Design for Manufacturing, Reliability, and

Economics
Team 19

Development of a Strength Training Measurement Device

Brad Bone bdb11c@my.fsu.edu

Jorge Cabrera jmc11h@my.fsu.edu

Kendall Parker kendall1.parker@famu.edu

Fiona Robertson fhr13@my.fsu.edu

Faculty Advisor:
Dr. Camillo Ordonez
Sponsor:
Dr. Michael Devine
Instructor:
Dr. Chiang Shih

Date Submitted: Friday, April 7, 2017

Team 19 Strength Training Measurement Device

Table of Contents
Table of Figures .......................................................................................................................... ii

Table of Tables .......................................................................................................................... iii

Abstract ...................................................................................................................................... iv

Introduction ............................................................................................................................. 1

Design for Manufacturing ....................................................................................................... 2

1.1 Component Selection ....................................................................................................... 2

1.2 Manufacturing Process ..................................................................................................... 3

Design for Reliability.............................................................................................................. 5

Design for Economics ............................................................................................................. 8

4.1 Cost ....................................................................................................................................... 8

4.2 Competitor Comparison ........................................................................................................ 9

Summary ............................................................................................................................... 11

References ............................................................................................................................. 12

Acknowledgments................................................................................................................. 13

Appendix ............................................................................................................................... 14

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Team 19 Strength Training Measurement Device

Table of Figures
Figure 1: Team 19's Cyclical Design Process ................................................................................. 3
Figure 2: Exploded View of Final Prototype Assembly with Experimental Housing .................... 4
Figure 3: Budget Breakdown .......................................................................................................... 8
Figure 4: Price Comparison of PowerTRAK to Those Currently on the Market ......................... 10

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Table of Tables
Table 1: Comparison of Use Amounts for an Average PowerTRAK Customer ............................ 5
Table 2: Failure Mode and Effects Analysis (FMEA) for PowerTRAK ........................................ 7
Table 3: Components Cost for Prototype...................................................................................... 14
Table 4: Competitor Comparison Table ....................................................................................... 15

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Abstract
Top athletes all over the world are constantly looking for ways to improve and track their
performance to maintain dominance in their competitive territory. Currently, the market for
wearable power measurement devices lacks an all-encompassing product that is both accurate and
affordable. PowerTRAK seeks to fill that void with an effective method for comparing and
progressing competitive athletes over all ranges of sports. PowerTRAK has designed a power
measurement wristband device using off-the-shelf electrical components that will track the
progress of athletes as they train over a period of time. These components include an
accelerometer, gyroscope, pulse rate sensor, Bluetooth module, and microcontroller. The device
collects data based on the motion of your wrist during a workout and analyzes that data in a
program created using Arduino software. Workout metrics, including heart rate, velocity, force,
and power, will be relayed to a smartphone application synced through Bluetooth. It is necessary
for the device to minimize size and cost, and it is targeted to competitive athletes at all levels.
PowerTRAK is revolutionizing the athletic and training world by providing accurate, user friendly
power metrics to track and improve training.

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Team 19 Strength Training Measurement Device

Introduction
The entrepreneurship requirement of this project has assisted in guiding the motivation and
market assessments. To evaluate the potential impact of PowerTRAK, a thorough competitor
assessment was performed. In addition, a target market of advanced athletes, their trainers, and
intermediate to advanced gym-goers was selected to assist in design development. To evaluate
potential liabilities and design progress, design for manufacturing (DFM), reliability (DFR), and
economics (DFE) assessments were completed for this project. Since the work involved on
PowerTRAK this year has been focused on building a successful prototype, the DFM discussion
will mainly focus on this aspect. DFR and DFE, however, will detail Team 19s expectations for
the market ready product. Results from these assessments will be used to make design pivots before
testing with athletes and trainers.

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Team 19 Strength Training Measurement Device

Design for Manufacturing

After a great deal of brainstorming and research, it was realized that a successful product would
require a unique design not currently available on the market. With the health and fitness market
growing exponentially, the need for advanced technological devices has increased greatly. Athletes
are constantly seeking ways to improve their strength, power, and athleticism. Team 19s goal was
to manufacture a product that was not only unique and affordable, but also beneficial to the target
market. A steep learning curve was encountered during preliminary design. Team 19 realized that
coding and component selection would be a crucial to the projects outcome. After considering all
alternatives Team 19 landed on the Arduino electronics platform. This open source family of
electrical components is abundant in resources and options to suit many design needs. Also,
Arduino utilizes C and C++ functions and libraries, which have been used by all of Team 19
members. In addition, Team 19 was very fortunate to find components to satisfy all design
requirements while staying near self-imposed size constraints of 2x2x2.

1.1 Component Selection

To maintain high precision in power metrics, the accelerometer used required a range that
encompassed the forces created from acceleration during lifting, but not large enough that accuracy
dwindled. During testing, some exercises exceeded 2 Gs so it was decided that PowerTRAK
workout band would need a range of 4Gs. The SparkFun IMU Breakout MPU 9250
accelerometer was selected to fulfill this purpose. The MPU 9250 has a nine axis MEMS sensor
that consists of an accelerometer, gyroscope, and magnetometer. In addition to its range, its size
and compatibility were major pluses.
The heart rate monitor, in addition to the power measurement technology, will create a
larger market for PowerTRAK. Team 19 pivoted from its first heart rate monitor which required
the use of biomedical leads to using a Heart Rate Click Sensor Breakout Board. This device
measures heart rate using photodetection from two small lights through pulsating blood. This
device is cheaper, smaller, and much easier to program than the original heart rate monitor.
Team 19 also decided to incorporate Bluetooth technology to allow for data to be
transferred to any smartphone or capable device. Users will be able to view live data during their
workouts and after their workout is complete. Team 19s design will use the Adafruit Bluefruit LE
nRF8001 Breakout which is compatible with the Arduino ProMini microcontroller. The Bluefruit
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Team 19 Strength Training Measurement Device

module uses Low Energy Bluetooth, which gives it advantages over devices that use classic
Bluetooth.
For all these devices to work cooperatively, they must be connected by a programmed
microcontroller and circuit board. Team 19 will be utilizing the Arduino Pro Mini 328
microcontroller. The microcontroller requires 3.3 V of power, but it also contains a voltage
regulator and can accept up to 12 V. The microcontroller has 14 input/output pins which is
sufficient for the PowerTRAK prototype. The microcontroller utilizes the Arduino Software IDE
to program it to control the necessary sensors and add-ons.
Finally, the SparkFun FTDI Basic Breakout module will be used to connect the
microcontroller to the computer for programming. This specific FTDI module is built for the
Arduino Pro Mini 328 microcontroller.

1.2 Manufacturing Process

Figure 1: Team 19's Cyclical Design Process

Team 19s manufacturing process did not utilize a straight-line method as most processes
do. Instead, it featured a cyclical manufacturing method depicted in Figure 1. This design process
began near the end of Fall semester and carried over into the Spring. It began with an initial
prototype stage, where the prototype was assembled and code was developed. Following this was
a verification stage, which includes testing and confirmation that the prototype is functioning
properly. After verification, the modification stage was used to analyze data and implement
changes to the design. Then the cycle repeated itself, where Team 19 added components to the
original prototype until all components are assembled and functioning.

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Team 19 Strength Training Measurement Device

The first prototype consisted of the accelerometer/gyroscope and microcontroller. Once

code was written to compute power metrics from the raw data, the data was verified against a more
sophisticated motion capture system. The next prototype involved the addition of the Bluetooth
module to the previous setup. The second version of the prototype was then verified and modified
after successfully transmitting data wirelessly. The third cycle of the design process added the
heart monitor to the Bluetooth-accelerometer/gyroscope-microcontroller setup. This proved to be
a difficult task since the accelerometer and heart rate monitor both required the use of a I2C
protocol. After many design iterations, a final circuit board was developed that would allow all
components to function simultaneously. After this final design was completed, the data was
properly relayed during testing and final code was modified. This entire cyclical manufacturing
process spanned from end of November to the first week in April. Team 19 had previously
expected to have a finalized prototype with full capabilities by early March. However, with the
learning curves and complications in assembly it took an extra month to develop.
To test these prototypes, components were connected to the circuit board via a combination
of pins and wires. The exploded view in Figure 2 shows the CAD assembly of the final prototype
in the experimental housing. It is simplified and does not include all the pins and wires needed for
function.

Top of Housing

Heart Rate Monitor

Accelerometer & Gyroscope

Bluetooth Module
Arduino ProMini
Microcontroller

Bottom of Housing

Figure 2: Exploded View of Final Prototype Assembly with Experimental Housing

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Design for Reliability

Similar workout assistants currently on the market do not give much hint to their device
lifespan, making it difficult to reverse engineer a competitive product. However, it is expected that
PowerTRAKs lifetime, with average to optimal care, will be heavily influenced by the batterys
lifespan. Planned obsolescence is not a priority for Team 19 as a future manufacturer since
retention of customers is key to long term success in the rapidly expanding power measurement
market.
Considering PowerTRAKs target market of intermediate to advanced gym goers and
athletes, it can be expected that a user will train with this device an average of 6 times a week [1-
3]. Table 1 compares various amounts of use with its equivalent period for a PowerTRAK user.
Wear down of the casing is expected to vary based on the type of plastic resin chosen, but it should
not wear down before 1000 uses. Between 500 and 1,000 uses there may be some failure with the
electrical parts, per original equipment manufacturer design. PowerTRAK will offer a 2-year
warranty to all customers to handle any electrical failures that may arise during this time. Only the
wristband will be offered as a spare part. After 1,000 uses, the product should show more obvious
signs of wear and tear. Assuming a lithium ion battery is used in the final device, one can expect
the battery lifespan to be roughly 3 years before replacement [4]. Thus, Team 19 hopes that the
rest of the PowerTRAK device will last for double the batterys lifespan, close to 2,000 uses.
Table 1: Comparison of Use Amounts for an Average PowerTRAK Customer
Number of Uses Equivalent Amount of Time for PowerTRAK Use

10 2 weeks

50 10 weeks

100 5 months

500 1 year, 1 month

1,000 3 years, 10 months

1,980 7 years, 8 months

10,000 38 Years, 4 Months

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Team 19 Strength Training Measurement Device

The main reliability concern for PowerTRAK is satisfaction of customer expectations. As

a workout assistant, there are fundamental attributes this product should have due to the
environment it will be used in. These attributes include comfort, waterproofing, stability, and a
long lifespan. Comfort is essential because of how frequently this device will be worn. The
wristband selection, casing, and device weight will influence the comfort level. Waterproofness is
also a necessary characteristic because sweat, water, or other liquids may spill on the product.
Therefore, the plastic resin used to mold the final casing must also repel liquids. Stability is
important to both the hardware and the software of PowerTRAK. Internal components must be
securely fastened to each other and to the casing to ensure valid sensor readings. Also, stability of
the device itself on the users wrist is critical to obtaining proper readings, and it can have an
impact on user comfort. Lastly, device lifespan will influence customer expectations and reliability
because the target market will expect a device which can keep up with the rigorous workout regime
they follow.
A failure mode and effects analysis (FMEA) was performed to understand the most detrimental
failures in PowerTRAK. Table 2 shows results from the FMEA. It is important to note that only 3
components were evaluated. This is because the primary failure mode for all components is
breakage and/or bad data. In order of precedence Team 19 hypothesized the following would be
the worst failures: (1) Microcontroller failure (2) Accelerometer breakage/bad data, (3) loss of
Bluetooth connection. Thus, those 3 components were assessed. Results show that microcontroller
failure has the lowest risk out of those analyzed, contrary to predictions. This is most likely due to
the ease of detection. The highest risk stems from bad accelerometer readings. There is no
detection method currently in place to combat this issue and no way to quantify how often this
error may occur. To improve device reliability, Team 19 will implement a detection method within
the code reduce the occurrence of bad readings.

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Team 19 Strength Training Measurement Device

Table 2: Failure Mode and Effects Analysis (FMEA) for PowerTRAK

Potential Potential Potential Current
Recommended
Component Failure Effects of S Causes of O Process D RPN
Actions
Mode Failure Failure Controls

Mobile
App
Inability to Mishandling, Return to
Check,
Breakage Collect 4 material 4 2 32 manufacturer
Program
Data Failure for repair
Self-
Accelerometer Inspection
& Gyroscope
Use reset,
Inaccurate Mishandling, return to
User
Bad Data Power 4 bad 2 7 56 manufacturer if
Inspection
Metrics connection problems
persist

Mobile
App
Inaccurate Mishandling, Return to
Check,
Breakage power 5 material 2 5 50 manufacturer
Program
metrics Failure for repair
Self-
Inspection
Bluetooth
Module
Mobile
Use reset,
App
No Mishandling, return to
Loss of Check,
Smartphone 5 bad 4 2 40 manufacturer if
Connection Program
Sync connection problems
Self-
persist
Inspection

Mishandling, Return to
Total device User
Microcontroller Breakage 6 material 2 1 12 manufacturer
failure Inspection
Failure for repair

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Team 19 Strength Training Measurement Device

Design for Economics

4.1 Cost
Key attributes of PowerTRAK are accuracy and affordability, thus the parts described in DFM
were selected based on a balance between cost and the efficiency. The cost of each component
ordered for use in the prototype can be found in Table 3 in the appendix. Upon building a market
ready device, bulk quantities and mass production will reduce the cost of each individual part
around 60%, allowing a steep profit margin. PowerTRAK will compete with the current market
after a proposed retail price of $99.
As several iterations of the prototype have been made, some duplicate components have been
ordered so that Team 19 can multitask and work simultaneously on assembly and programming.
Additionally, two Texas Instruments Chronos development watches were ordered to give a visual
aid during our prototype presentation and show the goal for a sleek design with our current
functionality. Because all the ordered components are low cost, there is nearly 75% of our budget
remaining, as seen in Figure 3, which can be used for further prototype developments.

Figure 3: Budget Breakdown

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Team 19 Strength Training Measurement Device

4.2 Competitor Comparison

The products that currently exist in the health and fitness market, identified as potential
competitors to PowerTRAK, include GymWatch, Push Band, Fitbit, Beast, Atlas Fit, FORM
Collar, Open Barbell, and Bar Sensei. These products are either a wearable or a tethered device
and perform a variety of functions, measuring either heart rate, velocity, force, power, steps,
calories, form, or some combination of these. Fitbit is one of the most popular, with many different
styles of bands and watches, and is easily one of PowerTRAKs biggest competitors. Fitbit
wristbands monitor movement and heart rate to track fitness and syncs wirelessly with your
smartphone to show data on the Fitbit app. The focus of Fitbits metrics is steps, measured with a
pedometer. Fitbit is targeted for the everyday consumer, encouraging a more fit lifestyle. It does
not have any features or metrics that measure strength or power. PUSH armbands monitor
movement and track bar speed, power output, establish 1 rep maximums (1RM), and measure jump
height performance, as well as reaction time. The band syncs wirelessly with your smartphone to
show data on the app. PUSH does not measure steps or heart rate like Fitbit, but instead focuses
on strength metrics. Hence, PUSHs target market is similar to PowerTRAKs, including athletes
and the average gym-goer. Bar Sensei is a small device that straps to a bar and measures power,
force, and bar speed. The device syncs wirelessly with your smartphone to an app. It is relatively
accurate in measuring displacement and power of the bar, but the device is limiting in that it must
be strapped to a barbell and cannot be used in a variety of workouts. A table summarizing the
functions, similarities and differences of all identified competing products against PowerTRAK is
shown in the appendix.
As mentioned, a primary objective of this design was to maintain simplicity and low cost.
Comparing the prices of competing devices on the market in Figure 4 shows that PowerTRAK
maintains a competitive price when compared to both the wearable and tethered products.

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Competitor Price Comparison

$600.00

$500.00
$495.00
$400.00

$300.00
$289.00
$200.00 $249.00 $249.00
$199.00 $199.00 $208.99
$100.00 $149.95
$100.00
$0.00

Figure 4: Price Comparison of PowerTRAK to Those Currently on the Market

This market assessment shows that an all-encompassing wearable power measurement device
does not currently exist. PowerTRAKs unique combination of technology features will fill the
void in this market. Current devices are expensive, bulky, and poorly marketed to potential
customers. These issues provide a need for a low cost, user-friendly power measurement device
to provide athletes with useful knowledge on peak power abilities and power progression.
PowerTRAK has a solution with a device that provides accurate power measurements and tracks
power progression.
PowerTRAKs marketing goal is to distribute the product in two ways. First is by establish
personal relationships with teams, trainers, and athletes through hosting hands-on demonstrations,
attending sporting expos, and creating sponsorships. Hands-on demonstrations allow us to show
the customer PowerTRAKs unique features as they use our device, and they can ask questions
and give feedback to our product. The second method is to create contracts with athletic
organizations for bulk purchases at a discounted price, as well as a package that includes
demonstrations, technology updates, and fulfilling the needs of that organization. Additionally,
PowerTRAK devices will be marketed and sold via impersonal communication, which consists of
website promotions and orders.

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Team 19 Strength Training Measurement Device

Summary
Team 19s vision is to access every competitive athlete so they can utilize PowerTRAK to
improve the way they train. PowerTRAK can revolutionize the athletic training world by providing
accurate, user friendly power metrics to track and improve exercise.
In developing the prototype for PowerTRAK, a DFM assessment assisted in improving the
electrical components selected for a well-functioning prototype. A DFR evaluation was essential
to pinpoint weaknesses in the proposed final device. In the future, these results will enhance
longevity, durability, and reliability in the product sold to customers. The DFE presents a
preliminary cost analysis for PowerTRAK as a future company. These results, with Team 19s
marketing goals, will help make this device a successful product down the line.

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Team 19 Strength Training Measurement Device

References
1. Suchde, Siddharth. "A professional athlete's fitness regime: An insider's guide."
TheHealthSite. N.p., 28 Feb. 2014. Web. 06 Apr. 2017.
2. Bric, John Michael. "Top Athletes Reveal How Many Hours A Day They Workout." The
Rx Review: Reporting on Fitness and CrossFit News. N.p., 06 June 2015. Web. 06 Apr.
2017.
3. Higgins, Marissa. "Do Olympic Athletes Train Every Day? These Rio Competitors Put In
Some Serious Work." Bustle. Bustle, 15 Aug. 2016. Web. 06 Apr. 2017.
4. Tektronix. "Lithium-Ion Battery Maintenance Guidelines." Newark. Premier Farnell, n.d.
Web. 6 Apr. 2017.

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Acknowledgments
Our group would like to extend gratitude to our sponsors for guiding us in the right
direction for the project. Dr. Devine, Dr. Gupta, and Dr. Ordonez provided great assistance to our
group to narrow our project down to a specific goal. We greatly appreciate the opportunity to
explore something we are passionate about, while using the skills we have acquired in our
engineering courses.
In addition, we owe a great deal to the trainers who helped us develop an idea that would
be beneficial to our target market. We provided surveys to a wide variety of trainers who gave us
their opinions on our device, and what they thought it should incorporate. We would like to thank
Taylor Jacobs, a former NFL player and trainer at Premier Health and Fitness who gave us his
expert opinion on whether our device would be suitable for Professional sports, and athletic
training. Also, we extend gratitude to two more personal trainers from Premier Health and Fitness
whose names are disclosed. Finally, we would like to thank two personal trainers from Top Dog
Fitness LLC. Sam Allsopp, and Eddie Matthews. They provided us with a great deal of insight,
and a different opinion on training techniques that was useful in the iteration stage of our project
idea.

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Appendix
Table 3: Components Cost for Prototype
Total
Part Name Quantity
Price

Bluetooth Module NRF8001 Bluefruit LE Breakout 1 19.95

Microcontroller & Circuit

Arduino Pro Mini 328 2 19.99
Board

FTDI Cable FTDI Cable 1 17.95

FTDI Module SparkFun FTDI Basic Breakout - 3.3V 2 29.99

Accelerometer SparkFun IMU Breakout 2 29.99

Heart Rate Monitor SparkFun Single Lead Heart Rate Monitor - AD8232 1 19.95

Cable for heart rate monitor Sensor Cable - Electrode Pads 1 4.95

Icstation MAX30100 Heart Rate Click Sensor

Alternate Heart Rate Monitor 1 19.99
Breakout Board

Velcro Wristband Generic 1 2.99

Total 12 $95.64

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Table 4: Competitor Comparison Table

Company/
Cost Similarities to PowerTRAK Differences to PowerTRAK
Device

Wearable strap-on sensor, large range of Recognizes and tells you to correct your form,
GymWatch $199 motion recognizes workouts, connects via live feedback, emphasis on form not
mobile app, wear during workout not all day power/velocity

Accelerometer and gyroscope, focus on

Analysis of power is different (based on arm
velocity and power, wearable wristband, sync
PUSH Band $289 length and angular accel rather than integrated
to mobile app, partners with sports
velocity)
organizations

$150 - Wearable and sync with mobile app, monitors Steps, no power/strength, everyday fitness and
FitBit
$250 heart rate wear all day not just workout

Accelerometer and gyroscope, mobile app.

Multiple accessories. Extra measurements
Tracks, reps, average power. Can check
Beast $249 such as explosiveness(G/s), strength (N),
progress. Mostly measures Power and
Energy burn (kJ), etc. Training volume.
Velocity.

Analyzes form, training volume, user can set

Tells peak heart rate and average heart rate, training goals. Shows 1RM over time, calories
Atlas Fit $199
reps, velocity burned, steps, heart rate zones, active and rest
times, exercise training guide.

Measures the form and performance of your Attaches to weight not to body, suggests
FORM collar $249 barbell lifts. Syncs to smartphone app with real efficient movement patterns, tells 1RM,
time and old workout data customizes workouts

A retractable string that you attach to your

OpenBarbell $208.99 Focused on velocity and number of reps.
workout equipment, studies range of motion.

Measures power, force. Syncs to smartphone Straps to a bar, measures bar speed. Cannot be
Bar Sensei $495
app used in a variety of workouts

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