BioHorizons_MidtermPP_Fall06
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  • Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure Expensive to machine Bearings (maintenance) Small error in load cell reading due to the bearing friction Angle of applied force will be less reliable Complicated – many possible places for failure

BioHorizons_MidtermPP_Fall06 Presentation Transcript

  • 1. BioHorizons Fatigue Test System
    • Corp 3
    • Midterm Concepts Presentation
  • 2. Team Members
    • Jonathan Hill
    • John Maddox
    • Allen Lindsay
    • Crichton Neal
    • Chris Howell
    • Felicia Craig
    • Bradley Johnson
  • 3. Project Overview
    • General Specification
    • ISO Standards
    • Primary Concept
      • Solid Edge
      • Advantages/Disadvantages
      • Water Bath
      • Economic Analysis
    • Secondary Concept
    • Phase II
  • 4. Specifications and Constraints
    • General Constraints
      • small and light enough to operate on a tabletop
      • clean and quiet enough to operate indoors at the BioHorizons offices
      • Able to perform fatigue tests as well as static load tests
      • Control system and sensors must measure failure load and cycles to failure and discontinue operation at this point
      • Entire system must be able to be calibrated accurately enough for continuous operation within ISO 14801 specifications and constraints
    • Economic Constraints
      • to produce a fatigue testing machine that can be reproduced and used for less than it currently costs to have the dental implants tested from an outside company
  • 5. ISO Standards
    • ISO provides more specific specifications and constraints in ISO 14801 —Dentistry—Fatigue test for endosseous dental implants
    • Several of the more pertinent specifiations are covered below, obtained from the ISO document:
      • The testing machine should be capable of applying the specified load with an error not exceeding ± 5% at maximum load.
      • The endosseous dental implant shall be clamped such that it makes a 30° ± 1° angle with the loading direction of the testing machine.
      • The device shall clamp the specimen at a distance 3.0 mm ± 0.1 mm apically from the nominal bone level as specified in the manufacturer’s instruction for use.
  • 6. ISO Standards (continued)
    • More constraints and specifications:
      • The dimensions of the loading member shall be chosen to define a distance l = 11.0 mm ± 0.1 mm from the centre of the hemisphere to the clamping plane.
      • For endosseous dental implants that include materials in which corrosion fatigue has been reported or is expected to occur…testing shall be carried out in water of Grade 2 according to ISO 3696, in normal saline [.09%]* or in physiologic medium. The fluid and the test specimen shall be kept at 37°C ± 2°C during the testing.
      • Fatigue testing shall be carried out with a unidirectional load. The load shall vary sinusoidally between a nominal peak value and 10 % of this value . The loading frequency shall be ≤ 15 Hz . Testing in liquid media shall be conducted at frequencies ≤ 2 Hz .
    *As specified by BioHorizons
  • 7. Other Applicable ISO Standards
    • ISO 1099 : Metallic materials—Fatigue testing—Axial force controlled method
    • ISO 1942-1 : Dental vocabulary—Part 1: General and clinical terms
    • ISO 3696 : Water for analytical laboratory use—Specification and test methods
    • ISO 4965 : Axial load fatigue testing machines—Dynamic force calibration—Strain gauge technique
    • ISO 7500-1 : Metallic materials—Verification of static uniaxial testing machines—Part 1: Tension/compression testing machines—Verification and calibration of the force- measuring system
  • 8. Concept Overview
  • 9. Different Views
  • 10. Exploded View Temperature Sensor Liquid Bath Container (Pyrex) Washer (Rubber) Container Base Linear Motor/Load Cell Frame (steel) Thumb Screw Insert (will be tapped to hold test piece) Mounting Screws Base (steel) Exploded View
  • 11. Advantages
    • Long life
    • Excellent precision and reliability
    • Ease in varying load and frequency
    • Low maintenance
    • Easy setup
    • Small number of parts
    • Conduct static and fatigue tests without changing setup
  • 12. Disadvantages
    • Initial costs are high
    • Replacement parts would be high
    • Possible motor cooling may need to be addressed
    • Different inserts need to be tapped for each implant tested
  • 13. Water Bath
  • 14. Major Components
    • Heating element
      • Small and compact
      • Low fluid volume rated
    • Temperature switch
      • Small and compact
      • +-2 °C tolerance
    • Dish
      • Metal bottom
      • Glass sides
      • Water tight
    • Water level switch
      • Small and compact
      • Safely maintain water level
  • 15. Dish
    • Metal base
      • Base for mounting heating components
      • Able to drain the dish through a ball valve
    • Glass tube
      • Forms sides
      • Able to withstand high temps incase of heating problems
      • Able to see the test specimen during testing
    • Washer
      • Or sealant as of yet to be determined
      • Seals the base to the glass
  • 16. Standards
    • ISO 14801:2003
      • 5.4 Testing Environment
        • testing shall be carried out in water of Grade 2 according to ISO 3696
        • fluid and the test specimen shall be kept at 37 °C+2°C or -2 °C
  • 17. Heating Element
    • Compact Cartridge-Style Immersion Heater
      • 1 5/8" long type 316 stainless steel element
      • Maximum temperature of 100° C
      • CSA Certified and UL-Registered
      • Can be fully immerged in saline solution
  • 18. Temperature switch
    • Submersible Cartridge Temperature Switch
      • Operates as a thermostat
      • 300 series stainless steel outer shell
      • adjusted between -73° and +315° C
      • 2” long element
      • UL-Registered
    • Search continues to refine this component
  • 19. Water Level Switch
    • Vertical-Mount Liquid-Level Switch
      • Maintain a safe water level for the Immersion heating element
      • Over all length of 1 7/8“
      • Max temperature rating of 105°C
      • When the fluid level drops too low
        • cut power to the heating element
        • turn on a warning light or trigger a system warning in the testing program letting the tester know to add more fluid
  • 20. Linear Servo Motor
    • Handles static loading up to 500 lbf.
    • Handles a cycling load from 0 to 150 lbf. at a rate up to 15 Hz
  • 21. Load Cell
    • Piezoelectric sensing cell
    • Highly repeatable
    • Fatigue Rated load cell
    • Low profile to fit easily within machine
  • 22. Controls
    • Load cell sends a signal through a DAQ card to LabView
    • LabView takes the data and depending on the load it will send a signal to the Driver which will in turn increase or decrease the current
  • 23. Economic Analysis
    • Linear Motor, Cooling Jacket, Controller, and Driver : $19600
    • Load Cell : $1000
    • Lab View : $1200 per year
    • Jig Frame and Base : $2000
    • Computer : $600
    • Heating Accessories : $300
    • Cables and Connectors : $200
    • Total Costs : $25000
  • 24. Alternative Design
  • 25. Advantages
    • Cheap saline bath container
    • Rotary motor is cheaper than linear motor
  • 26. Disadvantages
    • Bearings (maintenance)
    • Expensive to machine
    • Small error in load cell reading due to the bearing friction
    • Angle of applied force will be less reliable
    • Complicated – many possible places for failure
  • 27. Phase II-Completed by Dec.
    • Obtain more quotes on linear motors
    • Dimension Concept
    • Stress Analysis
    • Finalize Concept