AUTOMATED BLOOD SAMPLE DEPLOYMENT AND RETRACTION FOR ACOUSTIC RHEOMETER

Jeremy LeeShireen KheradpeyPeter IshiguroHsin-Chiao Frank LinAUTOMATED BLOOD SAMPLE DEPLOYMENT AND RETRACTION FOR ACOUSTIC RHEOMETERDetailed Design Review

MEBME & MEMEME||||

The droplet moving left and right after deploymentAs long as the droplet stops moving in seconds, it will be good for detecting blood clotting that the total timespan is over minutes

Our project was to design an automated blood deployment system for an acoustic levitator. To understand why the deployment system was necessary, I will first discuss what an acoustic levitator is and its potential applications in medicine.

COAGULOPATHYBlood unable to clot properlyTrauma-Leading cause of death 4-44 yrs-6M deaths per year-40% victims are coagulopathic-Excessive bleeding or clottingLiver surgery, blood transfusions, etc.

Statistics from the International Trauma Research Network

Coagulopathy can be excessive clotting as wellSlow clotting, rapid clotting

CURRENT SOLUTIONSMechanical Rheometers-Contact contamination-Large sample: 0.36mL-Qualitative not quantitative-Time consuming-No characterization of healthy blood

Can be *accurate* for clotting blood; they are accurate but not quantitativelyCan not characterize healthy blood

Non-contact manipulation-Squeezing-Rotation-OscillationSmall (0.03mL) sampleQuantitative-Whole healthy, liquid or solid-Clotting or clotted

ACOUSTIC LEVITATION

- Emphasis on healhty blood

PROPOSED SOLUTION

Think about the things that the audience needs to know to understand JUST the constraintsSmall position that needs to hitConstraints that is imposed on usENVIRONMENTAL CHAMBER! WHERE IS IT?- In the future improvements

THE PROBLEM: MANUAL DEPLOYMENTDesign an automated device to deploy a sample if known volume into an acoustic levitation field with minimal sample contact, instrumentation contamination, or human handling.

*watch the video with the audience**draw the audiences eye to where you want them to see*BIG DEAL, YO!

Say take a look at the video!. if that was bloodClean up; atomized with the manual deployment, No volume control

Show just the video, have the text after the video

CUSTOMER REQUIREMENTSGOAL:Design and fabricate a device to dispense a liquid sampleaccurately into the acoustic field to allow levitation-Automate sample deployment -Accommodate current modalities of blood samples-Deploy 0.03mL target volume-Minimally acoustically invasive

Let the picture distract the audience, SLOW DOWN

Introduce our customer; dont talk over it (5-10 sec)having thus setup , our goal to solve the problem

ENGINEERING SPECIFICATIONS

Dispense a target volume of roughly 0.03 mL Record range of successfully levitated drop volumesRange of entry exit speeds 0.46 in/sec - 2.29 in/secRecord range of successfully levitated drop volumesLevitate samples with 100% success rate (5x consecutively)Place 0.03 mL sample at pressure minimum of acoustic waves (approximately 6.02 from base of levitator)Allowable position tolerance in the lateral direction of 1 mm

GO SLOW, 1 minute slides

compare 0.03 ml to something tangible*because of the variability, discover the range that can repeatedly deployRequirements were rough targets; - Discover useable range; that can detect the entry and exit speed-Emphasize third bullet4. we will consider this later

Automated Sample Deployment Prototype

Deployment System

Holds Syringe

Accepts Liquid

Releases Syringe

Deploys Liquid

Entry/Exit System

Moves into Acoustic Field

Wait for Liquid Deployment

Exit Acoustic Field

Retrieval System

Removes Sample Safely

Adjusts Angle

3 different subsystems

CriteriaWeight FactorPeristalticSyringeMeteringVolume Control3021Manufacturability100-1Ease of Integration3020Cost100-1Reusability2000TOTAL0121

PUGH CHART:DEPLOYMENT PUMPS

*explain pugh chart: decision making matrix*Explain the numbers 3 Is important, etcSay :the way we decided bewteen initial designs, is giving a weighting factor of each design criteria, where Ease of integration: pumps and tubesverbally explain

PUGH CHART:SYRINGE EXIT/ENTRY SYSTEMCriteriaWeight FactorCAMLinear Drive(Lead Screw)PneumaticsRack & PinionEase of Integration200-11Cost30-2-11Repeatability/Accuracy20200Controllability201-11Speed20-200TOTAL0-4-77

CriteriaWeight FactorOpposing NeedleVacuumBlowerSample CatcherSample Versatility30122Maintenance2000-1Ease of Integration20-100Cost10-1-11Required Space200-10TOTAL0035

PUGH CHART:RETRACTION MECHANISM

Blower, but less important, so may or may not inclue into the prototype depending on the timefind one or two things to emphasize on

Parameter

Possible Solutions

Sample DeploymentPeristaltic PumpSyringe PumpMetering Pump

Syringe Enter and ExitPneumaticsLinear DriveRack & Pinion

Sample RetractionOpposing NeedleBlowerSample Catcher

SUMMARY: MORPHOLOGICAL CHART

PRELIMINARY DESIGN: Symmetric Needles

DOUBLE Syringe, quick retraction was only to break the surface tension the drop from the needle tip- Emphasize on the CAM and why it was needed

PRELIMINARY DESIGN: Pneumatics

Lead Screw Driven DeploymentPneumatic Entry/Exit

FINAL DESIGN:

sAM

Deployment System(Lead screw driven)Entry/Exit System(Rack & pinion driven)

why is it at any angle?Using gravity (BOTH gravity and acoustic force balances it :the phi)Max angle with the current geometry- Make the point; dual injectors (balance momentum)

DEPLOYMENT SYSTEM

Syringe

Syringe Pusher

Stepper Motor (1.8 steps)Syringe Mount

Motor Mount

Mounting Plate(Gear Rack on bottom)

Lead Screw(Lead = 0.05)

Lead Screw Nut

*any particular details*Choice of motors, why stepper?Choice of Commercial of the shelf syringesBACK UP SLIDESWith the syringe choice

DEPLOYMENT SYSTEM MECHANISM:

ENTRY/EXIT SYSTEM

Stepper Motor (1.8 steps)Angle BaseMounting Plate GroovesAngle BarHingePinion

Angle BarRadial Ball BearingStart Position Marker

Flexible with adjusting with different accoustic levitatorFuture designs are going to accommodate other levitators

ENTRY/EXIT SYSTEM MECHANISM:

ENTRY/EXIT ANGLE

-20 Shoulder ScrewAngle Base SlotsAngle Bars

3025

-

COMPLETE SYSTEM MECHANISM:

off the center axis notice how there are some translation oscillation that should be steadied.

Pave for future improvementsThe lateral force is 0 at the center; must be off centered; unless we have dual-injectorsThe drop sits on the syringe

SETUP

3.5 V Supply12 V SupplyArduino Microcontroller

Inputs:

-Entry / exit speed- Travel distance to acoustic field-Volume to deployStart Button

SETUP

TABLE TOP SETUP emphais

MOTORS

Shireen

SAMPLE VOLUME TESTING:

Deployable Sample Volume vs. Driving Voltage (mV)Constant Exit Motor Speed = 20 RPM = 1.8 in/sConstant Angle = 30Target volume 0.03 mL Driving Voltage(mV)Min Volume(mL)Max Volume(mL)4006.57E-031.75E-024505.47E-031.92E-025005.47E-032.57E-025504.93E-033.12E-026004.93E-033.33E-026504.38E-032.74E-027004.93E-032.85E-02

Levitator Driving Voltage not wave amplitudeSample Volume ErrorTalk about calibrationExplain points are absolute max and absolute minimumNo Standard Deviation, State range Reasons for smaller range at 650 and 700 mV: Instability

SAMPLE VOLUME TESTING:

Deployable Sample Volume vs. Exit Motor SpeedConstant Wave Amplitude: 600 mVConstant Angle = 30Target volume 0.03mLExit Speed(RPM)Min Volume(mL)Max Volume(mL)55.47E-032.85E-02104.93E-033.07E-02155.47E-033.50E-02204.93E-032.52E-02255.47E-032.46E-02

Target Volume (Rough Estimate) Can take data with any volume between ranges, more drop sizes is betterDrop due to backlash and disturbance (Include hypothesis)Too slow -> drop stays on needle, Too fast -> drop rips off

SAMPLE VOLUME TESTING:

Deployable Sample Volume vs. Exit Motor SpeedConstant Wave Amplitude: 600 mVConstant Angle = 25Target Volume 0.03 mLExit Speed(RPM)Min Volume(mL)Max Volume(mL)55.47E-032.74E-02104.93E-033.07E-02156.02E-033.01E-02204.93E-032.96E-02254.93E-032.85E-02

COST ANALYSIS:

Total Material Costs: $686.20

$203 from the Motorized Lead Screw

Remove BOM too smallChange to pie chart with percentages of cost (3 pie charts, 1 for total)

MATERIAL COST ANALYSIS:

Material Cost per Unit Based on Number Produced

Emphasize this is only one piece of manufactured unitOne modular unit of an entire system

Costs were calculated using machining time, plus an additional hour for assembly, a rate of $16/hr for a machinist.

MANUFACTURING COST ANALYSIS:

For Batch Production:Over 20% reduction in total cost per unit.

Over in hour saved in production time per unit.

TOTAL PRODUCTION COST:

GANTT CHART

Last Day to Machine

Prototype Assembled

Finished Machining

Started Machining

First Successful Levitation

First Successful Deployment

Mention Gantt chart created at beginning of semesterAdd something that says something (specific things to this project)Add important deadlines

REDESIGN

Rotation point about needle tipAngle adjustment without changing tip positionHeight AdjustmentRather than moving base & syringeIntegrate -20 Holes MountingMiniaturizeFit into environmental portMatch MotorsAllow single power source, decrease wire connectionsRetraction SystemSample catcherLabViewUser InterfacePosition CalibrationHoming limit switch

Add positioning registration (currently all manual for flexibility)Add picture of environmental chamber (Dont make it jarring)Design is bulky, miniaturize for possible chamber application as next logical step (Dont make it a big deal)Highlight important ones Implement Retraction System

Sponsors

ACKNOWLEDGEMENTSProject TeamDr. Glynn Holt, Associate Professor of Mechanical Engineering (Project Lead)Jarrod RisleyVahideh Ansari HosseinzadehSenior Capstone GuidanceBiomedical: Dr. Catherine Klapperich, Dr. Michael Smith, Dr. Thomas Szabo

Mechanical: Dr. Enrique Gutierrez

Dont read them, give specific thanks

BACKUP SLIDES

DEPLOYMENT EXPLODED VIEW:

Guide RailsLead Screw Nut Linear BearingsRadial Ball BearingsGear RackL-Bar

Motor Specs:Holding Torque = 6.6*10-2 NmSF = 67.7

100 L Syringe Requirements:Vmax = 6.40*10-3 m/sa = 2.80*10-3 m/s2Time = 5 sTorque = 9.75*10-4 NmNo. Steps: 2740

DEPLOYMENT MOTOR REQUIREMENTSSyringe Pusher Travel Distance = 1.74*10-2 m

1. Motor Turns Lead ScrewMotorLead Screw2. Nut and syringe pusher move horizontally together, deploying sampleNutSyringe Pusher

Motor Specs:Holding Torque = 6.6*10-2 NmSF = 7.22

500 L Syringe Requirements:Vmax = 6.40*10-3 m/sa = 1.50*10-3 m/s2Time = 5 sTorque = 9.14*10-3 NmNo. Steps: 654

DEPLOYMENT MOTOR REQUIREMENTSSyringe Pusher Travel Distance = 4.15*10-3 m

1. Motor Turns Lead ScrewMotorLead Screw2. Nut and syringe pusher move horizontally together, deploying sampleNutSyringe Pusher

ENTRY/EXIT EXPLODED VIEW

Mounting Plate Groove

Stepper Motor (1.8 steps)-20 Shoulder ScrewAngle BarPinionFlexible CouplingAngle BaseHingeHousing Bearing SideHousing Motor SideRadial Ball BearingPinion Shaft-20 Nut

\

Mounting plate fits into grooveRack & pinion mesh

Motor Rotates PinionDeployment System Moves ForwardENTRY/EXIT MOTOR REQUIREMENTSRequirements:Vmax = 6.98*10-2 m/sa = 0.256 m/s2Time = 1 sMin Torque = 0.103 NmNo. Steps: 55

Motor Specs:Hold Torque = 2.54*10-1 NmSF = 2.47

StepperMotor

Travel Distance: 3.81E-02 m

Electronics to Power Motors

Deployment Stepper

V/phase=3.85 VA/phase=0.51A

Power=1.96 WEntry-Exit Stepper

V/phase=12VA/phase=0.4A

Power=4.8 W

DEPLOYMENT MOTOR & LEAD SCREW SPECS

ENTRY/EXIT MOTOR & LEAD SCREW SPECS

Linear TorqueF = m*a + Ffriction

linear = F*lead/2

= 0.49, lead = 0.05/rev

Rotary Torquerotary = (Jscrew+Jmotor)*(a/lead)

Minimum Motor Torquemin= linear +rotary

DEPLOYMENT MOTOR TORQUE CALCULATIONParameterFor 100 L syringeFor 500 L syringeMass (m) 0.1 kgMotor Inertia (Jmotor)1.1*10-6 kgm2Screw Inertia (Jscrew)1.59*10-7 kgm2Total Frictional Force (Ffriction)2.357 N22.157 NAcceleration (a)2.80*10-3 m/s21.50*10-3 m/s2Applied Force (F)2.358 N22.158 NRotary Torque (rotary)2.79*10-6 Nm1.45*10-6 NmLinear Torque (linear)9.75*10-4 Nm9.14*10-3 NmMinimum Motor Torque (min)9.75*10-4 Nm9.14*10-3 Nm

FFFriction, railFFriction, plungera

30

Linear TorqueF = m*a + FFriction+ m*g*sinFfriction= PE on PEmg where PE on PE= 0.2

linear = F*R where R = Pitch Radius

Rotary Torquerotary = (Jpinion+Jmotor+Jshaft)*(a/R)

Minimum Motor Torquemin= linear +rotary

ENTRY/EXIT MOTOR TORQUE CALCULATIONFFFriction ParameterFor 25 AngleFor 30 AngleMass (m) 0.508 kgRotary Inertia (J)1.6*10-5 kgm2Total Frictional Force (Ffriction)1.54 N0.997 NAcceleration (a)0.256 m/s20.256 m/s2Applied Force (F)4.23 N4.61 NRotary Torque (rotary)1.84E-04 Nm1.84E-04 NmLinear Torque (linear)9.41E-02 Nm0.103 NmMinimum Motor Torque (min)9.41E-02 Nm0.103 Nm

amgsin

COST ANALYSIS:

Remove BOM too smallChange to pie chart with percentages of cost (3 pie charts, 1 for total)

Materials Cost Based on Batch Size

Single Prototype Fabrication TimePartOperation MachineAutomated Operation Time (s)Manual Operation Time (s)Setup Time (s)Transportation Time (s)2 Angle BarsCNC2,405.00600.00360.0060.00Pinion Housing (3 Plates)CNC; Drill Press; Tap1,260.00180.00120.00180.00Syringe Mount - Syringe SideCNC87.0030.00120.000.00Syringe MountMill/Tap0.00180.0060.0030.00Syringe PusherCNC90.0030.00120.000.00Syringe PlateCNC263.0060.00120.0090.00Motor Mount - TopCNC; Mill/Tap819.00300.00240.00300.00Motor Mount - SideCNC102.0060.00120.00180.00Motor Mount - BottomCNC428.0060.00120.00180.00Angle BaseChop Saw/Mill/Tap0.00600.0090.00120.00Pinion ShaftWet Wheel/Lathe0.00180.0060.0030.00RackBand Saw/Mill/Tap0.00300.0060.0060.00L-BracketCNC40.000.0060.000.00Total (s)5,494.002,580.001,650.001,230.00Grand Total (s)10,954.00Grand Total (hr)3.04Labor Cost per Part ($)48.68

Estimated Mass Machining Per Batch (5 Per Batch)PartOperation MachineAutomated Operation Time (s)Manual Operation Time (s)Setup Time (s)Transportation Time (s)2 Angle BarsCNC12,025.000.00360.00120.00Pinion Housing (3 Plates)CNC; Drill Press; Tap6,300.00180.00120.00120.00Syringe Mount - Syringe SideCNC450.000.00120.000.00Syringe MountCNC600.000.000.00180.00Syringe PusherCNC450.000.00120.000.00Syringe PlateCNC1,500.000.00120.000.00Motor Mount - TopCNC; Mill/Tap4,095.001500.00240.00300.00Motor Mount - SideCNC510.00300.00120.00180.00Motor Mount - BottomCNC2140.00300.00120.00180.00Angle BaseChop Saw/Mill/Tap0.00600.0090.00120.00Pinion ShaftWet Wheel/Lathe600.000.0060.0030.00RackBand Saw/Mill/Tap720.000.0030.000.00L-BracketCNC200.000.0060.000.00Total (s)29,590.002,880.001,560.001,230.00Grand Total per Batch (s)35,260.00Grand Total per Batch (hr)9.79Labor Cost per Batch ($)156.71Grand Total per Part (s)7,052.00Grand Total per Part (hr)1.96Labor Cost per Part ($)31.34

CONVERSIONS:Deployment Motor Step to Sample Volume1 Step = 2.5E-04 in = 1.09E-05 mL200 steps/rev

Entry/Exit1 Step = 2.75E-02 in1 Rev = 1.75 in = 5.49 in

RPMLinear Speed(in/s)Linear Speed(m/s)50.461.16E-02100.922.33E-02151.373.49E-02201.834.65E-02252.295.82E-02

Entry/Exit Motor RPM to Linear Speed