TRANSCUTANEOUS ENERGY TRANSFER SYSTEM
Transcript of TRANSCUTANEOUS ENERGY TRANSFER SYSTEM
TRANSCUTANEOUS
ENERGY
TRANSFER
SYSTEM
GOALS OF DETAILED DESIGN
REVIEW
Source:
http://www.nuclearcardiologyseminars.net/images/anterio
r.jpg
We are seeking customer approval of our design and approval to spend money.
Inform the customer of our decision making process.
MISSION STATEMENT TETS TEAM P13021
To design and produce a commercially viable Transcutaneous Energy Transfer system with the ability to power a left ventricular assist
device (LVAD). This TETS device will use a magnetic coupling to enhance the patients quality
of life while operating in a safe, efficient, reliable and user friendly manner.
Source:
http://www.nuclearcardiologyseminars.net/images/anterio
r.jpg
WORK BREAK-DOWN
STRUCTURE MSD II Work Breakdown
Name Role in meetings
Mike Brown ME ME Technical LeadDesign Housing
(Generate Prints)
Source Bio-
materialsMachine Assist
Andy Hladky ME Note TakerUpload Meeting
NotesRunning Tests
Assembly &
Manufacturing
Charles Borton ME Systems Integration Manufacturing Testing
Ian Dominick ME Purchasing Magnetic Coupling
Paul Blaszczynski EE EE Technical Lead
User Interface
(Zigby, Motor
control)
Separated
Generator Lead
Kyle Pickard EE Heat GenerationRectification
Ciruits
Abdoulaye Diaw EE Battery & Charging
Ariel Christopher ID Graphics DesignManage Power
Points
Human Factors &
Design for
Usability
Renderings
Alexander Turner IE Project ManagerInternal External
Communications
Manage Edge
Website
Testing plans
(DOE)
Tasks & Focus
CUSTOMER NEEDS ENGINEERING NEEDS and SPECS
ENGINEERING METRICS ENGINEERING NEEDS and SPECS
HOUSE OF QUALITY ENGINEERING NEEDS and SPECS
Customer Needs Cu
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Pro
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Lig
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(Sy
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Sm
all
Co
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Pre
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ure
Transmit Power
Wirelessly9 9 9 3 3
Complete
System9 3 3 3 3 1 1 3 3 3
Lasts Long and
is Reliable9 9 9 9 3 9
Implantable 9 3 9 3 3 9 9 1 3 3
Product is
Sealed/Safe9 9 3 9
Easy to
Use/Customer
Friendly
9 3 3 3 3 9 3 3
Small 3 9 9 1 9
Light 3 1 9 1
Comfortable 3 1 3 3 3 3 1 3 9
User Interface 3 9
Ta
rge
t V
alu
es
50
Wa
tts
12
~1
5 V
olts
> 1
0 Y
ea
rs
IP6
8
< 0
.02
54
m (
1in
)
5 y
ea
rs
< 0
.05
08
m (
2in
)
IP4
3
5 S
eco
nd
s
99
% R
ela
ibility
< 4
0 m
W/c
m2
0 A
mp
s
< 0
.45
kg
< 0
.07
62
m (
3in
)
25
N/c
m2
138 108 135 270 93 108 63 90 117 189 117 198 42 66 81
7.60% 5.95% 7.44% 14.88% 5.12% 5.95% 3.47% 4.96% 6.45% 10.4% 6.45% 10.91% 2.31% 3.64% 4.46%
4 8 5 1 10 8 14 11 6 3 6 2 15 13 12
Relative Weight
Rank
Engineering Metrics
Internal Assembly External Assembly
Raw Score
Output Power (From generator/stator)
• Tools: Multimeter (or Oscilloscope), Configurable Load
• Independant: rpm, gap, angle, medium (if shown to affect torque)
• Dependant: Amperage out, Voltage (Level & Freq.) out
Time to start operation:
• Tools: Stopwatch
• Independent: Range of motion, One hand vs. two handed
• Dependant: Time to start, Qualitative
TEST PLAN
Flux:
• Tools: Calorimeter (Styrofoam cooler, heating element, thermocouple)
• Independent: Wattage generated, RPM
• Dependant: ΔTemp
• Confounding: Ambient temp
Product life: Mechanics of failure, FMEA
Waterproof: Bubble test (Shows air-proof)
Dimensions: Calipers
Reliability: Failure Mechanics, Benchmarking
Weight: Scale
Contact Pressure: Test rig for last years device. (vary with gap)
TEST PLAN
FUNCTIONAL DECOMPOSITION ENGINEERING NEEDS and SPECS
FEASIBLILITY ANALYSIS PRO’S AND CON’S
Magnetic Coupling Separated Generator
Experimentation Validates No Moving Internal Parts
Known Improvements Small
Low Internal Heat Generation
No Magnetic/Attractive Forces
Scalable
Heavier Higher External Heat Generation
Very strong attractive force Distance Dependant Power Output
More Rotating Mass Large Input Power
Heat Generation 6.6 W of heat at 30 watts 5.4 W at 30 Watts (assume 12V)
Max Power Generated 30 watts 50 watts
Pros
Cons
Key Quantitative
Specs
SYSTEM PROPOSAL
RISK ASSESSMENT
RISK ASSESSMENT NON-TECHNICAL
Our Proposal
The Stator presents the best possibility to meet and beat customer specifications, by generating highly scalable power with less heat generation.
The Motor – Generator pair provides a path that has less risk, while still having the ability to complete the task.
Our team proposes to pursue both, with the intention to provide a meaningful comparison within the context of the TET - Device
Motor
• Maxon EC 45 Flat 50W
• Has max RPM of 10000 rpm and a relatively small depth, 24mm for the motor and an additional 17mm for the shaft, which could be shaved down to be only as long as the magnetic coupler is deep. Being just under 2 inches
Motor Housing
Motor Housing Thermal Analysis •External temperature is less 29C
•Safe for patient to hold after steady state operation
•Maximum heat flux is 17.3mW/cm2
•Only at extreme boundary conditions - high estimate
Motor Controller/ UI
• ESC- HobbyKing SS30A Weight: 22g Size: 24x52x6mm Cells: 2-3S (Auto Detect) Max Current: 25A Burst: 30A BEC: 3A
B-Field Calculations
Stator Calculations
Stator Heat Calculations Power through * (1-efficiency) = Heat generated
30 watts * .22 = 6.6 Watts
Heat generation for the Stator is a factor of the
Joule Heating, which can be calculated as
follows:
Per stator:
Current- I = W/V = 0.833
lossy of copper- rho = 1.72E-8
length of cable- 10m
Cross Sectional Area- 26awg = 1.28824934E-7
Number of stators- N = 6
=5.56Watts
Separated Generator Receiver Housing
Generator Receiver Housing
Receiver Housing Impact FEA
Thermal Analysis
Assumptions:
• Body Temperature (Environment) is 37˚C
• Heat distribution on outside of device will be modeled via FEA
• Heat transfer method inside body is conduction
• All energy inefficiencies result in heat generation
• Device is surrounded my muscle tissue which is at equilibrium between perfusion and heat generation
Critical Values
The purpose of our thermal model is to ensure this device will not harm the patient.
With a factor of safety of 2, our maximum heat flux through the tissue is 40mW/cm2
Data
• Reference Temperatures[C]: • Body Temp= 37 C • Ambient Air Temp= 25 C
• Conduction Coefficients : • Internal Organs and Muscle = 0.500 W/m*K • Skin and Fat=0.300 W/m*K • High Density Polymer=0.22 W/m*K (P13021 only) • Steel=50 W/m*K • Aluminum=204 W/m*K • Clothing=0.029 W/m*K • Convection Coefficients [W/m*K]: • Air=10.000
Conduction
Internal Environment
(Abdomen Muscle)
Engineering Model
Device
Boundary Temp: 37˚C
•The Device will be implanted in abdomen muscle
•Assuming a worst case scenario, the device will be surrounded by muscle tissue in all directions for an “infinite” thickness.
•An ANSYS model which includes the boundary temperature of 37˚C and all muscle properties will show worst case temperature and flux conditions
Generator Housing Thermal FEA
Stator Housing Thermal FEA
Torque Graphs
Breakaway Torque Test Results
20 8.723453 5.99 5.9549 19.938664 19.872739 19.725036 24.921568 24.9 24.896241
15 5.936889 6.644 7.1024 19.966121 20.039976 19.889522 35.705872 41.3 40.929263
10 11.876832 8.7775 8.6658 24.779658 24.740295 24.937439 35.6192 40.9 41.154175
Gap (mm)RPM / Breakaway Torque (mN·m)
2000 4000 6000
Pull Force Graph
Magnetic Coupling Simulation
Matlab Code • uo=4e-7*pi; % Permeability of the magnets
• M=1.6e6; % Magnetization of the magnets
• R=(.5/2)*(2.54/100); % Magnet Radius
• t=.25*(2.54/100); % Magnet Thickness
• th=(pi/4); % Theta (Angle between magnets)
• gap=[0:0.0005:.030]; % Gap between the arrays
• DR=(0.835-R*100/2.54)*(2.54/100); % Magnet ring radius
• s=sqrt((DR*th)^2+(gap).^2); %Linear distance between magnets
• n=8; % Number of magnets
• w=[0:100:12000]; % RPM
• for i=1:length(s)
• phi_o(i)=atan((gap(i))/(DR*th));
• Fo(i)=((pi.*uo)./4).*(M.^2).*(R.^4).*((1./(s(i).^2))...
• +(1./(s(i)+2.*t).^2)-(2./(s(i)+t).^ 2)); %Force Between Magnets
• Fy_o(i)=Fo(i)*cos(phi_o(i)); % Pull Force for single magnet
• To(i)=DR.*Fo(i)*cos(phi_o(i)); % Torque for single magnet
• end
• T=n*To; % Torque with 8 magnets
• F=n*Fy_o; %Force with 8 magnets
• figure(1)
• plot(gap,F,'-r'); %changed for gap
• hold on
• title('Pull Force');
• legend('Force');
• xlabel('Gap Distance in Meters');
• ylabel('Force [N]');
• grid minor
• hold off
• hold off
• figure(2)
• subplot(2,2,1);
• plot(gap,T)
• grid minor
• xlabel('Distance in Meters');
• ylabel('Torque [N*m]');
• title('Torque Available');
• Torquereq1=(50./w).*(60./(2.*pi)); % Torque Required for 50 watts of power (P=T*w)
• subplot(2,2,2);
• plot(w,Torquereq1)
• grid minor
• xlabel('RPM');
• ylabel('Torque [N*m]');
• title('Torque Required for 50W');
• Torquereq2=(30./w).*(60./(2.*pi));
• subplot(2,2,3);
• plot(w,Torquereq2)
• grid minor
• xlabel('RPM');
• ylabel('Torque [N*m]');
• title('Torque Required for 30W');
• Torquereq3=(10./w).*(60./(2.*pi));
• subplot(2,2,4);
• plot(w,Torquereq3)
• grid minor
• xlabel('RPM');
• ylabel('Torque [N*m]');
• title('Torque Required for 10W');
Rectification
• Ripple of 2.5%
Soldering Breadboard
for Rectifier
Conversion to Useful energy
• According to simulations after the rectification from either method of power transfer we will not need a Buck converter (Step down circuit) but if we do, this one would be adequate.
Battery Charger
• Can handle an input from 9V to 36V DC.
• Input pins for thermal warning from battery
• Optimal efficiency is input of 12-18V
• Can handle an upper charge current of 1.2A
Battery
• Li-Ion 2600mAh
• Dimensions 70mm X 55mm X 18mm
• Weight: 5.3 oz
• Max charge current: 2A
• Overcharge protection
What it Looks Like
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External Mounting
What we need to get there
• BOM PART 1
Part Name Material Manuf. Method Manufacturer Manufacturer
Part #
Distributor Distributor Part # Quantity
Needed
Unit MFG
Time (hrs)
Total MFG
Time (hrs)
Quantity
Ordered
Unit Price Total Price Lead
Time
Owner Comments
AC/DC converter NewEgg 9SIA0YE08B
2624
1 $45.00 $45.00 1 Week Paul
ESC HobbyKing HK-SS30A 1 $6.00 $6.00 1 Week Paul
ESC - Connectors (10) HobbyKing AM1001A 2 $1.60 $3.20 1 Week Paul
Outside motor Maxon Motor EC 45 Flat
50W
MaxonMotor 251601 1 $105.60 $106.50 2
weeks
Abdoul
housing(2 Pieces) HDPE Manual
Machining
McMaster
Carr
8671K79 1 25 25 $23.15 $23.15 1 week Charles
magnetic array 416 SS/
NdFeB
Made Magnetic
Technologies
Ltd
MTD-0.6-
0000
1 1 $41.00 $47.14 1 Week Ian Have began
testing with
this component
Mounting Fabric Elastic by hand Joann fabric 1 $20.00 $20.00 1 day Ariel
Buckles/velcro Plastic/
Metal
by hand Joann fabric 1 $10.00 $10.00 1 day Ariel
batteries AA Wegmans 6 $1.00 $6.00 1 day Abdoul
Xbee SparkFun WRL-08665 1
$23.00
$23.00
1 Week
Paul
Xbee - Shield SparkFun BOB-08276 1
$3.00
$3.00
1 Week
Paul
Arduino SparkFun DEV-11021 1
$1.00
$1.00
1 Week
Paul
headers - Male SparkFun PRT-00116 5
$1.50
$7.50
1 Week
Paul
headers - Female SparkFun PRT-00115 5
$1.50
$7.50
1 Week
Paul
2mm Sockets SparkFun PRT-08272 2
$1.00
$2.00
1 Week
Paul
LCD display Digikey NHD-12864WX-
T1TFH
1 $16.00 $16.00
1 Week
Kyle
Housing (2 Pieces) HDPE Manual
Machining
McMaster
Carr
8671K79 1 25 25 $23.15 $23.15 1 week Charles
Wire 1 $0.00
1 day
Kyle Found on
campus
P13021 Transcutaneous Energy Transfer System
Bill of Materials
OUTSIDE
UI
What we need to get there
• BOM Part 2 Housing ABS
(PEEK)
Manual
Manufacturer
Acrylonitrile
Butadiene
Styrene
(Poly Ether
Ether
Interstate
Plastics
1 30 30 (3.5,3.5
,2.5)
43.83
(296.17)
$43.83 1 week Charles Price/Availabilit
y of implantable
material
Grommet- housing Silicon
hose/pas
te
(maybe
paste)
1 $0.00 1 week Charles Paste idea from
Dr. Day
magnetic Hub array 416 SS/
NdFeB
Made Magnetic
Technologies
Ltd
MTD-0.6-
0000
1 1 $41.00 $47.14 1 week Ian Have began
testing with
this component
Motor Maxon EC 45 Flat
30W
200142 1 $74.00 $74.00 2
Weeks
Kyle
o-ring
EPDM O-
Ring
AS568A
Dash
Number 039
McMaster
Carr
9557K128 1 pkg $11.20 $11.20 1 week Ian 1 package
includes 50 o-
rings
Diodes Vishay BY500-400-
E3/54
Digikey BY500-400-
E3/54GICT-ND
6 - - $0.53
$3.18
1 Week Kyle
Rectifier PCB Advanced
Circuits
1 $0.00 3
weeks
Kyle Needs circuit
design
Rectifier PCB Advanced
Circuits
1 $0.00 3
weeks
Kyle Nees Circuit
design
Diodes Vishay BY500-400-
E3/54
Digikey BY500-400-
E3/54GICT-ND
6 - - $0.53
$3.18
1 week Kyle
Housing ABS
(PEEK)
Manual
Manufacturer
Acrylonitrile
Butadiene
Styrene
(Poly Ether
Ether
Keytone)
Interstate
Plastics
1 30 30 (3.5,3.5
,2.5)
43.83
(296.17)
$43.83 1 week Charles Price/Availabilit
y of implantable
material
o-ring
EPDM O-
Ring
AS568A
Dash
Number 039
McMaster
Carr
9557K128 1 Above $0.00 1 Week Ian
Grommet- housing Silicon
hose/
paste
(maybe
paste)
1 $0.00 1 Week Charles Paste idea from
Dr. Day
Heat Sink 6061 Al Manual
Machining
McMaster
Carr
1610T31 1 4 4 $16.51 $16.51 1 Week Andy
Ferous plate sheet
metal
Manual
Machining
1 2 2 $0.00 1 day Paul Spare Parts
Mag Wire Mag Wire Hand
Wrapped
6 plus
spare
2 14 $0.00 $0.00 1 day Paul Material at
school
Inside
Motor/gen
erator
Inside
Separated
Generator
What we need to get there.
• BOM Part 3
Housing ABS
(PEEK)
Manual
Manufacturer
Acrylonitrile
Butadiene
Styrene
(Poly Ether
Interstate
Plastics
1 30 30 (3.5,3.5
,2.5)
43.83
(296.17)
$43.83 1 week Charles Price/Availabilit
y of implantable
material
O-ring 1 $0.00 1 week Ian Size unknown
Grommet- housing Silicon
hose/pas
te
(maybe
paste)
1 $0.00 1 Week Charles Paste idea from
Dr. Day
Voltage Regulator 3.3 SparkuFun COM-00526 1 3 $2.00 $6.00 1 Week Paul
Xbee SparkFun WRL-08665 1 0
$23.00
$23.00
1 Week
Paul
Li-ion battery charger CircuitBo
ard
premade SilverTel AG112 Semiconducto
r Store
1 $12.50 $12.50 2
Weeks
Paul
Battery All-Battery AT: Tenergy Li- 2 $26.00 $52.00 Unsure Abdoul
Battery housing ABS
(PEEK)
Manual
Manufacturer
Acrylonitrile
Butadiene
Styrene
(Poly Ether
Ether
Keytone)
Interstate
Plastics
1 30 30 (3.5,3.5
,2.5)
43.83
(296.17)
$43.83 1 Week Charles Not sure of size
of battery
130 $774.17 $0.00
Inside
Battery
Charger
Internal
Battery
Totals
Legend
Ready to order
Do not know all info. and estimate time is
XX hrs.
Know what needs to be done and have XX
hrs of work
How we plan to get there
Week 1 Owner DOE & Analysis Other Tasks Other Tasks Owner
Rectification Designed & Build Kyle
Drawings for Charger & Battery Housing Mike Review for Manufacturability Charles
Motor Generator Pair bench test Ian Alex Build/find test rig Charles, Joe
Stator Bench test Paul Alex
Battery and Charger bench test Abdoul Assist with Battery Andy
Locating belt Designed Ariel
Modify Magnetic Array Charles Setup Assist Ian
Week 2 Owner DOE & Analysis Other Tasks Other Tasks Owner
Wireless communication & Display test Paul
Battery Charger & Battery Boxes Charles Setup Assist Andy, Ian
Test the Generator & Stator with rectifier Kyle (Comparison, Alex)
Battery Charger Status Call Abdoul
UI housing Engineerinig Drawing Mike User Experience/Manufacture Ariel, Charles
Week 3 - Functional Demo Owner DOE & Analysis Other Tasks Other Tasks Owner
Test the External Motor Through Battery Kyle Alex Set up Assist Abdoul
Drawings for External Housing Mike User Experience/Manufacture Ariel, Charles
Programming LCD for user display Paul
Presentation for Demo & Writing Paper Alex,Ian,Ariel,Andy
UI Housing Manufacture Charles Set Up Assist Andy, Ian
CITATIONS Bonfield, Tim. "Device to Help Hearts." Cincinnati Enquirer (November 7, 1999)
"How Artificial Heart is Made." Madehow. N.p., n.d. Web. 13 Dec. 2012.
U.S. National Library of Health and Medicine, ed. Medlineplus. N.p., n.d. Web.
13 Dec. 2012.
Cirtec Medical Systems, ed. Active Implants. N.p., n.d. Web. 13 Dec. 2012.
Cover photo: http://cdn.medgadget.com/img/he3sfe.jpg