DSR Final Draft

To: Brian Hnatkovich, QBC Diagnostics (814) 692-7661 [email protected]

From: Dane Bralich, [email protected] Thomas Boyer, [email protected] Rhian Kogan, [email protected] Ryan Patrick, [email protected] Jared Yarnall-Schane, [email protected]

Subject: Statement of Work Date: March 27th, 2014

Capstone Senior Design Project

E SC 497

The Pennsylvania State University

Spring 2014

Detailed Specification Report

2 Statement of Work

Executive Summary

In developing countries, disease runs rampant and often undiagnosed due to insufficient medical equipment and training. QBC Diagnostics has developed a product called the ParaLens Advance, which provides a low-cost opportunity for doctors in developing countries to use fluorescent microscopy as a means to diagnose malaria and tuberculosis specifically. The design team has been called upon to help QBC Diagnostic improve the ParaLens Advance. Specifically, the company would like for the team to develop a way for the ParaLens Advance to utilize LEDs of a higher intensity than is currently used so that they can bring a product to market that will increase positive medical outcomes and set themselves apart from competitors.

In order to solve this design problem, the team must figure out how to manage the increased heat that comes with utilizing LEDs that emit UV, higher-intensity blue, green and amber light. The current equipment melts when anything other than the low-intensity blue LED is used, and presents a significant challenge to QBC Diagnostics desire to expand its product offerings.

The team has developed several concepts, but will be pursuing a fiber optic system to take the heat source out of the aluminum body and into a separate device that can be more efficiently cooled using both passive and active cooling methods. With this design, the hope is that there will be a product created that is low in cost, is easy to use and manufacture, and is efficient in its heat management.

3 Statement of Work

Table of Contents

EXECUTIVE SUMMARY ......................................................................................................................... 2

1.0 INTRODUCTION ................................................................................................................................. 5

1.1 INITIAL PROBLEM STATEMENT ............................................................................................................ 5 1.2 OBJECTIVES ............................................................................................................................................ 5

2.0 CUSTOMER NEEDS ASSESSMENT ................................................................................................ 5

2.1 GATHERING CUSTOMER INPUT ............................................................................................................. 5 2.2 WEIGHTING OF CUSTOMER NEEDS ...................................................................................................... 7

3.0 EXTERNAL SEARCH ......................................................................................................................... 8

3.1 PATENTS .................................................................................................................................................. 8 3.2 EXISTING PRODUCTS ............................................................................................................................. 9

4.0 ENGINEERING SPECIFICATIONS ............................................................................................... 10

4.1 ESTABLISHING TARGET SPECIFICATIONS .......................................................................................... 10 4.2 RELATING SPECIFICATIONS TO CUSTOMER NEEDS .......................................................................... 10

5.0 CONCEPT GENERATION ............................................................................................................... 11

5.1 PROBLEM CLARIFICATION .................................................................................................................. 11 5.2 CONCEPT GENERATION ....................................................................................................................... 11 5.3 CONCEPT SELECTION .......................................................................................................................... 15

6.0 SYSTEM LEVEL DESIGN ................................................................................................................ 16

6.1 TWO CHAMBER ACTIVE COOLING ..................................................................................................... 16 6.2 FIBER OPTIC BOX ................................................................................................................................ 18

7.0 SPECIAL TOPICS .............................................................................................................................. 19

7.1 BUDGET AND VENDOR PURCHASE INFORMATION ............................................................................. 19 7.2 PROJECT MANAGEMENT ..................................................................................................................... 20 7.3 RISK PLAN AND SAFETY ...................................................................................................................... 21 7.4 COMMUNICATION AND COORDINATION WITH SPONSOR .................................................................. 21

8.0 DETAILED DESIGN .......................................................................................................................... 21

8.1 MANUFACTURING PROCESS PLAN ...................................................................................................... 21

4 Statement of Work

8.2 ANALYSIS .............................................................................................................................................. 22 8.3 MATERIAL AND MATERIAL SELECTION PROCESS ............................................................................ 23 8.4 COMPONENT AND COMPONENT SELECTION PROCESS ..................................................................... 24 8.5 CAD DRAWINGS ................................................................................................................................... 26 8.6 TEST PROCEDURE ................................................................................................................................ 26

APPENDIX .................................................................................................................................................. 0

APPENDIX A: PARALENS ADVANCE PROVISIONAL PATENT .................................................................... 1 APPENDIX B: ORIGINAL FIBER OPTIC BOX PATENT .............................................................................. 17 APPENDIX C: DRAWINGS FROM PATENTS ................................................................................................ 28 APPENDIX D: MULTIPLE WAVELENGTH LED ARRAY ILLUMINATOR PATENT .................................... 36 APPENDIX E: LW LUMIN SPECIFICATION SHEET ................................................................................... 37 APPENDIX F: HEAT TEST RESULTS .......................................................................................................... 38 APPENDIX G: INITIAL MEETING AGENDA ............................................................................................... 42 APPENDIX H: RESUMES ............................................................................................................................. 43 APPENDIX I: GANTT CHART ...................................................................................................................... 49 APPENDIX J: PROTOTYPE HOUSING SCHEMATIC ................................................................................... 52 APPENDIX K: ELECTRICAL ASSEMBLY SCHEMATIC .............................................................................. 53 APPENDIX L: ALUMINUM COMPARISON SHEET ...................................................................................... 54 APPENDIX M: CAD DRAWINGS ................................................................................................................ 56

5 Statement of Work

1.0 Introduction

1.1 Initial Problem Statement The goal of the project is to create a new version of the ParaLens Advance, a device sold by QBC Diagnostics, a company located in Port Matilda that focuses on diagnosing disease using hematology and fluorescent microscopy. While designing to fit the constraints of the developing markets that purchase the product, the goal is to develop upon the existing ParaLens Advance model to create a device that will:

1) Operate using additional wavelengths (green, amber and UV) to diagnose different diseases 2) Be able to withstand the heat associated with the LEDs that emit the above wavelengths of light 3) Improve upon the current blue LED light wavelength model

At the conclusion, the product should at the very least have solved the issue of heat management. However, there are also secondary objectives related to optimizing the design for use with different filters and light sources that could lead to the increased applications in the marketplace. To meet this secondary objective, we are tasked with providing QBC with design and manufacturing plans for our new product.

1.2 Objectives The design that we develop to solve the problem statement put forth by QBC Diagnostics will not deviate substantially from the general idea of the ParaLens Advance, since the customer does not want to deviate too far from its established manufacturing processes and operational methods, of which its customers are familiar. It will also stay within a reasonable price range, because in order to compete in the developing nation market QBC Diagnostics must keep its products low-priced. Our design will incorporate some sort of heat management system in order to expand the current ParaLens Advances capabilities, while also remaining lightweight, compact and easy to use. Overall, our design will be an improvement upon the existing model and will build off of several already-established facets.

2.0 Customer Needs Assessment

2.1 Gathering Customer Input It is important to note that we are creating a product to supplement an existing product line, ParaLens Advance. Because of the fact ParaLens is currently being sold on the market, we are tasked to create a product that is similar in form and function for the end consumer. According to QBC, there are three pressing needs that the ParaLens Advance II must address.

1) The ParaLens Advance II must be low cost, as the majority of their sales are to doctors, hospitals, and clinics in developing countries.

6 Statement of Work

2) To reduce cost, we are to try to keep the design and manufacturing process as similar to ParaLens Advance as possible.

3) The ParaLens Advance II must be able to be operated on a variety of electrical sources such as wall outlets, car outlets, and solar packs. It must draw a relatively small power supply so as to ensure it can work in unfavorable conditions.

4) The ParaLens Advance II must be able to operate on any standard optical microscope.

On top of these three identified needs, the ParaLens Advance II must be user friendly, with ease of assembly/disassembly. Many customers will not understand English, so actions must be intuitive. We also must consider safety by designing around preventing burns and possibly blindness due to the LED light.

*Since this product is being sold in developing countries, we are not able to perform direct customer research. The assessment is a combination of knowledge from QBC and personal experience.

7 Statement of Work

2.2 Weighting of Customer Needs Utilizing the framework for weighting customer needs provided by the Learning Factory, we accurately portrayed the customers needs so that our end product fit expectations. Beyond this overall goal to please the customer, utilizing the AHP Pairwise Comparison Chart was important to the success of our project because it focuses the team on which areas need to be attended to in order to achieve our objective, while at the same time pointing out which other areas are expendable attributes.

The AHP Pairwise Comparison Chart, which can be seen in Table 1 below, best fit our needs for weighing the main objective categories of our project. After weighing each category we found that our main focuses should be on Ease of Manufacturing, Cost, Safety, and Adaptability. Ease of manufacturing and cost seemed to almost go hand in hand since the main consequence of an increase in manufacturing would be an increase in cost. The adaptability was also a crucial part of this project in two regards. First, the whole selling point of the ParaLens Advance is its ability to attach to a normal light microscope and if you take away that ability you take away the purpose of the project. Second, it needs to be able to be plugged into different power sources since it will be used in different countries.

Table 1. AHP Pairwise Comparison Chart to Determine Weighting for Main Objective Categories

8 Statement of Work

For the hierarchical customer needs list, we first developed sub categories for each category. We then used conditional weighting to find a weight for each sub category within its respective category and within the full scope of the entire project. The results of this can be seen below is Table 2.

Table 2. Weighted Hierarchal Customer Needs List

3.0 External Search

3.1 Patents Currently, QBC Diagnostics hold a provisional patent for the ParaLens Advance (Appendix A). While they are still working their way through the process of a full patent, the provisional patent gives protection

Safety (0.14)

1) Burns (0.67, 0.094) 2) Eye Damage (0.33, 0.046)

Ease of Use (0.12) 1) Intuitive Design (0.75, 0.09) 2) Easy to Assemble (0.25, 0.03)

Ease of Manufacturing (0.16) 1) Use of Existing Manufacturers (0.40, 0.064) 2) Minimize Parts (0.20, 0.032) 3) Mass Production (0.40, 0.064)

Cost (0.15) 1) Material Selection (0.75, 0.1125) 2) Material Reduction (0.25, 0.0375)

Efficiency (0.06) 1) Able to be Used on a Small Battery Pack (1.00, 0.06)

Durability (0.07) 1) Transportability (0.50, 0.035) 2) Field Use (0.50, 0.035)

Portability (0.11) 1) Transportability (0.25, 0.028) 2) Low Weight (0.75, 0.083)

Adaptability (0.14) 1) Use on Any Microscope (0.75, 0.105) 2) Able to Use Any Power Supply (0.25, 0.035)

Aesthetics (0.04) 1) Professional Use (1.00, 0.04)

9 Statement of Work

in the marketplace. Originally, the design was protected under another patent (Appendix B), which has since expired, paving the way for competition to enter the marketplace. When searching through patents, it can be gathered that QBC has a strong grip on the intellectual property for this ParaLens product. More specific details related to the actual design of the patent can be found in Appendix C at the end of this report.

After selecting the fiber optic box design, we again revisited the patent search. In doing so we found a patent entitled Multiple Wavelength LED Array Illuminator for Fluorescence Microscopy. After studying the patent, we believe that the Fiber Optic box will be sufficiently different from the claims as to warrant a new or different patent. However, follow up with a patent attorney is highly suggested as to ensure we are not encroaching on any of the 22 claims. The full patent can be found in Appendix D.

3.2 Existing Products QBC Diagnostics ParaLens Advance competes with several products in the marketplace, all of which are summarized below.

1.) LW Scientific Lumin

LW Scientific, located in the USA, was originally the contract manufacturer for the ParaLens Advance. At the time, a patent did not protect the product so the design was copied. There are two specific products, the Lumin Illuminator and the Lumin 60x Objective, and both can be seen below in Figure 1. The specification sheets for these products are also attached to this report in Appendix D:

2.) FluoroTek

There is no information about this company or its product online, but based on the conversations with Brian we know that they are a direct competitor in Asia. Their product is a nearly exact counterfeit of QBC Diagnostics, and to complicate things further FluoroTek actually markets their product as a QBC Diagnostics ParaLens Advance.

3.) Godrej/RFCL

Figure 1. LW Scientific Lumin Products

10 Statement of Work

Much like FluoroTek, there is no information about this company that can be found online or by using any other resource. Brian provided us with his knowledge on Godreg/RFCL and informed us that they are an Indian conglomerate that, much like FluoroTek, and have a product that they market as the QBC Diagnostics ParaLens Advance.

4.) Partec

While Partec does not have the same product offering as QBC Diagnostics, it does have a product that diagnoses malaria specifically and is in the same markets at the ParaLens Advance. The product is made up of a completely different setup and costs more than the ParaLens, but is nonetheless a competing entity in the marketplace.

5.) Other FM Microscopes

Companies like Nikon and Olympus produce high-end microscopes that are used specifically for fluorescent microscopy. These are not necessarily in the same market as the QBC Diagnostics ParaLens because they are much more expensive, but they serve the same general purpose albeit to a different audience.

4.0 Engineering Specifications

4.1 Establishing Target Specifications The team, as well as QBC Diagnostics, determined the following target specifications to help guide the design process throughout the course of this project. Most importantly, this project is focused on the heat that is given off by the LED that is housed within the ParaLens Advance. The target specifications are based on heat tests, the results of which can be found in Appendix F, along with information about the LED lights we will be using. (*Note that we have several hundred pages of documents, we attached the most relevant.) Our goal is to develop a system that keeps temperature low, so these specifications are very helpful in providing a range that we would like to remain within. Furthermore, the outside housing of the equipment should be kept to a temperature lower than 40 Celsius so that the user will not be burnt or injured in any way from touching it. Regarding the LEDs, we hope to achieve the largest possible amount of intensity from them, while at the same time ensuring that the buildup of heat does not ultimately melt the entire device.

4.2 Relating Specifications to Customer Needs The customer, QBC Diagnostics, first and foremost wants for us to devise a plan to handle all of the heat that is dissipated by the LED in the ParaLens Advance. Specific to the LEDs, QBC Diagnostics is looking to implement the use of UV, Blue, Green and Amber light in that order of priority. The list of needs for this project is fairly straightforward, and all parties are on the same page with what the final deliverables should entail.


5.0 Concept Generation

5.1 Problem Clarification For the black box model of the overall product, please refer to the Figure 2 below. The improved version of the ParaLens Advance that the team is focused on creating will utilize the same basic functions as the current model. The ParaLens Advances primary function is to deliver images of cells affected by malaria and tuberculosis to the user through a microscope. The mechanisms by which this occurs are fairly simple, and consist of an electrical input that powers an LED light. The LED light in turn allows for fluorescent microscopy to occur, with heat as the main byproduct.

Figure 2. Overall Black Box Model for ParaLens Advance Phase II

5.2 Concept Generation The following concepts in this section were all generated utilizing the current model of the ParaLens Advance as a foundation, and brainstorming different ways that it could be improved so that the heat dissipated by the higher-powered LEDs could be managed.

In Figure 3 below, the first concept can be seen. In order to explore the possibility of active cooling along the outside of the current body of the ParaLens Advance, we developed this concept. The idea is based

Specific light hits cell sample

Deliver Image of Affected Cells Heat Electrical Input

LED Light Fluorescent Microscopy

LED Light LED sends light towards lens

Light travels through filter

Light returns to users eye for viewing

FM

LED turns on and emits light

Buildup of heat from constant light

Fins and heat sinks allow for some heat exit

LED increases intensity to a constant point

Input Heat


on a separate outer housing, centered on the current housing of the ParaLens Advance, that would be used to facilitate cooling airflow across the outside of the inner core body, in which the LED as well as the rest of the system would be creating heat and radiating outward towards the body. The create the airflow, a single fan blade would be attached to the back of the device and pushed out through a chimney off to the side of the device and away from the work area of the microscope.

After developing the first concept for the product based on active cooling of the ParaLens outer body, we decided as a group to try and explore different and novel approaches to the overarching issue of heat management.

For the second product concept, found in Figure 4, we focused on the issue of the power source being so close in proximity to the actual light source, the LED. We developed a concept that would be modeled very closely after the common computer charger. By removing the DC power supply from the back of the actual ParaLens Advance itself and housing it in its own box, it could mean that the LED and lens could be moved further back within the ParaLens Advance housing itself. The hope would be that by place it farther back, a the housing itself could be perforated with small holes that would better allow for passive cooling, while still allowing for it to be lightweight, functional and adaptable to the many environments and stresses that this product is used under.

After our initial analysis of the current ParaLens Advance product, it was seen that fins are currently used as an effective passive cooling instrument. It was also discovered that the current fin design is not robust enough to handle the increased heat load from the other LEDs that QBC Diagnostics desires to use in its next generation of the ParaLens Advance. By enlarging the fins and reorienting them so that they face the opposite direction as the current design, there would be an increase in surface area. The idea behind this

Figure 3. Product Concept #1


increase in surface area is that it would lead to a greater heat transfer across the aluminum body and keep the internal temperature at a manageable level. The drawing of this concept can be found in Figure 4.

Figure 4. Product Concepts #2 and #3 Sketches


The last and final concept that was developed by the team is actually modeled after the first version of the ParaLens Advance and can be seen in Figure 5. While the current version of the ParaLens Advance has all of its components housed in one body, the predecessor to the current design had a separate light and power source that connected to the filter, which is placed inside of the customized microscope objective.

With this design, there are several benefits. The first of which is the fact that the actual LEDs and subsequent heat source could be housed in a separate device, allowing for more flexibility when it comes to active and passive cooling methods. There is also potential with this design for scalability. We have a vision that we could essentially use this housing to offer different models of LEDs, all housed on a rotating base that would be set in front of the fiber optic lens depending on the customers preference. The fiber optic cable could then carry the light through to the filter that would be placed inside of the customized microscope objective. Overall, this was our strongest option and the choice that at this point we felt most comfortable with moving forward with.

Figure 5. Product Concept #4 Sketch


5.3 Concept Selection Below, the concept selection matrix for the 4 concepts that we developed, as well as the current model, can be seen in Table 3. From this, it can be clearly seen that the most promising design for us to pursue would be that which utilizes fiber optics as a way to transfer the light from the source to the filter.

From this

Each concept in the matrix has its own pros and cons, which are detailed below:

2-Cylinder Active Cooling System Pros: safe Cons: difficult to manufacture

Fiber Optics System Pros: safe, easy to use and easy to manufacture Cons: cost

Liquid Cooling System Pros: safe Cons: durability, cost, ease of use and ease of manufacturing

Table 3. AHP Selection Matrix

Aesthetics


Larger Heat Fins Pros: none Cons: aesthetics and ease of manufacturing

In summary, it was shown that the best concept for us to pursue would be that of the fiber optic system. It fits nicely under all of the constraints and specifications that have been laid out thus far in the project, and will be the design that we move forward with for the duration of this project.

6.0 System Level Design

6.1 Two Chamber Active Cooling The two chamber active cooling concept, as seen below, is a more simple design inspired from the current ParaLens. Keeping the housing close to the original design, we built an outer housing to go over the initial product. This serves two purposes. First, it can protect the users hand from the heat that would be generated on the inside housing in the original design. Second, with the use of a computer fan and an outlet at the front we can create active cooling using the outer housing as a tunnel. The inside piece is virtually the same with the fins being rotated to move along the inside housing, we are also considering moving the buckpuck DC power supply from directly behind the LED to outside of the entire device, making it part of the power chord (similar to a laptop charger).

Figure 6. Total System Level Design


Figure 7. Inner Housing Design

Figure 8. Outer Housing Design


6.2 Fiber Optic Box The fiber optics concept was inspired by a previous ParaLens model, with the idea that it would be easier to cool as well as allow for extra functionality. The housing is a simple box with slot openings one side for ventilation and a fan on the other side to blow out the hot air. Active heat transfer is again the primary use of cooling, and a micro fan is placed against one of the openings. An LED wheel is placed on the inside for easy transition between LED lights (a bonus for QBC). Also inside would be the buckpuck DC power supply. We have considered placing heat sinks on the individual LEDs, and possibly using an epoxy or other methods to cool the inside of the housing. On the outside you can see two chords, one being the power supply chord, while the other is the fiber optics cable. Below the fiber optics cable are two knobs to adjust the intensity and also to change the LED lights.

Figure 9. Fiber Optic Box


7.0 Special Topics

7.1 Budget and Vendor Purchase Information Based on the customer needs that we determined, our focus is on safety, ease of manufacturing, cost and adaptability. From this breakdown, we will be guided on how to best utilize our money over the course of this project. When it comes to materials, we have been lucky enough to benefit from the use of QBC Diagnostics facilities and materials, which will greatly reduce our costs related to materials and machining. However, if we feel as though our design should deviate from the materials available to us, we will need to use the money provided in our budget to cover those expenses. Travel expenses are also expected to be minimal, considering that QBC Diagnostics headquarters are located 20 minutes away in Port Matilda, PA. There really should be no need for us to utilize the budget for anything related to travel, lodging or meals.

The costs related to the presentation of our final product will also be present. While this is not something that has been actively discussed thus far, it will require a significant part of the budget and will be kept in mind throughout the entire course of the project. The majority of the budget will be used for the design parts. This is the section that we assume will prove the most costly. From our concept design meeting we created concepts that require little change to the current model and some that will require more deviation from the current model. For the design of parts that are not currently part of the manufacturing process, we will assume that testing will cause us to use more material to create our prototypes. We can also assume that we will have to have multiple tests for our new parts, which will increase our cost in design materials. We will need to factor in costs of active cooling fans, cooling epoxy and heat dissipation parts that will be used in concept testing. The table below outlines the initial budget plan as best as can be done at this point.


Table 4. Quantitative Breakdown of Current Budget Status

Budgeted Item Estimated Cost Actual Cost Supplier

Machining $0 $0 ~

LEDs $0 $103.03 Mouser

Electronics $100 $56.73 Luxeon Star, Mouser

Miscellaneous Parts $100 $15.40 Mouser

Heat Dissipation $200 $32.04 Micro Center, Newegg

Organization $50 ~ ~

Trips $100 ~ ~

Other $150 ~ ~

Final Project Poster $50 ~ ~

Table Cloth $15 ~ ~

Presentation $100 ~ ~

Total $865 $207.20 ~

7.2 Project Management The Gantt chart seen in Appendix I manages the project and serves as a guiding light for progress throughout the course of the semester. The team is made up of people that have very diverse backgrounds and interests, but each brings something unique and valuable to the entire group as a whole. The resumes for each member are included in Appendix H. Three of the five members have strong management and writing skills, and will be instrumental in ensuring that the group stays on track and communicates effectively with all of the necessary parties involved. On the technical side of things, two group members bring a strong understand of electricity and how to best construct an efficient power system. Collectively, the group also possesses strong technical knowledge in terms of solutions for cooling and methods for which to produce the different designs that may be conceived.

With the time that is left before the final deliverables are due, there is still much to do. Besides solidifying plans for a specific concept and design procedure, the team must prepare and familiarize itself with the capabilities of QBC Diagnostics manufacturing facilities. Furthermore, there must be a plan for producing a prototype in conjunction with QBC Diagnostics and finally a plan to present the new product at the final showcase.


7.3 Risk Plan and Safety The main risks associated with this project are safety risks associated with our design. These risks are outlined below:

LED - Class 1 Product: safe under almost all operating conditions - On spec sheet: LZ4-00A108 LED Engin - 125 degrees Celsius maximum at the diode junction - Use caution when operating LED in electrostatic intensive area (spec sheet) - Filters should be installed in the fiber optic device to eliminate harmful infrared radiation (invisible) in microscopy applications (Fiber Optic Association)

Power supply - Low voltage/current rating little to no risk involved - Same minor risks as household electronics - Power supply should be designed to handle load specifications - High currents through the body can be fatal. Power supply should be designed to isolate such currents from possible human contact -Power supply should be designed to limit heat. Not only can it cause device failure, but also poses a danger for burns upon contact

7.4 Communication and Coordination with Sponsor The communication between the team and sponsors consists of an email to update each other on progress at least once a week. The team also travels to the Port Matilda, PA headquarters bi-weekly to have a face-to-face meeting in which we go over any and all questions that either side may have.

8.0 Detailed Design

8.1 Manufacturing Process Plan Prototype

The following steps provide a detailed manufacturing process plan for the QBC Diagnostics ParaLens Advance II prototype.

*Note that this is the manufacturing plan for the prototype, and a mass production manufacturing plan will be included in the final report.

Housing Assembly Raw stock 24 x 20 x 1/16 sheet of 5052 aluminum o Use a water jet to cut the sections as shown in Appendix J


o Drill and debur twenty 1/8 rivet holes o Use the sheet metal brake to form 90 angles as shown in Appendix J o Rivet together the bottom and sides of the housing using 1/8 rivets and a rivet gun

Fan Assembly 80 mm computer fan o Align the fan to ensure that airflow blows through the housing assembly o Align rubber washers with the housing assembly and fan to reduce vibrations and noise o Attach the fan to the housing assembly using four 0.165 fasteners

LED Assembly LEDengin Blue LED (model for all LEDs) o Solder wires onto the LED leads o Mount the LED to the aluminum heat sink using a thermal conductive adhesive o Mount the LED and heat sink assembly to a PVC seat within the housing, as outlined in

Appendix J o Position the lens within the LED assembly and PVC seat

Electrical Assembly All connections made to a breadboard o Follow the schematics presented in Appendix K to solder the connections together o Place the potentiometers within the specified holes on the housing assembly o Mount the electrical components within the housing assembly

Mass Production

The following steps provide a detailed manufacturing process plan for the QBC Diagnostics ParaLens Advance II.

8.2 Analysis First and foremost, an analysis was needed to determine just how much needed to be managed. When calculating, we looked for the cubic feet per minute that would need to be removed in order to ensure that the internal components would not be affected.

Assuming a maximum temperature of 150F and a room temperature of 100F, the following equation was used to calculate the volumetric flow rate in order to properly manage the excess heat.

= 3.16 The power of each LED was gathered from the specifications found on the LED Engin website, as well as the original Luxeon Star LED that is currently used in the ParaLens Advance. Below are the final values, in cubic feet per minute, that represented how much heat needs to be removed for proper management.

Luxeon Star Blue LED: .214 LED Engin Blue LED: 1.032 LED Engin Green LED: 1.062 LED Engin Amber LED: 0.6636 LED Engin UV LED: 1.15


Analysis for Resistor Values:

In order to achieve the desired LED voltage range, a resistor was needed in series with the potentiometer. This value was calculated using the 16.65 V to 12.8 V drop (3.85 V). = 12.8 = 16.65 !!!!!!"#$ (Potentiometer resistance is at minimum)

= 10 , 12.8 16.65 = 11 + 10 R1 1 0.769 = 7.69 Solving for R1: = (in series with the potentiometer) Using the fans power rating, we can calculate the load resistance of the fan: = !/

= 1.08 = 12 ! ; = 12 !1.08 ; = 8.3 Material and Material Selection Process As we identified from section 2.2, the main areas of focus determined from weighting of customer needs are ease of manufacturing, cost, safety, and adaptability. To account for adaptability we are selecting small and robust components to ensure that our product remains portable and effective to use anywhere in the world. Since our product utilizes a fiber optic cable instead of connecting directly to the microscope, we did not have to worry about strict size constraints.

To ensure the product has a low cost and is easy to assemble we considered several materials for the housing. The first material we considered was 3-D printed plastic. After consulting with QBC we decided that 3-D printing is a long process, with many opportunities for failure and cost. At this point we are not considering plastic injection molding, as the cost to buy the required mold would be around $75,000.

Having crossed plastic off the list, we began to look at different types of metals. Since this is to be used for health related purposes we want to select something that will not rust or contaminate specimens. At the same time we are looking for a material that is relatively light, strong, and easily machined. Because of these requirements, we focused on aluminum products, specifically comparing 5052 and 6061 aluminum. The comparison sheet as seen in Appendix L provides an excellent breakdown of the potential applications of both metals. Our application includes machining and bending, making 5052 aluminum the ideal material for our product. The price of a 5052 aluminum sheet with a size of 24 x 24 x 1/16 is $17.22, compared to the price of a 6061 aluminum sheet of the same size with a price of $25.15. (source from www.onlinemetals.com )


8.4 Component and Component Selection Process The electrical component details, as well as the reasons why they were selected, are as follows:

Breadboard:

Model: Jameco Value Pro Breadboard Segment Dimensions: 6.65 x 2.125 840 Connection points Was chosen for its compact dimensions and its flexibility for our prototype

Power Supply:

The same power supply as in the previous ParaLens model will be used. ParaLume DC Power Supply, 9V, W / 4 Interchangeable Plugs Short Circuit protection/Over Voltage Protection 9 V Output Voltage 0 A - 1.4 A Load Current 1% Ripple and Noise Margin 2% Voltage Accuracy 1% Line Regulation 2% Load Regulation This power supply is cost effective, reliable, durable, and can be supported by power outlets in

multiple countries.

DC-DC Module Step-Up and Down Voltage Converter:

The LEDs require a minimum of 12.8 V for operation. Therefore, a step-up voltage regulator is required to achieve this voltage from a circuit input voltage of 9 V.

Model: LM2596S+LM2577S Operating Temperature Range: 0-125o C Input Voltage: 3.5-28 V Our operating input voltage: 9 V Desired input voltage: 16.65 V Maximum Input Current: 3 A (we are in the safe range, at less than 1 A). Maximum Output Current: 3 A (we are in the safe range, at less than 1 A). Our operating output current: 700 mA Internally Limited Power Dissipation The variable voltage regulator allows us to achieve a very specific voltage value (16.65 V) for the

LED. Although not the cheapest, this was the only device that allowed us to achieve this voltage.

Potentiometer:

Model: Bourns 10K 10% SQAURE SEALED Audio Logarithmic Potentiometer Through-Hole mounting style Price was reasonable


Operating temperature: 1-125o C Power Rating: 500 mW Resistance is not linearly related to the angular position of the knob. Contact Resistance Variation: 2% Power Rating at 70o C: 0.5 W Was chosen to allow for a perceivable LED intensity change

BuckPuck:

Model: Luxeon Star 700 mA, Externally Dimmable BuckPuck DC Driver With Leads Cost effective Output Current: 700 mA Input Voltage Range: 5 V 32 V (DC) Control Pin Voltage: 10 V (DC) Output tolerance: 5% Efficiency: 95% Was chosen to feed a constant current of 700 mA to the LED

Resistors:

Free of cost (from the Penn State Electrical Engineering Stockroom) The resistor is a linear circuit component, governed by ohms law (V=IR) Resistance Values (quantity): 33k (1), 51.5 (1) Calculated to achieve required parameters

The fiber optic cable we are using is from the predecessor to the ParaLens and can be seen in Figure 10 below.

Figure 10. Prototype Fiber Optic Cable


There are a few problems with the original cable, but we will be using it for our prototype. The cable can easily break when bent several times, and is geared towards visible light. Our prototype will be using only blue light from an LED, so this is not a problem. The original fiber optic model used a white halogen light. We will be using a lens to focus the light into the fiber optic cable. The cable will then fit into the microscope. The piece that mounts the original ParaLens behind the objective of the microscope will also fit this fiber optic cable. When we add the other LED's, we will have to worry about ultraviolet light. We will need to have a second fiber optic cable that can deal with the wavelength and intensity of UV light. When the other LED's are added we have decided to have several spots to insert the fiber optic cable into sockets on the housing (A socket for each LED). We are currently thinking about ways to have the device detect which socket/port the cable is plugged into. We are looking into using a magnetic system. Having a different size cable just for the UV LED will prevent the visible light fiber optic cable being used for UV light. When choosing which LEDs to use for our product, we utilized the expertise that was available to us in the form of QBC Diagnostics. Building off of their work and our own research, it was determined that the best option for the blue, green, amber and UV LEDs was a LED Engin, as opposed to the Luxeon Star LEDs that are used in the current version of the PareLens. The sole reason for this is because the LEDs offered by LED Engin offer levels of luminescence that are leagues beyond those offered by Luxeon Star. In terms of cost, they were more expensive but our sponsor made it very clear that this increase in cost was to be expected if they were to have brighter LEDs. They are of a superior quality and while they do not offer any improvement in terms of heat management, their increased brightness solves one of our projects biggest deliverables.

8.5 CAD Drawings For all CAD Drawings of the prototype and expected final design, please reference Appendix M.

8.6 Test Procedure In order to ensure that the product will not overheat (temperatures above 130 F) we will use a thermocouple probe to test the heat of the system at a variety of locations, including but not limited to:

LED Heat Sink LED connection Buck puck Inside of housing Outside of housing

In addition, we will leave the system on for an extended period of time (>4 hours) and repeat the tests, to ensure that the product is robust and can withstand misuse.

Most importantly, we need to ensure that the product achieves its primary function of enabling fluorescence microscopy to take place. In order to test this function, the following steps must take place:


Take blood sample and apply the appropriate malaria/tuberculosis test dye Place the blood sample on a slide and place on a microscope tray Place the LED box next to the microscope on a flat surface Decide which LED (blue, green, amber, UV) you would like to use to run the test Place the appropriate fiber optic cable into the correct aperture Attach the cable to the correct objective filter, and place into the microscope objective Turn on the appropriate switch for what LED light you are using Observe the blood sample for evidence of malaria/tuberculosis

0 Statement of Work

Appendix

Appendix A: ParaLens Advance Provisional Patent 1

Appendix B: Rathbone Patent 17

Appendix C: Patent Illustration 28

Appendix D: Multiple Wavelength LED Array Illuminator 36

Appendix E: LW Scientific Lumin Specification Sheet 37

Appendix F: Heat Test Results 38

Appendix G: First Team Meeting Agenda 42

Appendix H: Team Resumes 43

Appendix I: Gantt Chart 49

Appendix J: Prototype Housing Schematic 52

Appendix K: Electrical Assembly Schematic 53

Appendix L: Aluminum Comparison Sheet 54

Appendix M: CAD Drawings 56

1 Statement of Work

Appendix A: ParaLens Advance Provisional Patent

2 Statement of Work

3 Statement of Work

4 Statement of Work

5 Statement of Work

6 Statement of Work

7 Statement of Work

8 Statement of Work

9 Statement of Work


Appendix B: Original Fiber Optic Box Patent


Appendix C: Drawings from Patents


Appendix D: Multiple Wavelength LED Array Illuminator Patent


Appendix E: LW Lumin Specification Sheet


Appendix F: Heat Test Results

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LEDEngin Blue - Test 1 Relative Intensity

Intensity


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LED Base Heat Sink Tip


Penn State Senior Design Project

ParaLens Advance Phase II

Team Meeting

AGENDA

12:30 12:35 Review of Agenda

12:35 12:45 Team Introductions

12:45 1:15 Project Review B. Hnatkovich

o Scope/Goals of Project o Background o System Introduction o Handout PLA Design

Packet

1:15 1:45 Project Discussion, Questions & Project Planning

1:50 2:00 Review & Action Items

Deliverables:

o Action item list with responsibility and due date. o Preliminary project plan

28 January 2014

12:30 2:00 PM

Auditorium

Appendix G: Initial Meeting Agenda


Appendix H: Resumes


Appendix I: Gantt Chart


Appendix J: Prototype Housing Schematic


Description of Schematic:

The 9 V power supply (the same one used for the previous ParaLens model) supplies 9 V of DC power to the circuit. The voltage is then stepped up to 16.65 V using a voltage regulator, so that the LED can be within its operating voltage range. This voltage will be used to power the fan, as well as the LED. On the fans circuit branch, the 16.65 V will be divided among the fan load, and a chosen resistor. The voltage across the fan will be 12 V as a result.

Since the LED requires 700 mA of current, a buckpuck is placed after voltage regulator, and does not interfere with the fan branch of the circuit. In order to keep the LED in its operating voltage range (12.8 V -16.65 V), a potentiometer and resistor in series are used. The resistor was chosen so that the minimum voltage of 12.8 V can be maintained when the potentiometer is set at its lowest resistance. Both the LED and the fan are connected to ground at their lower voltage polarities.

Appendix K: Electrical Assembly Schematic


Appendix L: Aluminum Comparison Sheet


www.alcoaconsumerelectronics.comRevision 2010.12 2010 Alcoa, all rights reserved

Properties

Availability

For requirements outside of standard dimensions, please contact your Alcoa sales representative.

Available Finishes

M) Mill Finish

P) Preferred Mill Finish

BR) One side Bright

The Alcoa Advantage

OEMs are discovering that Alcoa can help them realize increasingly thinner, lighter and more durable products in a

wide variety of looks and finishes. And aluminum is preferred by designers because it is contemporary, stronger and

has an authentic, natural feel. Whether your company is designing the next hot cell phone, notebook computer, or flat

panel display, we can help:

>> Provide industry leading quality materials

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technology. Most important, it also requires the right partnera metals expert who can bring together all the tools

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Contact us today to learn how we can help your products stand out in the crowd.

Measured at a minimum thickness of .41mmMeasured at 77 F

Alloy Tempers Gauges Widths Finishes Typical Uses Anodizeable

5052 0, H32 0.014-0.1900.34-5mm

Up to 601500mm

M, P, SB, LB, C Laptops, Mobile devices

YES

6061 T4, T6 0.026-0.1250.635-3.2mm

Up to 60Up to 1524mm

M Mobile devices YES

MPa KSI MPa KSI %4D BTU in/hr-ftF

5052-0 193 28 89.6 13 25% 960

5052-H32 228 33 193 28 12% 960

6061-T4 255 37 152 22 23% 1070

6061-T6 345 50 290 42 13% 1160

Alloy Temper UltimateTensile Strength

TensileYield Strength

Elongation Thermal Conductivity

>> 505

2 an

d 60

61 A

lum

inum

She

et

SB) Short Brush pattern

LB) Long Brush pattern

C) Coated

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Side View

Appendix M: CAD Drawings


Isometric View

Top View

DSR Final Draft

Documents

Transcript of DSR Final Draft