Improvement of handle grip using reverse engineering, CAE and Rapid Prototyping

Abstract

The overwhelming majority of manual operations is even nowadays performed by using manual hand tools. These tools can be divided into 2 groups – hand tools designed for general use or a single-purpose hand tools for special operations. Tool described in this paper is used in assembling operation in the completion of electric motor. During the design of the existing tools the requirements for a functional part of the tool (lifespan, inability to damage the engine installation) were fully considered, demands for ergonomic grip area, however, were not taken into account. Long-term use of incorrectly designed tool causes carpal tunnel syndrome, hand-arm vibration syndrome, diminished sensitivity or tingling in the fingers of workers. These difficulties can be reduced or entirely eliminated due to proper design of the grip of hand tool. Most authors focus on adjusting the grip for optimum ergonomics at individual types of grips (cylindrical, palmar, lateral, etc.). However, as already mentioned, there are tools for specific operations when the working area is limited by space or a specific type of load on the grip is needed. In some cases, it is often necessary to change the type of grip or combine different types of grips. This paper describes the design of an optimal grip of hand tool used for specific operation when assembling motors. Design of prototype mold and production of functional prototypes for ergonomics assessment directly in the workplace were realized. New design of handle should reduce the risk primarily of developing carpal tunnel in long-term use.