Giving New Life to Unused Parts: Kop Chassis Transformed into Powered Wheelchair Device

Last year, I was contacted by ACCEL, a local school that focuses on special need education, to design a device that would convert a traditional wheelchair into a powered one. They had a number of students who qualified to receive a powered wheelchair through their insurance, but only if they could demonstrate that they were able to operate one safely via a driving test. The problem is, it’s hard to practice for the driving test if you don’t have the wheelchair yet. One of the physical therapists had the idea of making a platform that you could place a traditional wheelchair on in order to temporarily convert it into a powered one so that the students could practice before taking the test. Through a team effort of FRC Team 6413 (donated the parts) and students at Arizona State University (including some FRC alumni), we were able to convert an unused AndyMark KoP chassis into a functional prototype. They named it “Viktor” after the speed controllers :joy:

They still have some work to do before students will be able to use it, but I thought it was important to share yet another example of how the skills being taught in FIRST programs can directly lead to helping our communities. Plus, it’s always cool to see how people find clever new uses for things that were designed for another purpose. Anyone else find ways to give new life to spare parts you’ve collected over the years?

platform

25 Likes

Awesome project, few quick questions.

How does the wheelchair “lock” to the chassis to prevent it from moving?

Few more

  • How does it handle bumps?
  • How steep of an incline can it go up for a ~150lb person?
  • Battery life?
  • Maximum weight?
5 Likes

This is a project that my friend has been working on, in the same vein of things, but is a power assist powered by a old MK2 module rather than a KOP. I’m also going to mention: @bigbossg13 @DPOfFIRST and @spark_matter as I think they would be interested in this project.

2 Likes

Is putting a chair on a bot theoretically safe?, guess that’s a yes

7 Likes

Great questions! Currently the plan to fasten the chair to the platform is a combination of wheel chocks and straps. How does it handle bumps/inclines? Not well. We drove it over a cable protector and it tipped over (no one was hurt). However, those types of obstacles are outside the scope of the project. The platform is used as a training device in highly-controlled environments, not to replace traditional powered wheelchairs. It will only be used on flat smooth indoor surfaces (e.g. gym floor) under the supervision of a therapist with one hand on the emergency kill switch. The battery life question is a bit difficult to answer since it really depends. How much load is the system supporting? How frequently is the platform being driven? To give you a ball park, they were able to give occasional demonstrations with an average-sized rider for a little over 2 hours without any need to change batteries. The goal of this semester was simply to get something working. Nothing about it is optimized. We can always add larger/more batteries if that becomes an issue. For weight, we were asked to design it to support at least 300 lbs. With the tests they ran, they were able to support over 400 lbs, at which point they stopped since they already exceeded the design specification.

8 Likes

I guess you answered this question in a way the related thread couldn’t. Good Job.

A swerve chassis would provide unique mobility in certain cases. Although not the specific case the OP has of creating a trainer for a regular electric wheel chair.

Oh that’s awesome- definitely something I needed to see on my thread today! :grin: One thing I would be concerned about is- will there be something preventing it from rolling off the base? From the photos, it doesn’t look very secure- and one lesson I’ve learned is to never 100% rely on the wheelchair brakes, but also I’m very paranoid :sweat_smile:
@spark_matter what do you think? could any of this help with the swerve wheelchair thing you were working on?

1 Like

Yes! It’s hard to see in the GIF since they are black and the platform is also black, but there are wheel chocks between the big and small wheels. Between those and the brakes, it’s really solid in the forward/backward directions. However, if it got pushed from the side…the plan is to attach straps for the final securement. That will allow the flexibility needed to work with many different types of wheelchairs, while also providing the safety needed in this application.

Yeah that’s not gonna stay on well enough, especially since the chair youve got on there doesn’t have anti tippers. Look into “transit ties” designed for wheelchairs to go on buses.
As a wheelchair user, i have some additional thoughts:
-Can it fit through standard doorways?
-Where is the large, easily accessible, kill switch button? It needs one hardwired to immediately cut the power from the battery for safety.
-Bumpers? Doesn’t have to be frc style but something to prevent wall/ankle damage
-Can you switch out the chair? The vast majority of wheelchair users use an “active ultralight” chair with therapeutic cushion/positional adjustments. You’ve got a “hospital style” chair which is designed as a one size fits all but lacks important safety elements like seatbelts and pressure reducing cushions individual to the person (not everyone can safely sit in a hospital style chair even for a little bit)
-How do people get on it? If the answer is they have to transfer into the chair or get lifted into it, this will only work for ambulatory people or with two people to help lift and you’re gonna miss the opportunity to help most of the people in the intended user audience. The vast majority of people who are eligible for a powerchair won’t be able to get onto this unassisted unless a ramp gets integrated (Ideally a ramp that becomes the back safety railing folded up)
-Does it use a standard powerchair joystick? It’s useless for practice unless the joystick is the same.

9 Likes

Yeah that’s not gonna stay on well enough, especially since the chair youve got on there doesn’t have anti tippers. Look into “transit ties” designed for wheelchairs to go on buses.

Thanks for the advice. Yes, one of the requirements of this project is that it needs to be compliant with Section 38.23(d) of the DOT ADA. This is just a prototype, we understand that additional work needs to be done.

As a wheelchair user, i have some additional thoughts:
-Can it fit through standard doorways?

Yes! This is also one of our requirements (and one I encourage for all of our FRC robots as well).

-Where is the large, easily accessible, kill switch button? It needs one hardwired to immediately cut the power from the battery for safety.

In the right side of the GIF, you can see a black cord resting in the seat of the chair. There is a kill switch with ~8 feet of wire connecting it to the chair that the therapist will hold at all times. We’ve also discussed the possibility of using a wireless relay to kill power to the motors.

-Bumpers? Doesn’t have to be frc style but something to prevent wall/ankle damage

Yep! There’s a ring of black foam around the outside of the platform.

-Can you switch out the chair? The vast majority of wheelchair users use an “active ultralight” chair with therapeutic cushion/positional adjustments. You’ve got a “hospital style” chair which is designed as a one size fits all but lacks important safety elements like seatbelts and pressure reducing cushions individual to the person (not everyone can safely sit in a hospital style chair even for a little bit)

Great question! Yes, there’s a lot of variety in the types of chairs that the students at ACCEL use, so our solution requires that it be adaptable. The chair that is shown in the GIF is not typical of what the students use. Many of the students use different variations of the wheelchair you described. ACCEL didn’t have any extra wheelchairs for us to use in the prototype, but the students had access to this chair, so that’s what they decided to use for these initial tests.

-How do people get on it? If the answer is they have to transfer into the chair or get lifted into it, this will only work for ambulatory people or with two people to help lift and you’re gonna miss the opportunity to help most of the people in the intended user audience. The vast majority of people who are eligible for a powerchair won’t be able to get onto this unassisted unless a ramp gets integrated (Ideally a ramp that becomes the back safety railing folded up)

Yes, there is a ramp! This is not the best photo of it (it’s resting on its side), but it gives you an idea of what it looks like. They are still working on the final design for this as well.

image

-Does it use a standard powerchair joystick? It’s useless for practice unless the joystick is the same

This is a good point. ACCEL actually asked us to create the controller using the five arcade buttons rather than a standard joystick. My understanding is that some of their students may not have the fine motor control to use the joystick, but they can activate the buttons. I’m assuming they have a way to adapt these wheelchairs to use a similar interface, but it would be good to get more clarification on that. Either way, if we had to change the code to use a joystick, it would not be a major change. Thanks for the feedback!

2 Likes

With the arcade buttons, I assume they are mapped to a set speed limit, do you have a way to “shift speeds” into a high and low range? This might prevent the need for a joystick ever. On Powerwheels type vehicles they have a button with LEd indicator you hold to set the speed mode. It’s an artificial governor that really just limits the maximum PWM to the motor controller.

This is seriously awesome! The best things we’ve done with old parts is reusing CIMs in our Goosebots and we made a right angle bracket to take the old KOP gearboxes and mount them into a flat sheet for a really quick chassis. The normal flush mount way mean it could only ever be used in a kitbot or similar 2 walls per side design.

I would highly recommend an occupant kill switch as well, that’s the gold standard for safety.

1 Like

That’s what the center button on the user controller is for :slight_smile:
Also, the motors are turned off if none of the buttons are being pressed.

2 Likes

With the arcade buttons, I assume they are mapped to a set speed limit, do you have a way to “shift speeds” into a high and low range? This might prevent the need for a joystick ever.

Currently the buttons will slowly ramp the speed up to a preprogrammed value. ACCEL wanted to start with ~7 ft/s. At the moment, there is no feedback, so it simply drives to a set motor effort. This means that the speed will vary depending on the battery power and the weight on the vehicle. This is not ideal, so one future step would be to add encoders and have set speed targets.

On Powerwheels type vehicles they have a button with LEd indicator you hold to set the speed mode. It’s an artificial governor that really just limits the maximum PWM to the motor controller.

A next step is for the team to add LED indicators on the side of the platform as well as some way to set the maximum velocity. One idea is to just use a dial/potentiometer. We could have an LCD showing the current set maximum speed, or just a series of LEDS (4 on = fastest speed, 1 = slowest). That way the therapists and students have some idea of how fast it may go before they run it. Although, we would still recommend they start with the slowest speed and then increase it as necessary.

This is seriously awesome! The best things we’ve done with old parts is reusing CIMs in our Goosebots and we made a right angle bracket to take the old KOP gearboxes and mount them into a flat sheet for a really quick chassis. The normal flush mount way mean it could only ever be used in a kitbot or similar 2 walls per side design.

What is a Goosebot? :thinking:

1 Like

Off season project we use to train newbies about robotics basics without the overhead of FRC equipment. We use old servos, motors wheels and then an Arduino and RC controller as the main MCU. This eliminates a lot of cost for putting together a robot and let’s the students learn a little bit of C and basic Arduino circuits.

It all started with a donation of Goose Decoy shells from a family friend. We have about 15 of these things in semi decent shape. The students then cut out a basic wooden base plate with jigsaws to match the shape of the shell. They 3d print motor mounts and then put it together. We have Spark Max, Talon SRX or TalonSR motor controllers that work with PWM inputs from the Arduino. The RC controller is mixed by the Arduino and can be used to trigger various stuff. The servo controls the angle of the neck and then LEDs in the eyes for that extra creepiness (soldering practice and running wires through a tube (neck column))

GIF-231210_131215

I’ll get a picture of the base next meeting. The latest iteration had FTC motors due to the size of the Torquenado style motors, the original use mini cims

Until we run out of shells or parts we can keep doing this indefinitely. It’s also just fun and funny to see an RC goose drive around.

FRC 8115 the Platinum Peacocks have an RC peacock they bring to competition. It’s a great outreach item and gets people’s attention.

3 Likes

that’s a very cool project but i am incredibly unsettled by it for some reason

3 Likes

I think it’s the red glowing eyes :joy:

3 Likes

I love how you’re using the materials you have readily available to help train students. Has your team ever considered working on assistive technology (AT) projects? You can accomplish the same goals, but there’s also the added benefit of designing something that increases the quality of life for someone in the community. I posted some stories about my experiences working with students on AT projects in another thread. Send me a message if you want to learn more about it.

As oddly specific as this sounds, geese-themed robots have a special place in my heart. To keep the students engaged during the height of the pandemic (Fall 2020), the FRC team I mentor, Degrees of Freedom, started a spin-off FTC team called “Da Geese of Freedom.” They were really good at incorporating geese into their team imagery. You could say they took to it like a duck takes to water!

This was their robot. We didn’t know what to call it, so we eventually went with “The Untitled Goose Robot.” :joy:

That was the season of “Ultimate Goose,” and no matter how fierce the competition got, they made sure to practice “Goosecious Professionalism.”
Ultimate_Goose

Eventually the team made a 3D printed mascot, Goostavo.

One of the students then made their own, Lucy.
image

And just last weekend I met Goosiver, who happened to be a referee at an FLL competition.

Does anyone have any photos/videos? That sounds really cool!

5 Likes

You need to give them a voice.

1 Like

I will find out, didn’t see any in our Google photos, but we also have contacts with them. They’re relatively close geographically.

Will definitely give the AT ideas some thought