Files for Recurrent Manufacturing ORSELLI SMARTEX Peer Reviewers Name Organization Andreas RAPTOPOULOS EXUS Vassilis KILINTZIS AUTH Ioannis KOUTRAS EXUS Revision History Version Date

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FP7-611223

Project co-funded by the European Commission under the

Information and Communication Technologies (ICT) 7th

Framework Programme

Files for Recurrent Manufacturing

Document Identifier: D4.4 Due Date: 30/10/2015

Delivery Date: 06/11/2015 Classification: Public

Editors: Josias WACKER, Olivier CHÉTELAT Rita PARADISO Laura CALDANI

Document Version: 1.0

WELCOME Wearable Sensing and Smart Cloud Computing for Integrated Care to COPD Patients with

Comorbidities

Contract Start Date: 1st November 2013 Contract Duration: 48 months

Project Partners: EXODUS (GR), CSEM (CH), KINGSTON (UK), AUTH (GR), INVENTYA (UK), CAU (DE), ROYAL COLLEGE OF SUR (IR), SMARTEX (IT), CIRO+ B.V. (NL), Kristronics GmbH (DE), UNIVERSADE DE COIM (PT), Croydon Health Servi (UK)

D4.4 – Files for Recurrent Manufacturing Page 2 of 18


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Contributors

Name Organization

Olivier CHÉTELAT CSEM

Josias WACKER CSEM

Michaël RAPIN CSEM

Christophe MEIER CSEM

Abdessamad FALHI CSEM

Etienne HÄNNI CSEM

Jacques-André PORCHET CSEM

Rita PARADISO SMARTEX

Laura CALDANI SMARTEX

Carlo MANCUSO SMARTEX

Maria PACELLI SMARTEX

Olimpia SACCHETTO SMARTEX

Roberto ORSELLI SMARTEX

Peer Reviewers

Name Organization

Andreas RAPTOPOULOS EXUS

Vassilis KILINTZIS AUTH

Ioannis KOUTRAS EXUS

Revision History

Version Date Modifications

01 14/10/2015 V1 released

0.3 04/11/2015 Corrected according to internal reviewers’ comments

1.0 06/11/2015 Submission


Executive Summary

This report sums up the files for recurrent manufacturing of all sub-units of the WELCOME vest

system. Namely, these sub-units are the measuring sensors (type I and type V), the reference sensor

and the textile vest (with cabling and accessories such as press buttons and a zipper).


Table of Contents

Executive Summary .................................................................................................................................. 5

1 Introduction ..................................................................................................................................... 7

2 Type V sensor ................................................................................................................................... 8

2.1 Electronic components ........................................................................................................... 8

2.2 Mechanical components ......................................................................................................... 8

3 Type I sensor .................................................................................................................................. 10

3.1 Electronical components ...................................................................................................... 10

3.2 Mechanical components (housing) ....................................................................................... 10

4 Reference Sensor ........................................................................................................................... 12

4.1 Electronical components ...................................................................................................... 12

4.1.1 Optical part PCB ................................................................................................................ 12

4.1.2 Processing part PCB .......................................................................................................... 12

4.2 Mechanical components (housing) ....................................................................................... 13

5 Textile vest ..................................................................................................................................... 14

5.1 Fabrication procedure of the vest......................................................................................... 14

5.2 Buttons .................................................................................................................................. 15

5.3 Cabling .................................................................................................................................. 16

6 Conclusions .................................................................................................................................... 17

Abbreviations ......................................................................................................................................... 18


1 Introduction

WELCOME is a European project which aims at improving the quality of life of patients who suffer

from chronic obstructive pulmonary disease (COPD). One strategy to reach this goal is to closely

monitor several relevant health parameters of COPD patients. One part of the WELCOME system is

therefore a vest containing sensors which are in direct contact with the patients’ skin and measure

various physiological signals (e.g. electrocardiogram [ECG], activity, blood oxygen saturation [SpO2]

electrical impedance tomography [EIT] of the chest).

While D4.1 has detailed the design of the WELCOME vest, this document assembles all necessary files

for the production of all sub-systems of the WELCOME vest. These subsystems are namely:

Type I sensors

Type V sensors

Reference sensor

The textile vest

Each measuring sensor consists of an electrical part (battery and PCB with mounted electronic

components) and of a mechanical part (housing and structural elements inside the sensor housing).

Both, mechanical and electrical parts are detailed with drawings and production files. Files for

production of electrical parts were transferred to KRISTRONICS..

The vest consists of a textile part with wiring and of accessories (snap buttons and a zipper). These

items are also detailed in the respective chapter.

For reasons of confidentiality, this document does not detail every part of the vest. For each item of

the vest, we therefore list the files which are comprised in the full master document. All files are

available at request (contact [email protected]).

mailto:[email protected]


2 Type V sensor

Type V sensors measure ECG and EIT tensions and chest sounds.

2.1 Electronic components

Figure 1 and Figure 2 show photographs of a prototype of the type V sensor electronics.

The following files for recurrent manufacturing were transferred to KRISTRONICS:

The layout schematics of the electronic circuits

The assembly drawings of the routed PCBs

Drawings with the mechanical dimensions of the PCBs

The bill of materials

The pick and place file specifying the assembly of the electronic components on the PCB

Figure 1: Prototype of the electronics of a type V sensor, made with rigid/flexible PCB technology (outer face).

Figure 2: Prototype of the electronics of a type V sensor (inner face).

2.2 Mechanical components

Figure 3 and Figure 4 show cut views along two different axes of the type V sensor.

The files for recurrent manufacturing contain:

3D drawing of the silicone hood

Technical drawing of the button

Technical drawing of the conductive foam between interior electrode and electret

Technical drawing of the conductive foam between pin and PCB

Technical drawing of the exterior electrode with hole (type V)

Technical drawing of the interior electrode

Technical drawing of the pin


Technical drawing of the foam piece between PCB and housing top piece

Technical drawing of the printed electret, including instructions for printing on a foil

3D drawing of the housing cover

Bill of materials

Assembly procedure

Figure 3: Sagittal cut view of a type V sensor.

Figure 4: Longitudinal cut view of a type V sensor.


3 Type I sensor

Type I sensors inject small currents for EIT measurements.

3.1 Electronical components

Figure 5 and Figure 6 show photographs of a prototype of the type I sensor electronics.

The following files for recurrent manufacturing were transferred to Kristronics:






Figure 5: Prototype of the electronics of a type I sensor, made with rigid/flexible PCB technology (outer face).

Figure 6: Prototype of the electronics of a type I sensor (inner face).

3.2 Mechanical components (housing)

Figure 7 and Figure 8 show cut views along two different axes of the type I sensor.


3D drawing of the silicone hood

Technical drawing of the buttons

Technical drawing of the electrode

Technical drawing of the foam between PCB and housing top piece

3D drawing of the housing top piece

Bill of materials

Assembly procedure


Figure 7: Sagittal cut view of a type I sensor.

Figure 8: Longitudinal cut view of a type I sensor.


4 Reference Sensor

4.1 Electronical components

4.1.1 Optical part PCB

Figure 9 and Figure 10 show 3D drawings of a prototype of the mounted reference sensor PCBs.

The following files for recurrent manufacturing were transferred to KRISTRONICS:






Figure 9: 3D drawing of the optical part PCB of the reference sensor (inside face).

Figure 10: 3D drawing of the optical part PCB of the reference sensor (outside face).

4.1.2 Processing part PCB

Figure 11 and Figure 12 show 3D drawings of a prototype of the mounted reference sensor PCBs.

The following files for recurrent manufacturing were transferred to Kristronics:







Figure 11: 3D drawing of the processor part PCB of the reference sensor (inside face).

Figure 12: 3D drawing of the processor part PCB of the reference sensor (outside face).

4.2 Mechanical components (housing)

Figure 13 and Figure 14 show cut views along two different axes of the reference sensor.


3D drawing of the case

3D drawing of the cover

Technical drawing of the outer electrode

Technical drawing of the inner electrode

Technical drawing of the screens above the LEDs

Technical drawing of the screens above the photodiodes

Technical drawing of the buttons

Bill of materials

Figure 13: Sagittal cut view of the reference sensor.

Figure 14: Longitudinal cut view of the reference sensor.


5 Textile vest

The garment consists on the following materials:

Light fabric composed by 75% PA (Polyamide), 25% EA (Elasthan)

Heavy fabric, composed by 50% PA, 50% EA

Labels (textile and printed)

Snaps buttons

Stainless steel multifilament insulated cable

Zippers

100% PU (Polyurethane) adhesive film

100% PA fabric net

The suppliers of the above mentioned materials have been contacted to buy the needed material to

produce in total 90 vests in two models, required in the project.

5.1 Fabrication procedure of the vest

To start with the realization of the vest the design of the garment shape is needed; this first step is

fundamental in order to have a functional final product. The design is realized following the

requirements on the wearability and the deployment of the electrodes on the shirt.

Once the textile vest has been designed, the process proceeds with the:

Drawing of the paper patterns in male and female models

Development of the paper patterns in the different sizes for female and male model.

Once the paper patterns have been developed and the sizes of the garments have been fixed, the

procedure to manufacture in a recurrent way is:

Placing of the paper patterns on the fabric in order to industrialize the cutting process

Cutting the fabric

Marking the 82 snap positions on the fabric

Cutting 41 rectangles of adhesive film (to reinforce the snaps positions)

Transferring the cut rectangles on the fabric, on the snap positions

Transferring of the 41 printed labels on the fabric with the letters indicating the right

positions of the sensors

Partial assembly of the garment

Application of the snaps buttons on the garment (partially assembled)


Soldering of the cable on the snap buttons (cabling)

Final assembling of the garment and finishing with the application of zippers and sewing

labels

Ironing and packaging.

Figure 15: Two steps of the manufacturing process: The photo on the left shows the development of the paper pattern in different sizes; in the right photo the positioning of the 41 rectangles of adhesive film on the fabric is shown.

The most important steps of the manufacturing process have to be done manually: a high precision is

required in the placing of the snaps to make sure that the electrodes are placed at the correct spot on

the body, which greatly influences the functioning of the EIT reconstruction algorithm; more precisely

the distances between the snaps must change with sizes and shapes of the garment.

Due to the novelty of the product in the textile industry, there are no standard procedures to

automatize the steps done manually. In particular to automatize the positioning and the application

of the buttons on the vest a new procedure should be implemented, and it has to be different for

each size of the vest; but for the project, the number of vests to produce for each size does not justify

the implementation cost. This means that at this stage a mass production of the vests cannot be

done.

5.2 Buttons

The snap buttons have been selected by CSEM (beneficiary Nr.2), to be compatible with the

electronics. From the textile point view, the dimension of the selected snap buttons makes the

garment heavier, compromising the wearability of the vest. Lighter buttons with the same size are not

acceptable from the electronic point of view, because this implies a redesign of the electronics;

furthermore stainless steel buttons with a smaller diameter are not available for sale in stock service:

we would have to purchase a large quantity of these items because the seller needs to start a new

production process to answer to our request; this option will be taken into account for a future mass

production of the vests.


5.3 Cabling

The cabling of the vest is not an industrializable process, due to the difficulties of the soldering: the

selected cable is an insulated stainless steel multifilament (see Error! Reference source not found. ),

the insulation has to be removed from the cable before soldering it on the top of the snap buttons.

This has to be done in for each button; moreover the thick diameter of the cable, needed to reduce its

electrical resistance, makes it more rigid than the previous one (see Error! Reference source not

found.): this makes it difficult to manage the cable between two soldering points; the consequence is

that the cabling is done manually which is time- and resource consuming.

For recurrent manufacturing the production of a special cable is required to simplify the soldering

process, but this implies the purchase of a large quantity; this option can be taken into account for a

future mass production of the vests.

Figure 16: The new cable

Figure 17: A comparison of the diameters of the new and the old cable (black sheath)

6 Conclusions

In this report, we have presented the files necessary for recurrent manufacturing of the WELCOME

vest. In more detail, these files contain the mechanical design and the electrical schematics of all

components of the sensor vest. The files were sent to the partners and sub-contractors for

manufacturing analysis and have already been produced for a prototype vest. The parts are being

produced in the next 6 months. Moreover we have described the steps for the realization of the

textile vests; the final model of the vest has been developed and a final prototype has been realized;

in the next months we will start with the production of the garments foreseen in the project.


Abbreviations

COPD: Chronic Obstructive Pulmonary Disease

ECG: Electrocardiogram (recording of the heart activity through electrodes)

EIT: Electrical Impedance Tomography (imaging procedure which is based on

the impedance of the inspected object)

EA: Elastan (synthetic material)

PA: Polyamide (synthetic material)

PCB: Princted circuit board (board on which electrical components are

connected to each other)

PU: Polyurethane (synthetic material)

SpO2: Blood oxygen saturation

Documents

Files for Recurrent Manufacturing ORSELLI SMARTEX Peer Reviewers Name Organization Andreas RAPTOPOULOS EXUS Vassilis KILINTZIS AUTH Ioannis KOUTRAS EXUS Revision History Version Date