1. • Surgical headlamps improve visibility during
procedures
• Current headlamps:
Current Problems:
• Large, bulky, and heavy
• No eye protection
• Place a lot of pressure around surgeon’s head
• Light protrudes into space above surgeon’s head
• No video recording capabilities
Goal: Design a new illuminating and recording
surgical headlamp for UCSM
Recording and Illuminating Headlamp for Surgery
Team #13: Alexander Roeca, Elliot Miller, Emily Venner, James Harris, Patrick Muljadi, Riley Pepia
Client: University of Colorado School of Medicine, Dr. Maria Albuja-Cruz Director: Dr. Kenneth Taylor
University of Colorado Mechanical Engineering Senior Design
Special thanks to the following people who have
provided support, guidance, technical assistance
throughout the completion of this project:
• Project Client: Dr. Maria Albuja-Cruz
• Project Director: Dr. Ken Taylor
• Class Instructors: Dr. Daria Kotys-Swartz and Dr.
Julie Steinbrenner
• Also thanks to Greg Potts, Tim May, and Dr.
Walter Beamer
Iteration #1: Combination
Between Goggles and Glasses
Make sure to set out a detailed,
explicitly written contract with suppliers
of major parts
• Make sure that the client knows the
realistic outcome of the project
•Make sure to order and test electronics
far in advance
• Be prepared to adjust your plan and
design multiple times
1Integra Surgical Illumination and Visualization System. (2011, September 1). Retrieved October 30, 2015, from
http://www.integralife.com/products/pdfs/pm11207 illumination_692.pdf
Iteration #2: Goggles and
Row of LEDs with Collimators
Requirement Specification Test Results
Light
Brightness
Headlamp must emit above 50,000 lux of
white light
Headlamp emits
52,000 lux
Power
Duration
Batteries can power the headlamp for 12
hours (2-3 battery changes is acceptable)
One battery lasts
6.5 hours
Ergonomics
Headlamp must be comfortable to wear for
12 hours so it must weigh between 4-14 oz
The headlamp
weights 13 oz.
Video Quality Video quality must be at least 720-P
The video quality is
1080-P
Video
Transfer
Video transferring must be “drag and drop”
format for easy use and uploading
Video transferring is
easy
Headlamp
Robustness
Headlamp must be able to survive a 3 foot
drop test
Headlamp survived
drop test.
Headlamp
Lifetime
Headlamp buttons and hinges must survive
500 cycles
The headlamp
survived 500 cycles.
Background Engineering Specs and Test Results Headlamp Design Iterations
Integra LED
Headlight System1
Headlamp Final Design Lessons Learned
Future Plans
Special Thanks
Lighting
Goggles
Camera
Accelerometer
IR Receiver
Nylon Belt
Battery Pack
Microcontroller
3 high powered cool-white LEDs
illuminate the surgeon’s field of
vision. They are connected to
an aluminum mounting plate
that acts as a heat sink.
An IR Receiver with a remote
control turns on/off the video
camera. This can will be done
by a non-sterile nurse in the
operating room.
An accelerometer is used for
turning on/off the light based on
the surgeon’s head angle. If the
surgeon looks up, the light turns
off in order to prevent it from
blinding other OR personnel. All
electronics are housed in a
durable, Delrin case.
Shatter-proof Bangerz goggles provide eye
protection for the surgeons. They also have a
comfortable, adjustable elastic headband to
securely keep the headlamp on the surgeon’s head.
This adjustable Raspberry Pi
video camera can both live
stream to a computer via Wi-Fi,
and it can download videos as
mp4 files to a USB drive.
A Raspberry Pi Microcontroller
is used to control all electronics
including the IR receiver,
accelerometer, and camera. It is
housed in a durable, machined
Delrin case.
This durable Nylon belt and plastic clasp hold the battery pack and
RasPi case securely to the surgeon's waist. The flexible material is
comfortable, and the thick diameter prevents twisting.
The Anker Astro E5 15000mA battery
can power the headlamp for up to 6
hrs, and it can be replaced without
rebooting the electronics.
This project will hopefully be continued
in ME Graduate Design with goals of:
• Developing a more compact , and
potentially brighter lighting system
• Condensing the electronics into a
smaller package
Challenges of this project will include:
• Minimizing the heat from the LEDs
• Minimizing the weight
• Limited power from the portable
battery