Mass Flow Analysis (Between Pump outlet and Ventilator outlet)
P13027: Portable Ventilator Team Leader: Megan OConnell Matt Burkell Steve Digerardo David Herdzik Paulina Klimkiewicz Jake Leone 1 of 75 Technical Review Overview Engineering Specs Proposed redesign Battery and Power Calculations Power: Electrical
Electric Board Layout SPO2 Sensor CO2 Sensor Pneumatic Design Pressure Sensor Testing Housing Vision-Casing Structure Project Comparison System Testing BOM Risk Assessment Project Passover Questions? 2 of 75
Engineering Specifications Portable Emergency Ventilator Engineering Specifications - Revision 1 - 03/19/13 Specification Number Source Function Specification (Metric) Unit of Measure
Marginal Value S1 PRP System Volume Control Liters S2
PRP System Breathing Rate BPM, Breaths per Minute S3 PRP System
Pick Flow Liter/Min S4 PRP System Air Assist Sensitivity cm H20
0.5 0.5 S5 PRP System High Pressure Alarm cm H20 10 - 70
S6 PRP System DC Input Volts 6 - 16 S7
PRP System DC Internal Battery Volts 12 S8 PRP
System Elapsed Time Meter Hours 0 - 8000 S9 PRP System
Pump Life Hours 4500 S10 PRP System O2 / Air mixer
O2 S11 PRP System Secondary Pressure Relief cm H20 75
S12 PRP System Timed Backup BPM S13 PRP System
Weight Kg 8 Drop Height meter S14 3 of 75
Robustness Ideal Value Comments / Status 0.2 0.2 4 -15 15 - 60 21% - 100 % 1
Due to battery, must be greater than 9V Revision B- Proposed Redesign Update: 1. Battery Size-> Reduce Size & keep same capacity 2. Reduce Circuit Board size-> Create custom board for all electrical connects 3. Reduce Electrical Drive Motor 4. Display Ergonomics 5. Reduce Size and weight of PEV 6. Instruction manual Additions:
7. Visual Animated Display-> Moving Vitals 8. Memory capabilities 9. USB extraction of Data 10. Co2 Sensor as additional Feature to PEV 11. Mechanical Overload Condition due to Pump Malfunction 4 of 75 Battery Choice: Tenergy LiIon 14.8 V 4400mAh 0.8375 lbs 7.35cm x 7.1cm x 3.75cm Rechargeable up to 500 times Price: $50.99
Bulk pricing Each cell: $3.18 = $25.44 (8 cells) $10 Protection Circuit Module ~$40 with packaging and connectors 5 of 75 Power Calculation Current (A) Voltage
(V) Power (W) Pump 3 11.1 16.65 MCU + electronics
0.5 3.3 1.65 LCD 0.15 10 1.5
Total 6 of 75 3.65 Battery Voltage (V) 19.8 14.8 Battery Capacity (Ah) 4.4
Battery Capacity (Wh) 65.12 Expected Battery Life (Hrs) 3.29 Charger (Brick) HP AC Adapter 18.5V 3.5Amps
Power: 65W Max power: 70W Price: $14.35 (Amazon) Bulk pricing: $6.48 when quantity of 1000 is bought 7 of 75 DC-DC Boost Converter T.I. TPS55340 8 of 75
Component Calculations Designed for Vin = 12-18V, Vout=18V, Iout= 2.5A Most components were chosen using TIs WEBENCH component selection tool Calculating RFREQ RFREQ(k) = 57500 ) = 57500 sw(kHz)-1.03 Calculating minimum Inductance required for CCM 9 of 75
Voltage Regulation Input and output capacitors were chosen with regard to values on datasheets. 10 of 75 Battery Charging Circuit Suggested Solution: 11 of 75 Our Solution
12 of 75 Battery Charging Circuit Many discrete components suggested by proposed solution were used Determining the values of R8 and R9: Timing Capacitors changed in order to set longer charging times for larger battery Thermistor not needed for our application, replaced with resistor. Current sense resistors set by: IFSS = 0.1V/R12 and IFSI = 0.2V/R18 Dual-channel Power MOSFET chosen for power switch rated well
for our application All components chosen with safety margins in order to achieve proper operation 13 of 75 Electrical Schematics Refer to Electrical Schematics (confidential) 14 of 75
Revised Board Layout 15 of 75 Connections to PCB User Inputs and Power 16 of 75 Sensors
and Audio LCD SpO2 Sensor Difference in Absorption between Red and Infrared is used to determine SpO2 17 of 75 SpO2 Sensor Continued Simplified Design:
18 of 75 SpO2 Flow Chart 19 of 75 Source: Freescale Pulse Oximeter Fundamentals and Design CO2 Sensor 1. Original Target -> Telaire 6004 OEM Module Problem: Supplier went out of business, similar models are not being sold by GE Sensing
2. GE SENSING: Does not sell CO2 OEM Module within concentration range needed Upon Further Investigation: The average exhale returns ~ 40,000 ppm of CO2 Dollar Range for CO2 OEM Concentration Modules (using NDIR) 20 of 75 CO2 Meter- K-30 10% CO2 Sensor Cost $249 for 1
$163 for 250+ Programmable Range: 0-100,000 ppm Accuracy: 30 ppm 3 % of measured value (up to 3% CO2) Sensor Life Expectancy: > 15 years Sampling Method: Diffusion Current Consumption: 40 mA average Simple analogue output sensor transmitter signal directed to OUT1 and OUT2 21 of 75 Electrical Bill of Materials
Total Cost: For 1: $311.94 For 100:$193.43 (This includes PCB, MCU, Sensors, and LCD) Refer to Electrical BOM for complete parts list (confidential) 22 of 75
Initial Test Plan for PCB Assembly Weeks 1 and 2: PCB Assembly First two weeks will be spent soldering PCB. 1. Check that all pads match component footprints If any component(s) do not match footprint, attempt to solder jumper wire to pins. If jumper wire is not possible or if component overlaps another component, make changes to PCB and reorder (2 week lead time +$66) 2. Solder components in CIMS using heat
gun and solder paste. Larger components such as connectors will be hand-soldered 23 of 75 Week 3: Power System I and Hello World Program Power System I: Powered from only external or only Battery 1. Apply 18V to external input power using Lab Power Supply. Set Current Limit to 500 mA to prevent damage to circuits. 2. Measure voltage on 10V, 5V and 3.3V nodes to confirm
outputs are as expected. 3. Disconnect external power and connect charged battery. 4. Measure voltage on 10V, 5V and 3.3V nodes to confirm outputs are as expected. Hello World Program: 5. Plug in JTAG connector. Ensure correct orientation. 6. Test to see if JTAG Debugger has connection to MCU. 24 of 75 Week 4: Power Systems II Motor Drive Testing Power Systems II: Battery Charging and various DC inputs 1. Connect depleted battery and attach oscilloscope
across battery and battery current sense resistor. 2. Apply external Power with Current Limit set to 2.5 A. 3. Observe that current stays less than or equal to 2 A and voltage on battery steadily increases up to but not over 16.8V. Monitor battery temperatures and discontinue temperatures if battery exceeds 110 F in Ambient. Motor Drive Testing: 4. Download PWM program to MCU 5. With Motor Disconnected, observe proper pulsing from MOT_PWM 6. Connect Motor 25 7. of 75
Test Motor from DC=.05 to DC=.66 Initial Testing 26 of 75 Initial Testing- Differential Pressure Sensor Model 27 of 75 Differential Pressure Sensor System Architecture No Capacitor
No Backpressure Differential Pressure Sensor Capacitor Backpressure 29 of 75 Static Pressure Sensor System Architecture No Capacitor No Backpressure 30 of 75
Screen Shots System Architecture DP Sens or GP Sens or 31 of 75 Screen Shots
Mechanical Capacitor DP Sens or GP Sens or 32 of 75 Screen Shots Electrical RC Circuit 10 k Resistor
Capacitor 100 FF DP Sens or 33 of 75 Screen Shots DP Sensor GP Sensor Results of temporarily resisting flow
and then releasing Pressure builds Flow spikes and then quickly levels 34 of 75 Video Proof Impact of mechanical capacitor in system Flow speed Sensor dampening Proof of flow sensor accuracy
Conversion of Mechanical Flow Sensor: Cheat: 12 = 20 l/min 35 of 75 Human TrialsDetermine if sensor can observe human backpressure System Architecture No Capacitor 36 of 75
Voltage to Pump Flow Pressure Sensor Free Reading V 3 6.5 7.5 l/min
375 400 Pressure Observed by Patient mV 202 65 56 Mechanical Relief Valve Pressure Release at 1 psi Reusable
37 of 75 Rough Correlation to Factory Specifications System Pressure 0-4.5 kPa (0-.65 psi) Patient Pressure 0.5-2 kPa (.07-.29 psi) 38 of 75 Concerns- Calibration Currently have no way of measuring pressure accurately
Mechanical gauge cannot handle pulsation Uncertainty as to whether we can calibrate against another digital sensor 39 of 75 Housing Modifications 13026 Physical Extremes: 15in long X 10in high X 7in deep Projected 13027 Physical Extremes: 12in long X 7.5in high X 7in deep
40 of 75 Team: 13026 Team: 13027 Housing Vision 41 of 75 Housing Vision Speaker
Mode O2 Sensor port CPR Compression CO2 Sensor port Manual Mask tube ports Power 42 of 75
BPM Flow Rate Pressure Limit Housing Vision 43 of 75 Housing Vision 44 of 75
Housing Vision 45 of 75 Housing Vision 46 of 75 Project Comparison GOAL: Analyze the size and weight reduction between major contributing components of MSD 13026 PEV to our projected design. 47 of 75
Summa ry: 48 of 75 Casing Assembly Material: Plastic, Styrene for molding with rubber soles to protect damaging case Goal: Create an enclosed structure for our system components. Problem: Limiting the capabilities to ability/ access vacuum molding
machine to produce similar appearance result as MSD 13026 49 of 75 Option 1- Recruit RIT Industrial Design Major to recreate vision Option 2- Create a paneled assembly from plastic Cons: - Visual appearance would degrade - Casing would not be seamlessly enclosed - Expense for sheet plastic (ranges from $50-$200 based Option
3- Purchase premade on thickness) Cons: - Visual appearance would degrade - Casing would make entire device be larger & heavier than intended casing System Testing 1. Usability Study
-Imagine RIT -Medical Personnel Discussions 2. Vibration Testing 51 of 75 1. Usability Study Breakdown 1 2 3
INSTRUCTIONAL INTERACTION LIKERT SCALE RATING COMPONENT COMPARISON Goal: Gain user feedback from actual interaction with device.
Goal: Gain a mass feedback on overall look and operation of the device. 1. Guide user through medical scenario and operation. 2. Instruct user to operate with system inputs 3. Ask questions about the user/device
interaction 1. Create handout to be filled out by on-viewers 2. Scaled rating (110) of critical components of design. Conversational Feedback Goal: Understand and Maximize usability of
critical user operated components. 1. Knob Board Comparison with physical examples 2. Overall geometry comparison (using Davids sketches) 3. Original MEDIRESP III to MSD 13026 hands on part Mass feedback from comparison
overall system aesthetic Direct Feedback of liking to a specific Likert Survey for Imagine RIT (5/4/13) FOR IMAGINE RIT 13027 will provide: 1. Survey Print Outs 2. Clip boards 3. Folder for
completed forms 4. Pens 5. Knob Board 53 of 75 2. Vibration Analysis Performed pump vibration testing with the assistance of Dr. Lam. Pump was run at 100% duty cycle at 12v. Mono-axis accelerometer used Data was collected in Labview.
Data collected on 3 axes. 54 of 75 Vibration Analysis- Part 1 Raw data in volts Volts Gs Acceleration Force Force=V*exp factor*gravity*mass of pump For worst case, maximum voltage was .1V in any direction F(N)=.1V*1G/100mV*9.81m/s^2*1.731kg
Maximum Force = 1.69795 N 55 of 75 Vibration Analysis- Part 1 This force then used in failure analysis. 1st failure scenario: vertical tear-out 56 of 75 *not to scale Vibration Analysis-Part 1 Static Analysis
Ultimate strength of polystyrene is 40 MPa. Evaluated at a factor of safety of 2.5X The calculated minimum nut diameter is 1.3299e-5in This is significantly smaller than any practical nut and bolt combination that would be used. 57 of 75 Vibration Analysis- Part 1 Fatigue Analysis
58 of 75 Source: Characterization and Failure Analysis of Plastics, ASTM, 2003 Vibration Analysis- Part 1 Designing for infinite life Assumed completely reversing stresses For polystyrene =10 Mpa (infinite life) For safety factor of 2.5X, evaluate at 4MPa Evaluating using the previous formula. The calculated minimum nut diameter is .00209in
This is significantly smaller than any practical nut and bolt combination that would be used. 59 of 75 Vibration Analysis- Part 2 2nd failure scenario: lateral tear-out 60 of 75 *not to Vibration Analysis Part 2 Static Analysis
Ultimate strength of polystyrene is 40 MPa. Evaluated at a factor of safety of 2.5X, evaluate at 16MPa. Stress concentration factor for plate with circular hole, Kf=2 The calculated minimum distance to the mounting plate edge is 8.14715e-4in This is a very reasonable distance to design to. 61 of 75 Vibration Analysis Part 2 Designing for infinite life
Assumed completely reversing stresses For polystyrene =10 Mpa (infinite life) For safety factor of 2.5X, evaluate at 4MPa Evaluating using the previous formula. The calculated minimum distance to the mounting plate edge is .00652in This is a very manageable distance to design to. 62 of 75 Bill of Materials (BOM) See BOM REV 5_1_13 within Confidential Folder.
63 of 75 Manufacturing Cost Analysis 64 of 75 Revised Technical Risk Assessment Revised Operational Risk Assessment 66 of 75
13027 Fall Staffing Request 1. Industrial Design Major Contributions: a. Case Construction b. Create improved case vision c. Improve user interface design (based on usability study) 2. Computer Engineer Major(s) Contributions: a. Programming of PEV system functions b. Integrate hardware outputs on display for visualization c. Design further advanced logic for software components
67 of 75 13027-Project Passover 70 of 75 71 of 75 72 of 75 73 of 75 13028 Staffing Proposal
1. Mechanical Engineer (1-2) 2. Electrical Engineer (1-2) 3. Computer Engineer (3-4) ** 4. Industrial Engineer (1) 5. Industrial Design Major (1) 74 of 75 QUESTION S? 75 of 75
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