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ME461 Final Presentation
The document proposes an automated blood sample deployment and retraction device for acoustic rheometry. It discusses current solutions for blood coagulation analysis and their limitations. The proposed device aims to automatically deploy a 0.03 mL blood sample into an acoustic levitation field with minimal contamination or handling. Design requirements include accurately dispensing the target volume, minimizing acoustic invasiveness, and automating the sample deployment process. Several design concepts and a preliminary design are presented and evaluated. A final design is selected consisting of a syringe-based deployment system and a rack-and-pinion driven entry/exit system. Testing shows the design can deploy volumes within the target range.
ME461 Final Presentation
- 1. Jeremy Lee Shireen Kheradpey PeterIshiguro Hsin-Chiao “Frank” Lin AUTOMATED BLOOD SAMPLE DEPLOYMENT AND RETRACTION FOR ACOUSTIC RHEOMETER Detailed Design Review ME BME & ME ME ME | | | |
- 2. COAGULOPATHY Blood unable toclot properly Trauma -Leading cause of death 4-44 yrs -6M deaths per year -40% victims are coagulopathic -Excessive bleeding or clotting Liver surgery, blood transfusions, etc. Statistics from the International Trauma Research Network
- 3. CURRENT SOLUTIONS Mechanical Rheometers -Contactcontamination -Large sample: 0.36mL -Qualitative not quantitative -Time consuming -No characterization of healthy blood
- 4. Non-contact manipulation -Squeezing -Rotation -Oscillation Small (0.03mL)sample Quantitative -Whole healthy, liquid or solid -Clotting or clotted ACOUSTIC LEVITATION
- 5. PROPOSED SOLUTION 𝐅 ∝𝐕𝐝𝐫𝐨𝐩 𝛚𝛁𝐏𝐳(𝛒𝐜) 𝐅𝐠𝐫𝐚𝐯𝐢𝐭𝐲 𝐅𝐚𝐜𝐨𝐮𝐬𝐭𝐢𝐜 = 𝟏
- 6. THE PROBLEM: MANUALDEPLOYMENT Design an automated device to deploy a sample if known volume into an acoustic levitation field with minimal sample contact, instrumentation contamination, or human handling.
- 7. CUSTOMER REQUIREMENTS GOAL: Design andfabricate a device to dispense a liquid sample accurately into the acoustic field to allow levitation -Automate sample deployment -Accommodate current modalities of blood samples -Deploy 0.03mL target volume -Minimally acoustically invasive
- 8. ENGINEERING SPECIFICATIONS • Dispensea target volume of roughly 0.03 mL • Record range of successfully levitated drop volumes • Range of entry exit speeds 0.46 in/sec - 2.29 in/sec • Record range of successfully levitated drop volumes • Levitate 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
- 9. Automated Sample Deployment Prototype Deployment System HoldsSyringe 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
- 10. Criteria Weight FactorPeristaltic Syringe Metering Volume Control 3 0 2 1 Manufacturability 1 0 0 -1 Ease of Integration 3 0 2 0 Cost 1 0 0 -1 Reusability 2 0 0 0 TOTAL 0 12 1 PUGH CHART: DEPLOYMENT PUMPS
- 11. PUGH CHART: SYRINGE EXIT/ENTRYSYSTEM Criteria Weight Factor CAM Linear Drive (Lead Screw) Pneumatics Rack & Pinion Ease of Integration 2 0 0 -1 1 Cost 3 0 -2 -1 1 Repeatability/Accuracy 2 0 2 0 0 Controllability 2 0 1 -1 1 Speed 2 0 -2 0 0 TOTAL 0 -4 -7 7
- 12. Criteria Weight Factor Opposing Needle Vacuum BlowerSample Catcher Sample Versatility 3 0 1 2 2 Maintenance 2 0 0 0 -1 Ease of Integration 2 0 -1 0 0 Cost 1 0 -1 -1 1 Required Space 2 0 0 -1 0 TOTAL 0 0 3 5 PUGH CHART: RETRACTION MECHANISM
- 13. Parameter Possible Solutions Sample Deployment PeristalticPump Syringe Pump Metering Pump Syringe Enter and Exit Pneumatics Linear Drive Rack & Pinion Sample Retraction Opposing Needle Blower Sample Catcher SUMMARY: MORPHOLOGICAL CHART
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- 15. PRELIMINARY DESIGN: Pneumatics LeadScrew Driven Deployment Pneumatic Entry/Exit
- 16. FINAL DESIGN: sAM Deployment System (Leadscrew driven) Entry/Exit System (Rack & pinion driven)
- 17. 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
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- 19. ENTRY/EXIT SYSTEM Stepper Motor (1.8°steps) Angle Base Mounting Plate Grooves Angle Bar Hinge Pinion Angle Bar Radial Ball Bearing Start Position Marker
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- 21. ENTRY/EXIT ANGLE ¼-20 Shoulder Screw AngleBase Slots Angle Bars 30° 25°
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- 23. SETUP 3.5 V Supply 12V Supply Arduino Microcontroller Inputs: -Entry / exit speed - Travel distance to acoustic field -Volume to deploy Start Button
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- 26. SAMPLE VOLUME TESTING: DeployableSample Volume vs. Driving Voltage (mV) • Constant Exit Motor Speed = 20 RPM = 1.8 in/s • Constant Angle = 30° • Target volume 0.03 mL Driving Voltage (mV) Min Volume (mL) Max Volume (mL) 400 6.57E-03 1.75E-02 450 5.47E-03 1.92E-02 500 5.47E-03 2.57E-02 550 4.93E-03 3.12E-02 600 4.93E-03 3.33E-02 650 4.38E-03 2.74E-02 700 4.93E-03 2.85E-02
- 27. SAMPLE VOLUME TESTING: DeployableSample Volume vs. Exit Motor Speed • Constant Wave Amplitude: 600 mV • Constant Angle = 30° • Target volume 0.03mL Exit Speed (RPM) Min Volume (mL) Max Volume (mL) 5 5.47E-03 2.85E-02 10 4.93E-03 3.07E-02 15 5.47E-03 3.50E-02 20 4.93E-03 2.52E-02 25 5.47E-03 2.46E-02
- 28. SAMPLE VOLUME TESTING: DeployableSample Volume vs. Exit Motor Speed • Constant Wave Amplitude: 600 mV • Constant Angle = 25° • Target Volume 0.03 mL Exit Speed (RPM) Min Volume (mL) Max Volume (mL) 5 5.47E-03 2.74E-02 10 4.93E-03 3.07E-02 15 6.02E-03 3.01E-02 20 4.93E-03 2.96E-02 25 4.93E-03 2.85E-02
- 29. COST ANALYSIS: $433.08 $212.86 $40.26 Cost Breakdown DeploymentSystem Entry/Exit System Motor Control • Total Material Costs: $686.20 • $203 from the Motorized Lead Screw
- 30. MATERIAL COST ANALYSIS: MaterialCost per Unit Based on Number Produced
- 31. Costs were calculatedusing machining time, plus an additional hour for assembly, a rate of $16/hr for a machinist. MANUFACTURING COST ANALYSIS:
- 32. For Batch Production: •Over 20% reduction in total cost per unit. • Over in hour saved in production time per unit. TOTAL PRODUCTION COST:
- 33. GANTT CHART Last Day toMachine Prototype Assembled Finished Machining Started Machining First Successful Levitation First Successful Deployment
- 34. REDESIGN Rotation point aboutneedle tip Angle adjustment without changing tip position Height Adjustment Rather than moving base & syringe Integrate ¼-20 Holes Mounting Miniaturize Fit into environmental port Match Motors Allow single power source, decrease wire connections Retraction System Sample catcher LabView User Interface Position Calibration Homing limit switch
- 35. Sponsors ACKNOWLEDGEMENTS Project Team • Dr.Glynn Holt, Associate Professor of Mechanical Engineering (Project Lead) • Jarrod Risley • Vahideh Ansari Hosseinzadeh Senior Capstone Guidance • Biomedical: Dr. Catherine Klapperich, Dr. Michael Smith, Dr. Thomas Szabo • Mechanical: Dr. Enrique Gutierrez
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- 38. DEPLOYMENT EXPLODED VIEW: GuideRails Lead Screw Nut Linear Bearings Radial Ball Bearings Gear Rack L-Bar
- 39. Motor Specs: Holding Torque= 6.6*10-2 Nm SF = 67.7 100 µL Syringe Requirements: Vmax = 6.40*10-3 m/s a = 2.80*10-3 m/s2 Time = 5 s Torque = 9.75*10-4 Nm No. Steps: 2740 DEPLOYMENT MOTOR REQUIREMENTS Syringe Pusher Travel Distance = 1.74*10-2 m 1. Motor Turns Lead Screw Motor Lead Screw 2. Nut and syringe pusher move horizontally together, deploying sample Nut Syringe Pusher
- 40. Motor Specs: Holding Torque= 6.6*10-2 Nm SF = 7.22 500 µL Syringe Requirements: Vmax = 6.40*10-3 m/s a = 1.50*10-3 m/s2 Time = 5 s Torque = 9.14*10-3 Nm No. Steps: 654 DEPLOYMENT MOTOR REQUIREMENTS Syringe Pusher Travel Distance = 4.15*10-3 m 1. Motor Turns Lead Screw Motor Lead Screw 2. Nut and syringe pusher move horizontally together, deploying sample Nut Syringe Pusher
- 41. ENTRY/EXIT EXPLODED VIEW MountingPlate Groove Stepper Motor (1.8° steps) ¼-20 Shoulder Screw Angle Bar Pinion Flexible Coupling Angle Base Hinge Housing Bearing Side Housing Motor Side Radial Ball Bearing Pinion Shaft ¼-20 Nut
- 42. Mounting plate fits intogroove Rack & pinion mesh Motor Rotates Pinion Deployment System Moves Forward ENTRY/EXIT MOTOR REQUIREMENTS Requirements: Vmax = 6.98*10-2 m/s a = 0.256 m/s2 Time = 1 s Min Torque = 0.103 Nm No. Steps: 55 Motor Specs: Hold Torque = 2.54*10-1 Nm SF = 2.47 Stepper Motor Travel Distance: 3.81E-02 m
- 43. Electronics to PowerMotors Deployment Stepper V/phase=3.85 V A/phase=0.51A Power=1.96 W Entry-Exit Stepper V/phase=12V A/phase=0.4A Power=4.8 W
- 44. DEPLOYMENT MOTOR &LEAD SCREW SPECS
- 45. ENTRY/EXIT MOTOR &LEAD SCREW SPECS
- 46. Linear Torque F =m*a + Ffriction τlinear = F*lead/2πη η = 0.49, lead = 0.05”/rev Rotary Torque τrotary = (Jscrew+Jmotor)*(a/lead) Minimum Motor Torque τmin= τlinear +τrotary DEPLOYMENT MOTOR TORQUE CALCULATION Parameter For 100 µL syringe For 500 µL syringe Mass (m) 0.1 kg Motor Inertia (Jmotor) 1.1*10-6 kgm2 Screw Inertia (Jscrew) 1.59*10-7 kgm2 Total Frictional Force (Ffriction) 2.357 N 22.157 N Acceleration (a) 2.80*10-3 m/s2 1.50*10-3 m/s2 Applied Force (F) 2.358 N 22.158 N Rotary Torque (τrotary) 2.79*10-6 Nm 1.45*10-6 Nm Linear Torque (τlinear) 9.75*10-4 Nm 9.14*10-3 Nm Minimum Motor Torque (τmin) 9.75*10-4 Nm 9.14*10-3 Nm F FFriction, rail FFriction, plunger a
- 47. 30° Linear Torque F =m*a + FFriction+ m*g*sinθ Ffriction= µPE on PEmg where µPE on PE= 0.2 τlinear = F*R where R = Pitch Radius Rotary Torque τrotary = (Jpinion+Jmotor+Jshaft)*(a/R) Minimum Motor Torque τmin= τlinear +τrotary ENTRY/EXIT MOTOR TORQUE CALCULATION F Parameter For 25° Angle For 30° Angle Mass (m) 0.508 kg Rotary Inertia (J) 1.6*10-5 kgm2 Total Frictional Force (Ffriction) 1.54 N 0.997 N Acceleration (a) 0.256 m/s2 0.256 m/s2 Applied Force (F) 4.23 N 4.61 N Rotary Torque (τrotary) 1.84E-04 Nm 1.84E-04 Nm Linear Torque (τlinear) 9.41E-02 Nm 0.103 Nm Minimum Motor Torque (τmin) 9.41E-02 Nm 0.103 Nm a mgsinθ θ
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- 49. Materials Cost Basedon Batch Size
- 50. Single Prototype FabricationTime Part Operation Machine Automated Operation Time (s) Manual Operation Time (s) Setup Time (s) Transportation Time (s) 2 Angle Bars CNC 2,405.00 600.00 360.00 60.00 Pinion Housing (3 Plates) CNC; Drill Press; Tap 1,260.00 180.00 120.00 180.00 Syringe Mount - Syringe Side CNC 87.00 30.00 120.00 0.00 Syringe Mount Mill/Tap 0.00 180.00 60.00 30.00 Syringe Pusher CNC 90.00 30.00 120.00 0.00 Syringe Plate CNC 263.00 60.00 120.00 90.00 Motor Mount - Top CNC; Mill/Tap 819.00 300.00 240.00 300.00 Motor Mount - Side CNC 102.00 60.00 120.00 180.00 Motor Mount - Bottom CNC 428.00 60.00 120.00 180.00 Angle Base Chop Saw/Mill/Tap 0.00 600.00 90.00 120.00 Pinion Shaft Wet Wheel/Lathe 0.00 180.00 60.00 30.00 Rack Band Saw/Mill/Tap 0.00 300.00 60.00 60.00 L-Bracket CNC 40.00 0.00 60.00 0.00 Total (s) 5,494.00 2,580.00 1,650.00 1,230.00 Grand Total (s) 10,954.00 Grand Total (hr) 3.04 Labor Cost per Part ($) 48.68
- 51. Estimated Mass MachiningPer Batch (5 Per Batch) Part Operation Machine Automated Operation Time (s) Manual Operation Time (s) Setup Time (s) Transportation Time (s) 2 Angle Bars CNC 12,025.00 0.00 360.00 120.00 Pinion Housing (3 Plates) CNC; Drill Press; Tap 6,300.00 180.00 120.00 120.00 Syringe Mount - Syringe Side CNC 450.00 0.00 120.00 0.00 Syringe Mount CNC 600.00 0.00 0.00 180.00 Syringe Pusher CNC 450.00 0.00 120.00 0.00 Syringe Plate CNC 1,500.00 0.00 120.00 0.00 Motor Mount - Top CNC; Mill/Tap 4,095.00 1500.00 240.00 300.00 Motor Mount - Side CNC 510.00 300.00 120.00 180.00 Motor Mount - Bottom CNC 2140.00 300.00 120.00 180.00 Angle Base Chop Saw/Mill/Tap 0.00 600.00 90.00 120.00 Pinion Shaft Wet Wheel/Lathe 600.00 0.00 60.00 30.00 Rack Band Saw/Mill/Tap 720.00 0.00 30.00 0.00 L-Bracket CNC 200.00 0.00 60.00 0.00 Total (s) 29,590.00 2,880.00 1,560.00 1,230.00 Grand Total per Batch (s) 35,260.00 Grand Total per Batch (hr) 9.79 Labor Cost per Batch ($) 156.71 Grand Total per Part (s) 7,052.00 Grand Total per Part (hr) 1.96 Labor Cost per Part ($) 31.34
- 52. CONVERSIONS: Deployment Motor Stepto Sample Volume ● 1 Step = 2.5E-04 in = 1.09E-05 mL ● 200 steps/rev Entry/Exit ● 1 Step = 2.75E-02 in ● 1 Rev = 1.75π in = 5.49 in RPM Linear Speed (in/s) Linear Speed (m/s) 5 0.46 1.16E-02 10 0.92 2.33E-02 15 1.37 3.49E-02 20 1.83 4.65E-02 25 2.29 5.82E-02 Entry/Exit Motor RPM to Linear Speed