Design validation of a handstand device

Abstract

This project aimed to validate the mechanical design and functional performance of the Handsat, a spring-assisted training device designed to support users during handstand learning by applying stabilizing torque at the shoulders. Two main challenges were addressed: ensuring structural integrity under extreme user loading and maintaining consistent torque assistance across users of different body sizes. A comprehensive mechanical and kinematic analysis was first conducted to characterize the system’s loading and motion. Based on this analysis, twenty-five representative user scenarios were defined by combining five user mass categories with five lever extension settings. The most critical case, corresponding to a 120 kg user at maximum lever extension, was subsequently evaluated using finite element analysis. Stress distributions and mesh-refined singularity assessments confirmed that all components remain below material yield limits. In parallel, torque variations across all scenarios were quantified, leading to the development of an adjustable pretensioning mechanism. This redesigned system enables preload tuning to individual users, ensuring uniform torque delivery and improved usability across a wide range of users