Hey All!
This is my first time on the forum but I have been watching the blog for a couple years now, so bear with me.
I am studying mechatronic engineering and have started branching out more into the electrical world, mostly thanks to cheap microcontrollers. For my senior project at university, we are building a prosthetic hand for a boy who has had all of his fingers amputated. He was in a house fire when he was 3 years old, and suffered extreme burning. For his privacy I don't want to reveal his name, or post too many pictures etc. I have, however attached pictures of both of his hands.
Left Hand:
Right Hand:
Anyway, we thought the best way to go about controlling finger position would be to use an EMG on the muscles of his forearm to measure how much energy a specific finger was using to either flex or extend. Seeing as how I have more digital experience than analog, my goal was basically to build an amplifier that was just clean enough to get the signal through to an ADC so I could just program from there. I have never really used instrumentation amplifiers before (or much of op-amps for that matter) so I was very pleased when we actually got some EMG signals onto the oscilloscope.

We used a microchip MCP6N11-100 for the In-Amp. I have attached the design concept for the original amplifier schematic, as well as the results of testing the EMG on myself (titled "Original Amp" and "Self Test" respectively). I was actually able to clean up the signal a lot more after this capture by adding an active-first order high pass filter.
Original Amp:
Self Test:
Well, that was all well in good. But I did some reading and it turns out the extensive nerve damage can significantly INCREASE the strength of an EMG signal. However, I also read that scar-tissue and skin grafts (which he has in excess) can change the impedance of the skin. So needless to say when it actually came time to meet him and test it out, I really did not know what to expect in terms of an input signal.
Regardless, my design worked horribly. I suspect that scar-tissue and skin-grafts have effectively attenuated significantly. In order to get any response whatsoever, I had to remove the DC blocking filter to in-amp. Furthermore, increasing the gain did not help that much since the in-amp was easily saturated by noise (the in-amp operates between 0-5V with a DC offset at 2.5v. So with a minimum gain of 100, 2.5mV of noise renders the circuit completely useless).

To make things more complicated, he is really not accustomed to USING his finger muscles since he has essentially gone his whole life without using them in a traditional manner. So when I tell him to flex his left ring finger, it doesn't really mean much to him. We were able to work through it eventually by applying some pressure on the area of the palm that corresponded with the "correct" finger. I have attached some of our results in the files "Left Hand Electrodes" and "First Test".
Hand:
Test:
So, in an effort to better filter out the noise, I started reading up on higher order sallen-key filter configurations. My idea was to put an active, adjustable bandpass filter (between about 10 and 100 Hz) with a 60 Hz notch filter in between every electrode and its corresponding in-amp. Does this seem like sound reasoning?
So, specifically, I am currently working on an electrode pre-amp that comes before the in-amp. Any guidance would be much appreciated.
The goal with next round of design is to build an amplifier circuit that successfully find amplitude and frequency range for each movement (flexion and extension of each finger).
To me this means:
1) The pre-amp should have adjustable attenuation (because nerve damage can INCREASE the emg signal) between about 10% and unity.
2) The pre-amp should have an adjustable bandwidth (between about 1 & 20 Hz on the highpass, and about 45 and 150 on the lowpass).
3) The notch filter should have adjustable center (it seems mains power center frequency changes depending location?)
I have started building the circuit in spice, and have included a picture of the schematic and bode plot ("Sallen-Key Pre-Amp" and "sallen-key pre-amp bode").
Schematic:
Bode:
So I have the following questions:
1) Does a filter BEFORE the in-amp seem like the right way to go?
1) How do I implement an effective notch filter embedded within the bandpass filter?
3) How do I make adjustable bandwidth and attenuation on the pre-amp? Any suggested reading?
4) How far do you think I need to attenuate the signals outside the the frequencies of interest?
5) What do you guys think of the design overall? Are there any glaring issues I have overlooked?
Ultimately, I would like to change this direct contact design into a non-contact one. So instead of an electrode essential glued to his arm, I would like the bottom copper-layer of a PCB to sit touching/very close to his forearm. The silkscreen could act as a dielectric in the capacitive bond. I have seen this done in some papers on IEEE for EKGs.
I liked this idea because it completely isolates him from the circuit, makes the electrodes re-usable, and allows us to embed the electrodes into the frame of the prosthetic so he can put it on by himself.
I have tons of questions about this stuff, so any help is greatly encouraged and appreciated!!!