needed for tipping only increases due to the added weight. Tipping calculations were done for the final base
design to determine the impulses the system can handle. The results for the force needed to tip the bench are
shown in Table 1 below.
TABLE 1: FORCE NEEDED TO TIP 5-CHAIR BASE AND CHAIRS WITH VARYING NUMBER OF PLAYERS SITTING
No persons 43.13 lbs.

1 person 93 lbs.
2 persons 142.87 lbs.
These calculations were done assuming a force location at the very top of the seat back, an absolute worst case
scenario force application. A more realistic tipping calculation was also done with the location of applied force 5
inches lower on the seat back. This yielded a result of 331.7 lbs. needed to tip the bench with 5 players. Though
tests and calculations show promising results, it is difficult to perfectly simulate the forces that could tip a chair.
When a player sits in a chair, the center of mass does not move much horizontally, but the external force can be
distributed in several different ways. The player can push off the ground with his toes, which can push back on the
back cushion of the chair with a positive moment, However, when a player pushes on the back cushion, he also
can push down on the seat cushion of the chair with his thighs, which can result in a significant counteracting
negative moment. It is difficult to accurately simulate this effect, so calculations are largely based around the worst-
case scenario, where there is not a counteracting external force on the seat cushion. The modifications made are
assumed to provided enough stability to prevent any player from tipping over under most reasonable
circumstances.
35
7.3 Tear Out Testing
The purpose of this test was to determine a replacement material and internal thread fastener combination for
the backing of the seat and back cushions. However, early in the semester it was determined that the T-nuts
for the most recent prototype were inserted incorrectly, causing them to tear out of the wood easier and more
frequently. If installed correctly, the -20 T-nuts are more than effective for this application. To demonstrate
this fact, one T-nut was properly installed with an appropriately sized bolt into attest piece of wood. A digital
force gage was then attached to the bolt and a perpendicular force was applied. The load was applied multiple
times, with a maximum force of 120.7 lbf, and there was no evidence of the T-nut tearing out. This force
application is shown in Figure 39.
FIGURE 39: FORCE GAGE DISPLAYING TENSILE FORCE OF 120.7 LBS. WITHOUT T-NUT FAILURE
In the final prototype, any perpendicular force is distributed amongst 4 T-nuts, which only increases the
overall tear-out strength of the system.
36
7.4 Performance Testing
One of the main goals of the project as identified by the client was to create a bench chair that is shown to
maintain metabolic homeostasis better than current bench chairs, with attention paid to leg muscle
temperature. A testing plan was created to compare the performance results of athletes comparing the
Milwaukee Bucks current bench chair to the prototyped chair. The testing plan included vertical jump and
shuttle run tests to determine the effect of the ergonomic design and inclusion of muscle heating on athletic
performance. The test was completed with the Bucks chair as a baseline, and compared to the results with the
prototype chair. The detailed testing procedure is as follows.
7.4.1 Test Procedure

DAY ONE - CURRENT BENCH CHAIR
1. Warm Up: Complete a light jog 5 times around the basketball court to warm up
2. Stretch: Stretching for 5 minutes
3. Shuttle Run: Starting from the baseline, run to the free throw line (touch with hand), run back to
baseline, run to center court, then run back to the baseline to finish. Record the players time
4. Vertical Jump: After a 10 second break, perform 3 vertical jumps with 5 seconds of rest between
each jump. Record the players height on each jump using a Vertec vertical jump apparatus
5. Skin Temperature: Using the temperature gun, measure the temperature of the bare hamstrings.
6. Heart Rate: Record the number of heartbeats over 10 seconds (taken at the neck).
7. Normal Sit: Sit in the regular, unheated chair for 10 minutes
10. Shuttle Run: Repeat the shuttle run. Record the players time
DAY TWO - PROTOTYPED HEIGHT-ADJUSTABLE, HEATED CHAIR

1. Heat Chair: Let chair heat up to max power.
2. Set Seat Height: Have the participant adjust the height of the adjustable chair to a comfortable
height where their legs are at 90 degrees.
3. Warm Up: Complete a light jog 5 times around the basketball court to warm up
4. Stretch: Stretching for 5 minutes
5. Shuttle Run: Starting from the baseline, run to the free throw line (touch with hand), run back to
baseline, run to center court, then run back to the baseline to finish. Record the players time
9. Normal Sit: Sit in the height-adjusted, heated chair for 10 minutes
12. Shuttle Run: Repeat the shuttle run. Record the players time
Note that subjects were randomly assigned to a rest chair for their first testing day to ensure that if learning
the test procedure influenced the subjects performance, this would be normalized.
37
DATA ANALYSIS
1. Load subjects performance testing data into Excel spreadsheet.
2. Multiply heart beats data by 6 to get heart rate.
3. Calculate average vertical jump height for each three-trial step.
4. Calculate percent improvement in shuttle run for day one and day two.

100%

5. Calculate percent improvement in average vertical jump for day one and day two.

100%

6. Calculate percent change in heart rate for day one and day two.

100%

7. Calculate percent change in skin temperature for day one and day two

100%

Complete a MANOVA test with all data, and individual ANOVA tests for each performance statistics using
the Real Statistics Resource Pack for Excel
7.4.2 Test Results

7.4.2.1 Graphs for Individual Performance Measures
Below in Figure 40 are the results from the 16 test subjects in the four performance measures. The dark green
data corresponds to the prototype chair, while the light green data corresponds to the current Bucks chair.
FIGURE 40: PERCENT CHANGES IN INDIVIDUAL PERFORMANCE MEASURES
Looking at the data, one can see a large variation in the data. Performing a statistical analysis was necessary to
determine the significance of the data.
38
7.4.2.2 Descriptive Statistics for All Performance Measures
To begin looking at the data, the averages and standard deviations for all four performance measures were
calculated and plotted on the same graph. The resulting figure is shown below in Figure 41.
FIGURE 41: AVERAGES AND STANDARD DEVIATIONS FOR ALL FOUR PERFORMANCE MEASURES
The descriptive statistics depicting the results for each performance measure indicate that there may be a
statistical difference between percent change in performance of an athlete when they sit on our prototype
chair for a 10-minute rest period compared to when they sit on the Milwaukee Bucks current bench chair. To
determine this, the null hypothesis that there is no statistical difference between the performance after resting
in the prototype chair when compared to the performance after was created. This hypothesis was tested using
a MANOVA test, as well as individual ANOVA tests for each performance measure. The conclusions drawn
are in Table 2.
TABLE 2: RESULTS OF MANOVA AND ANOVA TESTS OF PERFORMANCE TESTING DATA
Hypothesis Test Confidence Interval p-value Conclusion

One-way MANOVA 0.1 90% 0.011 Statistically significant
One-way ANOVA - Shuttle Run 0.1 90% 0.008 Statistically significant
One-way ANOVA - Vertical Jump 0.1 90% 0.086 Statistically significant
One-way ANOVA - Skin Temperature 0.1 90% 0.019 Statistically significant
One-way ANOVA - Heart Rate 0.1 90% 0.019 Statistically significant
From the hypothesis tests, we can conclude that there is a statistical difference between the samples groups
when comparing all the performance measures as well as testing them each individually. Therefore, we can
state with 90% confidence that our prototype bench chair maintains metabolic homeostasis better than the
Milwaukee Bucks current bench chair.
39
8 Handoff with New Zealand
8.1 Overview
The New Zealand Senior Design team from University of Canterbury began working with the University of
Colorado Senior Design team in the beginning of February 2017. The initial meetings focused on getting the
New Zealand team up to speed with the CU teams research, prototypes, and current progress throughout the
past semester, as well as the Milwaukee visit, and further spring semester progress. Recent meetings have
provided more insight into the final prototype, and working through the plans for work for the New Zealand
team to continue with moving forward. In addition, all members of the New Zealand team have been given
complete access to the project Google Drive folders and the GrabCAD website that contains the SolidWorks
files.
8.2 Future Expectations
The Colorado team has outlined some specific goals for the New Zealand team to focus on:
Base
Weight Reduction - The current 5-chair-base weighs about 48 lbs. This makes up about of the
total weight of the entire bench (about 192 lbs. total) - goal is 50% weight reduction
o Lighter material - The whole base is made of steel currently. Steel is very strong and very
machinable, but it is very heavy.
o Eliminate or alter the back bar - The bar weighs about 10 lbs. and does not add much to the
overall design.
o Reduce piston sleeve size - The sleeves are very heavy and do not bear much load.
o Change the feet - The feet most likely will not have wiring running through them, so hollow
tubing is not needed. The feet will bear a lot of stress though, so be careful.
Better Wire Integration- Despite our intent, it is still difficult to integrate and adjust the wiring and
circuit elements in our current design. Particularly, we still have a lot of interference between the
bottom of our pistons in the base and the wires running through the base. It is also difficult to access
and adjust the wires inside the base.
o Increase the diameter of holes in the base - allow for easier insertion of wires
o Wider main base piece (piece below piston and piston sleeve) - allow wires more room to slide past
piston
o Separate hollow piece of tubing to house the wires - eliminates interference of wires with the piston
o Increase size and number of holes for feeding wires - especially for furthest chair down line
Stability- There is a small amount of wobble and shakiness in our base due to the warping of our
welds. It is difficult to get 100 inches of metal with protruding feet to sit flat, even with felt pads on
the bottom. Plus, the floor has to be perfectly flat for no wobble, which is not always the case.
o Threaded holes in base w/adjustable feet - allows each part of the base to be adjusted separately to
counteract any manufacturing/floor defects
Handles- The bench is very heavy, and it would be nice to have a clear place to grab and lift it. It
would be much easier to lift the bench by the chairs rather than bending all the way down and
picking it up by the base.
o Handles added to outside of base - might be the easiest to grip, but could take up space between
bench sets and possibly decrease the aesthetic of the bench
o Handles cut into the base - more readily hidden, but would need to be lined with rubber or some
other easily gripped material to protect lifters from sharp edges of the manufacturing steel,
as well as help increase the grip
o Removable handles - would provide the support of handles manufactured on the outside of the
base, but allow for removable to maintain appearances
40
Frame
Weight Reduction- Consider some of the same possible weight reduction elements that we
mentioned for the base. However, the stress is a lot more unpredictable in the frame, so be careful.
Any weight savings in one chair is compounded for 5 chairs.
o Lower gage steel tubing - already a fairly small gage of steel, so extensive FEA analysis would
need to completed to determine if this is viable
o Lower gage steel plate - same issues as above; extensive FEA is needed
o Shorter back pieces - frame is already upholstered, surrounded by foam, and supported by the
wood piece in the seat back, so perhaps the steel pieces do not need to be as tall
o Alternative materials - investigate lighter materials (lighter steel, fiberglass), will need new FEA
and tipping calculations to ensure viability
Wires and Hide-All Integration- Troy made it clear that he wants as little attention as possible drawn
to the bench, particularly to the wires and electronics. Conceal the circuit elements as much as
possible.
o Placement of wire holes - the hole in our final product was retrofit once the manufacturing was
completed. Looking at the design and having an idea of how the wires will behave might
give better insight earlier on in the design process and lead to a better location for these
holes
o Way to secure loose wires tightly to the base - currently the heating wires are taped along the
underside of the base. If some sort of clip or other securing mechanism could be added to
hold the wires, it would be a much more elegant solution
o Hide-All Solution: While current wire hiding methods are adequate, a final solution to hide all
wires more elegantly is needed.
Plastic vent tubing - we have looked into air duct piping, which was too stiff for
our purposes. We didnt have time to try and integrate it, but we also looked into
RV sewer pipe, which seemed to be more flexible, but may not be the most elegant
solution
Fabric skirt - loop of fabric surrounding the piston. Will droop on the ground
when the chair is at its lowest position, which might not look the best, but it will
hide all the wires very effectively and you could allow for slack in the wires
Hiding wires behind the piston sleeve - with the advertising signs on the front,
delicately placing the wires directly behind the piston and piston sleeve could be
adequate. Could run into problems with slack in the wires, however
Telescoping apparatus - this option is seen in a lot of office chairs and could be
sourced from a chair company, 3D printed, or fabricated out of 2 different
diameters of PVC pipe
41
Heating
Better female/male connector wires: The current connector wires work and are not noticeable but
we fear they may become worn. Switching to more durable connecting wires may be useful. They
also have a very snug fit, which is good in theory, but when disconnecting there is a potential to rip
the connectors off of the wires. Look at wiring harnesses.
Explore other alternatives: Are there any benefits to pulse wave modulation (PWM)? Is the current
circuit reliable and effective? Can we better meet Troys vision for temperature control (3 settings,
more hidden/discrete control)? Can the 2 controllers be combined into one? (see next)
Consolidating wires coming out of Digital Temperature Reader Boxes: As of now, we have one wire
coming from each of the two boxes that are then plugged into the wall. To eliminate number of
wires needed to go into a power strip, NZ could try to connect both the wires coming out of the
Digital Temperature Reading boxes into one such that there was only one outlet plug per chair. To
do this, NZ should start by soldering the green, white and black wires together that come out of the
box. One could then put these soldered wires into the female and male/connector wires and that
would then be connected to the plug-in wire. However, you should still perform some safety testing,
measure the current of the hot wire coming into the boxes and make sure that consolidating this
doesnt affect the temperature. If it does, then the sensors would need to be re-calibrated.
Heat Control Box: Troy has expressed his desire to move from 2 control boxes to 1 single box that
controls the heating pads. The current heating box is 3D printed and we will need a more long term
solution for the final chair.
One single heating pad as opposed to two: If possible, it may be worth looking into manufacturing a
new heating pad that would fit the dimensions of the chair exactly. Although what we have does
cover most of the chair, the heating pads have edges that overlap when placed onto the cushion
where no heat reaches. Manufacturing our own would help increase uniform heating dissipation
throughout the bottom and back.
Electro-mechanical Actuation
Use CO previous research: If the NZ students look at the CO presentations and reports from
August-November, there was a lot of valuable research conducted into alternative actuation methods.
Determine Plausibility: Determine if there is an electronic actuation method that is plausible based on
cost, weight, stroke, size, effectiveness, reliability, etc.
Consider effects on base design with different actuation method
Advertisement
Start from scratch: We did not give much thought to advertising while working on the bench,
however, it is a high priority due the money that it can bring to the organization. Advertisement has
to be beneath the seats and on the backs as well. The more noticeable it is, the happier their sponsors
will be. Weight will have to be considered, if advertisements are too heavy or not removeable this
could cause a problem.
o How will it be programmed/changed?
o How will it attach to the frame/base?
o What are the additional power/weight costs?
42
Appendices
Appendix A: Preliminary Ideas
Name Picture Summary Pros and Cons
Simple Piston A singular piston that Pros:
is elevated from the - Handle beneath seat
ground to provide - Extra height due to
stability and give the higher datum of piston
stroke distance such - Low profile
that any sized NBA - Easy and smooth
player could adjust to adjustability
their desired height.
Cons:
- Players have to stand
to adjust
FIGURE 42: SIMPLE PISTON CAD - Difficult to reach same
MODEL height every time
Piston and A single piston Pros:
Scissor Lift supported by a scissor - Can have handle
lift on either side. The beneath seat
piston allows for easy - Uses adjustable piston
actuation and desired and scissor lift to
stroke for the maximize strength
necessary height range, - Similar aesthetic design
while the scissor-lifts to current NBA bench
provide extra stability seats
FIGURE 43: RAISED POSITION OF
- All mechanical to
PISTON AND SCISSOR LIFT improve reliability
Cons:
- Higher weight limit
due to extra support
- Players have to stand
to adjust
- Difficult to reach same
height every time
FIGURE 44: LOWERED POSITION OF
PISTON AND SCISSOR LIFT
Power Pedestal This power pedestal is Pros:
similar to that of a - 6 of stroke
pneumatic but is - Sturdy
heavier duty and was - Easy to use lever to
considered because it adjust height
was a well-known
technology and is Cons:
relatively easy to adjust. - No weight limitation
known
FIGURE 45: POWER PEDESTAL CAD - Base must be installed
MODEL on chair to attach power
pedestal
43
Cybex Prestige Workout chairs are Pros:
Strength VRS highly used and have - Simple actuation of
Inspiration to be durable. This one adjustment lever
would have simple - Lever is below the seat
actuation with a lever and is hidden but has
below the seat and easy access
would glide smoothly - Able to purchase kit
up and down. More from Cybex
important, this device
can be purchased Cons:
therefore we know it is - Complex internal
reliable. assembly
- Could run into some
issues given it is another
FIGURE 46: CYBEX PRESTIGE companies product
STRENGTH VRS - Limited on variability
which could cause
problems later
Cable-Actuated Height adjustment is Pros:
Spring Pin achieved through two - Can have handle
inner legs with holes beneath seat
for the spring-loaded - Can customize height
pins to lock into. adjustment range
When handle beneath - Two supports increase
seat is squeezed, the force and distribute load
cables running through
the chair are pulled, Cons:
releasing the pins from - Handle could be
the inner legs and difficult to use
FIGURE 47: CABLE-ACTUATED
SPRING PIN CAD MODEL allowing the chair to be - Heavier chair due to
adjusted. two supports
Ribbed Back The ribbed back is Pros:
based off current - Used in workout
height actuations in equipment
chest and shoulder - Inexpensive
press workout - Low profile
machines. We can
disengage the Cons:
cylindrical shafts - Players have to stand
(green) on the back to adjust
which will allow it to - Difficult to get best
move up and down. height every time
- Might not get
adjustment shafts
FIGURE 48: RIBBED BACK CAD aligned properly
MODEL (slipping)
- Only allows for
adjustment of seat (back
is stationary)
44
Motorized Inserting a small motor Pros:
Rack and inside of the legs of the - Easy adjustability
Pinion chair could work for - Possibility for pre-
height adjustment. programming
Versions of this are
used to adjust the Cons:
height of office desks. - Expensive
For the motors used in - Motors/coding can get
office desks, they can complicated
be raised at two inches - Higher chance of
FIGURE 49: RACK AND PINION per second. failure
- Weight limit unknown
FIGURE 50: MOTORIZED RACK AND

PINION IN A CHAIR SYSTEM
Counterbalance Features compression, Pros:
tension, or torsion - Easy to hide and
springs to resist integrate with added
downward force technology
(gravity) and provide - Easy and smooth
lift assist for user height transitions
control.
Cons:
- Highly complex,
intricate system
FIGURE 51: COUNTERBALANCE - Still would need
DIAGRAM pistons to raise chair
Pin-in-Slot This is the simplest Pros:
mechanical idea that - Can customize height
would be the most adjustment range
reliable option. - Simple and self-
However, the pin and explanatory actuation
slot would be awkward - can raise the entire
to change during the chair not just the seat
game.
Cons:
- Must stand when
adjusting
- Location of the pin is
out of the way
- Pin location might be
inaccessible in a side by
side
FIGURE 52: PIN IN SLOT CAD
MODEL
45
Four-Way The four-way piston Pros:
Piston would ensure that no - Automatic and
matter what weight uniform heating
limit of a practical adjustment
human, the chair - similar design to
would be safe and current NBA bench
sturdy to use. The chairs
problem with this is - could have the
that it may be hard to potential for
raise all four pistons at programmed
the same time. customization
Cons:
- Higher weight limit
FIGURE 53: FOUR WAY PISTON CAD due to four supports
MODEL - complex system with
higher chance of failure
Pillar Chair The pillar chair is Pros:
based off a pin-in-slot - Custom seat and
actuation system where backrest height
the backrest and seat - Very stable system
are attached separately
to a pillar. Cons:
Unfortunately, this - No resemblance of
design has no current chairs
resemblance to current - hard to adjust height
NBA seats.
FIGURE 54: PILLAR CHAIR CAD

MODEL
46
Appendix B: Adjustability Kepner-Tregoe
TABLE 3: KEPNER TREGOE REQUIREMENTS FOR ADJUSTABILITY

Probability
Requirements Cost Ease Weight Aesthetics Reliability
of Success
0 (Not
important) - 10 3 8 9 4 7 9
(Crucial)
TABLE 4: KEPNER TREGOE MATRIX FOR ADJUSTABILITY METHODS

Probability
Design Cost Ease Weight Aesthetics Reliability TOTAL
of Success
Seat Piston 9 9 8 7 7 8 320
Piston and
9 9 7 6 7 8 307
Scissor Lift
Power Pedestal 7 8 8 5 8 8 305
Cybex Prestige
6 8 8 7 7 8 303
Strength VRS
Cybex Eagle
3 7 9 5 7 8 287
NX
Cable-Actuated
6 8 7 5 8 7 284
Spring Pin
Ribbed Back 7 7 6 6 8 7 274
Motorized
Rack and 3 6 9 5 8 5 259
Pinion
Counterbalance 4 3 8 5 7 7 240
Pin-in-Slot 7 8 4 6 5 5 225
4-Way Piston 2 5 10 4 5 4 223
Pillar Chair 9 9 2 2 1 9 213
47
Appendix C: Seat Cushion Assembly
Bottom Cushion
Bottom Seat Cushion Specifications
High density polyurethane

18 in (0.4572 m) x 18 in (0.4572 m) x 3 in (0.0762 m) thick
48
Bottom Seat Cushion Assembly
1. Cut a piece of plywood to be 18in by 18in with a 3 in radius on all corners (see dimension
specifications)
2. Using a 5/16 drill bit, drill 4 holes corresponding to the piston mechanism and frame pattern. A drill
press with a stencil will yield the best results
3. Install - 20 T-nuts into the side that will be covered with foam. Hammer into drilled holes and
apply wood glue for extra support.
4. Spray adhesive on the wood and attach the bottom seat foam piece. Place weights on top of the
foam and leave for at least 20 minutes to allow the wood and foam to form a better connection
5. Attach the heating pads side by side on the top of the cushion using the adhesive strips that comes
on the heating pads
6. Add a thin layer of Dacron on top of the heating pads for support/comfort
7. Bottom cushion is now ready for professional upholstery
49
Seat Back Cushion
Seat Back Cushion Specifications
Medium density polyurethane

19 in (0.4826 m) high x 17 in (0.4318 m) wide x 3 in (0.0762 m) thick maximum
40 in (1.016 m) curvature: 2 in (0.0508) thick - inside, 3 in (0.0762 m) thick outside
50
Seat Back Wood Support Pieces
1 - 19 in (0.4826 m) high x 17 in (0.4318 m) wide x in (0.00635 m) thick (plywood) with 3 in (0.0762 m) radius corners
1 1 in (0.0254 m) high x 15 in (0.3810 m) wide x in (0.00635 m) thick (poplar) with in (0.00635 m) radius corners
51
Seat Back Support Assembly
1. Cut plywood to be 19in by 17 in with 3in radii on the top corners (see dimension specifications)
2. Using a wood drill press and a 5/16 drill bit, drill holes corresponding to frame pattern for the -20
T-nuts. The hole placement should ensure that the seat back cushion does not prevent proper
placement of the bottom cushion. There should be 1-3 of space between the top of the bottom
cushion and the bottom of the seat back.
3. Cut poplar piece to be 1in by 15in by in with in radius corners, which helps prevent sharp corners
poking through the fabric.
4. Install T-nuts into the plywood onto the side that will be covered with foam. Hammer into drilled
holes and apply wood glue for extra support.
5. Drill 4 pilot holes through both pieces of wood, making sure the poplar piece is centered on the
plywood and flush to the side that will be covered in foam. The diameter of the bit should be smaller
than the screws used.
6. Re-drill over the 4 holes in the poplar piece with a drill bit approximately the same size as the outer
diameter of the screw.
7. Using a countersink drill bit, countersink the 4 holes in the poplar piece to allow the heads of the
screws to be flat to the poplar surface.
8. Utilizing clamps, apply wood glue to the common surfaces of the poplar and plywood pieces and drill
in the four screws.
9. Keep clamped for approximately 30 minutes to allow the glue to set for the best hold.
52
Seat Back Cushion Pieces
2 3 in (0.0762 m) wide x 18 in (0.4572 m) long x 1 in (0.0254 m) thick

53
Seat Back Cushion Assembly
1. Place two slender strips of 1 in (0.0254 m) foam on either side of the plywood, making sure the foam
is flush with the wood at the bottom. Add spray adhesive and weight down to ensure adequate
adhesion.
54
2. Place the thinner 2 in (0.0508 m) thick piece along the bottom of the plywood. Glue the
foam down in the middle first, utilizing weights to apply pressure, then glue the outsides
down on top of the existing slender pieces. This is what gets the curvature of the seat back.
55
3. Using the same technique method in step 2, glue down the large 17 in (0.4318 m) by 15 in
(0.3810 m).
56
4. Cut extra foam off the top corners to round them, and apply the heating pads side by side.
57
5. Add additional foam to fit on the backs and sides, covering up any exposed bolts, frame
steel, or wood pieces that could rub the upholstery fabric. Adding this foam also helps fill in
the fabric sleeve.
58
Appendix D: Manufacturing Procedure
1) Buy materials
a) Reference Bill of Materials at end of Report
2) Manufacture the Frame
a) Cut individual pieces to size (see engineering drawings in Appendix G)
b) Mill holes for wiring (see engineering drawings in Appendix G)
c) Weld individual pieces together
i) Ensure perpendicularity by using a height gauge that is locked on a 90-degree datum. These can
be found online but most welding shops will also be equipped with this type of equipment.
3) Manufacture the Base
a) Cut individual pieces to size (see engineering drawings in Appendix G)
b) Mill holes in 2x3-feet, 98-inch square steel tube for wirings coming down from frame (see
engineering drawings in Appendix G)
c) Mill holes in 2x3x98-inch square steel tube for piston sleeves (see engineering drawings)
d) Set 2-inch OD piston sleeves perpendicular to the top of 2x3x98-inch square steel tube and then
weld on (see engineering drawings in Appendix G)
e) Take 2x1x20-inch steel tubes and weld them to each end of the 2x3x98-inch square tube (see
engineering drawings in Appendix G)
f) Finally, weld 1x2x98-inch onto back of already assembled base (see engineering drawings in
Appendix G)
4) Fabrication of Seat Cushions (see individual assembly guide in Appendix C)
59
Appendix F: Inkbird ITC-1000 Digital Temperature Controller User Manual
Visual Representation of Important Keys
Below is a diagram showing the functions of each button when operating the Inkbird ITC-1000
Digital Temperature Controller. Knowing these keys will help the end user program and set desired
values for the 12 V DC heating pads. Note that no cooling pads were used in the latest prototype
but the device can connect such. Setting codes and instructional use is found below this diagram.
60
Menu Instruction
When the set temperature is degrees Celsius (FC C)
When the set temperature is degrees Fahrenheit (FC F)
Inkbird ITC-1000 Instruction Manual
1. Turning on device:
a. When off, press and hold the Power Key for more than 1 second to turn on the
controller.
b. When on, press and hold the Power Key for more than 3 seconds to turn off the
controller.
2. Parameter Setting:
a. To change parameters, hold S for more than 3 seconds to enter set mode. The
first item on the menu is TS.
b. Press or keys to move up or down the menu to display different menu
codes
c. Press S to enter the parameter setting of current menu code. (The parameter value
will start to flash).
d. Press or keys to adjust the parameter value under the current menu code
e. Press the Power Key to save the parameter modified value.
f. To exit the parameter setting and change a different menu code, press the S key.
3. User Manual PDF
4. For more instructions and information on the Inkbird ITC-1000 Digital Temperature
Controller please reference the following PDF:
http://pmod79883.pic31.websiteonline.cn/upload/2016_cq2r.pdf
61
Appendix G: Engineering Drawings
62
63
64
65
66
67
68
69
70
71
72
Team # 8 Revision Table Date Initials *prices don't include tax
Sponsor: Milwaukee Bucks A 11/29/16 EOP
Financial Manager: Emily Pearson B 5/3/17 EOP
Per Chair Cost Estimate: $898.64
5-chair Base $534.50
5-chair base + 5 chairs $5,027.70
Quantity (per Labor Time

Part Number Brief description of item Price Estimate (US $) * Vendor Serial Number via Vendor Labor Costs ($/hr) Total Labor Cost Business Purpose Additional Notes
chair) (hr)
100 Heavy Duty Non-Rotating Piston 1.00 $52.98 Chairpartsonline S6142 Piston used for height actuation Had to call vendor because no non-
rotating piston available online; phone
number is 616-608-9088
200 Mechanism 1.00 $24.98 Chairpartsonline S4650-A Attaches to piston and have a lever
that allows the piston to move up or
down
300 Raw Base Assembly Manufacture
300-1 2" x 3" x 98" 14 gauge rectangular 1.00 $24.94 Milwaukee Central $20.53 2 $41.06 Steel tubing to make a secure H- Price based on Boulder vendor; Link
steel tube Steel & Wire Frame base to a potential Milwaukee Vendor
Company included
300-2 1" x 2" x 20" 16 gauge rectangular 2.00 $6.06 Steel tubing to make a secure H-
steel tube Frame base
300-3 1" x 2" x 98" 16 gauge rectangular 1.00 $10.92 Milwaukee Central $20.53 1 $20.53 Steel tubing to make a secure H-
steel tube Steel & Wire Frame base
Company
300-4 1" x 2" x 9.5" 16 gauge rectangular 1.00 $2.01 Steel tubing to make a secure H-
ASTM A36 steel tube Frame base
300-5 2" ID ASTM A36 steel round tube 5.00 $22.37 Milwaukee Central $20.53 1 $20.53 Steel tubing to make a secure H-
at .154 wall thickness and 10" tall Steel & Wire Frame base
Company
300-6 1/4-20 set screws, 1/2" long 10.00 $9.80 Home Depot (Internet#) 204274231 Set screws to secure piston such
that it doesn't rotate
300-7 Rust Clean Metal Primer 4.00 $15.04 The Home Depot (Internet#) 100143442 $17.31 10 $173.10 Primer to paint the steel metal base Will need to sand the metal first which
is included in the labor costs for the
metal pieces
300-8 Rust Flat Black Spray 4.00 $15.04 The Home Depot (Internet#) 100670370 $17.31 10 $173.10 Black spray paint to go over primer
400 Raw Frame Assembly
400-1 1" x 1" X 72" 16 gauge square 3.00 $17.35 Milwaukee Central Steel tubing to make main chair
ASTM A36 steel tube Steel & Wire frame
Company
400-2 7" x 16" 11 gauge ASTM A36 steel 1.00 $5.74 Milwaukee Central plate to sandwich between main
plate Steel & Wire frame and piston/mechanism; adds
Company to the overall integrity
400-3 1/4-20, 1/2-inch long 8.00 $4.72 Home Depot Screws to attach piston and
(Internet #) 204274885 mechanism to frame
400-4 1/4" washer 4.00 $4.72 Home Depot (Internet #) 204276462 Washers to go between screws and
wood interface
400-5 Rust Clean Metal Primer 2.00 $7.52 The Home Depot (Internet#) 100143442 $17.31 5 $86.55 Will first need to prime the base in
order to get a better finish
400-6 Rust Flat Black Spray 2.00 $7.52 The Home Depot (Internet#) 100670370 $17.31 5 $86.55 Black paint to finish the frame and
give it that sleek look
500 Bottom Seat Cushion Assembly
500-1 Vinyl Waterproof Fabric 1.00 $90.00 $12.29 2 $24.58 Fabric to cover bottom seat cushion Labor cost due to sewing fabric to
cushion; lead time includes getting
material from vendor and seamstress
time
500-2 18" x 18" x 3" HD Foam Q41 Firm 1.00 $29.00 Foam Source Custom High Density Foam for seat
Boulder cushion will cut to specified dimensions
500-3 Dacron Waterfall Wrap w/ Foam 1.00 $20.00 Foam Source Goes on top of high density foam Foamsource will cut and attach dacron
Boulder to high density foam
500-4 18" x 18" x 1/2" Pine Plywood 0.50 $17.48 Home Depot (Internet#) 202677224 plywood used for hard base of
cushion Will most likely move to a plastic base
600 Back Rest Cushion Assembly
600-1 Vinyl Waterproof Fabric 1.00 $90.00 Gonzlez Upholstery Fabric to cover back rest cushion Labor cost due to sewing fabric to
cushion; Contact Gonzalez upholstery
to determine exact vinyl fabric used
600-2 1" x 17" x 19" Medium Density 1.00 $57.74 Foam from JoAnns Medium density foam for back rest
Foam cushion
600-3 17" x 19" x 1/2" Pine Plywood 0.50 $17.48 Home Depot (Internet#) 202677224 plywood used for base base of back
rest cushion
700 Seat Heating Element
700-1 HSK150 Deluxe Heated Car Seat 2.00 $105.18 Walmart Deluxe Crimestopper HSK-150 Heated seat pads with a dual color
Heated Seat and heat option; used for heating
element in seat
700-2 AC to DC converter 2.00 52.78 AC DC Converter 490-SDI65-12-U-P5 Converts the AC voltage of the
heating element to DC such that it
can be plugged into a wall
700-3 Cords for AC/DC converter 2.00 $11.24 Cords Cords that plug into the AC/DC
490-AC-C13NA converter
700-4 Digital Temperature Controller 2.00 $33.98 Inkbird Digital Temp Inkbird ITC-1000 Digital temperature reader in which
Controller user can input desired temp (low,
med or high) and reader uses
feedback to keep this temp at that
setting
700-5 Female Adapters 2.00 $5.99 Female Adapters Used to solder onto wires coming out
of the heating pads and to connect to
the AC/DC converters
700-6 Male/Female connector pairs 2.00 $3.58 Male/Female Clamps that connect the wires
Connectors coming out of the Digital
Temperature boxes to the power
cord so that you don't need to take
off the circuit box
700-7 18 Guage wiring 1.00 $5.00 Electrical wiring to connect box to
AC/DC converter and to connect it to
the power outlet
800 3D printed circuit box
3D printed box that holds all the
circuitry and another 3D printed part
800-1 3mm PLA plastic black 1.00 $30.00 PLA filament that is the cup holder

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Team 8 Milwaukee Bucks Final Report

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Milwaukee Bucks Chair

Spring Semester Report

Connor Swanson Project Manager

FIGURE 1: DALLAS WALTON ON STANDARD BENCH CHAIR

4 Requirements and Specifications

Heating The chosen design must incorporate heating elements High

FIGURE 2: CHANGES IN BLOOD FLOW VELOCITY WITH VARIATIONS IN SEATING POSITION

FIGURE 3: POPLITEAL HEIGHT

FIGURE 6: CAD MODEL OF INITIAL PISTON IDEA

FIGURE 7: FIRST PROTOTYPE ITERATION

FIGURE 8: SECOND ITERATION WITH MESH BACK

FIGURE 11: CAD MODEL OF PROTOTYPE WITH ADJUSTABLE BACK SYSTEM

- 20 Bolt (4x) Back Frame

FIGURE 14: CAD MODEL OF ASSEMBLED END-OF-SEMESTER PROTOTYPE

FIGURE 15: HIGH-RESOLUTION PROTOTYPE OF THE FALL SEMESTER

FIGURE 16: DATA FROM LOAD CELL TESTING

FIGURE 17: PLAYER OPINION TESTING RESULTS

FIGURE 18: SCHEMATIC OF BOTTOM CUSHION

FIGURE 19: SCHEMATIC OF SEAT BACK CUSHION

FIGURE 20: CAD MODEL OF THE FRAME

FIGURE 23: FEA FOR BASE WITH VON MISES STRESS

FIGURE 24: CAD MODEL OF WATER BOTTLE HOLDER

FIGURE 25: CAD MODEL OF CIRCUIT BOX

FIGURE 27: 5-CHAIR BASE ASSEMBLY

FIGURE 28: SIMPLE LAYOUT OF HEATING PADS IN CHAIR

FIGURE 32: DIGITAL TEMPERATURE CONTROLLER WIRING DIAGRAM

FIGURE 33: FOAM PIECES NECESSARY FOR SEAT BACK CREATION

FIGURE 34: TOP VIEW OF POPLAR PIECES ATTACHED TO

FIGURE 35: FRONT VIEW OF POPLAR PIECES ATTACHED TO

FIGURE 37: WELDED, GROUND-DOWN FRAME

FIGURE 38: BASE DRYING AFTER BEING PRIMED AND PAINTED

No persons 43.13 lbs.

7.4.1 Test Procedure

DAY TWO - PROTOTYPED HEIGHT-ADJUSTABLE, HEATED CHAIR

7.4.2 Test Results

FIGURE 40: PERCENT CHANGES IN INDIVIDUAL PERFORMANCE MEASURES

TABLE 2: RESULTS OF MANOVA AND ANOVA TESTS OF PERFORMANCE TESTING DATA

Hypothesis Test Confidence Interval p-value Conclusion

Consider effects on base design with different actuation method

FIGURE 50: MOTORIZED RACK AND

FIGURE 54: PILLAR CHAIR CAD

TABLE 3: KEPNER TREGOE REQUIREMENTS FOR ADJUSTABILITY

TABLE 4: KEPNER TREGOE MATRIX FOR ADJUSTABILITY METHODS

Bottom Seat Cushion Specifications

High density polyurethane

Seat Back Cushion Specifications

Medium density polyurethane

2 3 in (0.0762 m) wide x 18 in (0.4572 m) long x 1 in (0.0254 m) thick

When the set temperature is degrees Fahrenheit (FC F)

Inkbird ITC-1000 Instruction Manual

Quantity (per Labor Time

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