Final ABET Presentation

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Medisense Medication Dispenser

From Left:Nicholas Kemme – Chief EngineerAndrea Kemmerrer – Editor-in-ChiefGregory Hutchins – Manufacturing EngineerThomas Wojtas – Team LeaderRyan Campbell – Test EngineerJeremiah Dwight – Quality Control Manager

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Problem Statement

Sorting your medications into single doses is a tedious and mistake-prone process, especially for older, more forgetful people. A fully autonomous system that sorts and dispenses pills and alerts the user would save time and decrease this likelihood of user error, leading to a safer means of taking frequent, complex combinations of medications.

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RequirementsPart 1 of 6

Prototype Requirement Method of Validation

1 Weigh less than 20 pounds Place final device on scale and record final weight

2 Be less than 24 in x 24 in x 18 in in size

Measure final product with a tape measure or other measuring device.

3 Machine must take less than 30 minutes to generate one pill

Using a stopwatch or other timing device the dispense device will be timed on how long it takes to sort and dispense one pill

4 Back up battery must last more than 2 days

Disconnect the machine from a power source and run it under normal conditions, at end of 2 days machine must still be functioning at full capacity.

4

Requirements


5The noise of the machine while it is sorting must be less than 70 dB

The machine will be placed on a stand and a decibel meter will be placed next to it to as the machine is sorting to determine its loudness.

6 Alert noise clearly audible from 20 feet

No notable decrease in volume from 20’ when compared to immediately next to the device

7 System reliability must be greater than 95%

95% dosage delivery rate over the 100 pills trial

Part 2 of 6

5

Requirements


8 The dosage must be be accurate 99% of the time

The correct dosage amount must be given 99 times out of 100 runs

9 Cost less than $150 (Production)

Production model overall cost will be valued at less than $150

10 Prove ability to handle up to 6 pill containers

One pill container will work well and a system will be introduced to prove the implementation of multiple containers

11 Must be able to program full dosage in less than 10 minutes

An individual unfamiliar with the device or the technology used within it will be timed while setting up the medication to determine if the system is easy enough and fast enough and that it takes them less than 10 minutes

Part 3 of 6

6

Requirements


12 Must be able to retrieve dosage in less than 5 seconds

Once dosage has been sorted and dispended and the user has been notified of its readiness it must take less than 5 seconds for the user to retrieve their medication. This will be timed using a stopwatch.

13Must be able to sort any pill between Zyrtec (small, pressed pill) and Nyquil (large, gel capsule)

A variety of pills will be placed in different hoppers and the machine must sort all of them equally as well, with high accuracy. In addition, mechanical analysis (kinematics, dynamics, structural analysis, etc.) will be performed on key components.

14Must run on standard outlet (120V) or standard batteries (AA)

The device will be configured to accept these power supplies, and perform at the same level

Part 4 of 6

7

Requirements


15 Any font must be greater than 20pt size

When programming the user interface a font size greater than 20pt will be used

16 Inside must be accessible in less than 30 seconds

Utilizing a stopwatch an individual unfamiliar with the product will be timed as they attempt to open the device

17 Must require no tools to access inside

The device will be designed so that no tools will be required to open up the Medisense dispenser. A system of latches will be implemented.

18 Time to clear a stuck pill must be less than 1 minute

An individual unfamiliar with the Medisense device will be timed as they attempt to clear an obstructing pill from the device

Part 5 of 6

8

Requirements


19 Maintenance interval must be greater than 6 months

The parts within the Medisense device must have a high durability to ensure that they will not need regular care and maintenance

20 Must survive a drop from 4 feet, 3 times

The machine will be dropped from a height of 4 feet 3 times then checked to ensure it is still sorting and dispensing pills properly.

21 Lid must withstand pulling force of 100 lbs

Pull on lid with a force greater than 100 lbs while using a force meter to verify

Part 6 of 6

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Schedule

Deliverable Completion Date

Pre Concept Design 9/22/15

Conceptual Design 10/16/15

Preliminary Design 12/6/16

Detailed Design 1/8/16Fabrication, Assembly, and Testing 4/6/16Initial Delivery, Support and Improvement 4/29/16

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Labor Loading Chart

• Approximately 10 hours per week, per person• Suggested time to

spend on project per week• Considerations made

for breaks

16 18 20 22 24 26 28 30 32 34 360200400600800

10001200

Labor Budget Chart

MEE 488 MEE 489

Project Timeline (Weeks)

Cum

ulat

ive

Labo

r (h

ours

)

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Basic Physics - V-Channel

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Basic Physics - Laser

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Conceptual Design

• Sorting methods considered: screw conveyor, laser, V-channel, scale, vacuum, push nozzle, trap door, centrifuge, shaker plate, camera, thermal sensor

• Trade studies narrow sorting methods to screw conveyor, laser, V-channel, and scale

• Return system included

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Preliminary Design

• Packaging determined• Several screws printed and

tested to determine best pitch• V-channel printed to confirm

surface roughness and angle

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Final Prototype

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Final Prototype: Screw Conveyor

1

2

3

4

1 Fans Cool Stepper Motors

2 Stepper Motors Move Conveyor Screws

3 Hoppers Holds pills

4 Conveyor Screws

Moves pills out of the hoppers and into the system

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Final Prototype: V-Channel

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7

8

9

1011

5 Curved V-channel Moves pills into straight line

6 Lasers Detects pills passing through

7 Photoresistors

Sends signal indicating pill has passed through

8 Light blocker

Allows photoresistors to work more optimally

9 V-channel Moves pills through system in single file

10 Solenoids Moves doors

11 Doors Blocks unwanted pills

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Final Prototype: Sorting12

1314

1516

12

Rotating funnel

Moves pill to dispensing cup or reject tray

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Load cell Measures to ensure only one pill has made it through

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Dispensing cup

Holding chamber for dosage of medication

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Reject tray Holding chamber for extra/wrong pills

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Servo motors

Moves the rotating funnel/reject tray

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Rotating funnel

Moves pill to dispensing cup or reject tray

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Final Prototype

Performance • Testing has been done to validate functionality of prototype

Meets the NeedMachine must be able to quietly and accurately sort and dispense a wide variety of medication

• Quiet: Operates at <40dB for majority of sorting• Accurate: Reliability testing passed• Dispense: Can differentiate between pills and dispense them correctly• Variety: Prototype has been successfully been tested with materials

ranging from 0.2g to 2g

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FMEA

• Failure modes• Motor imprecision• Pill speed• Bad device

• RPN reduction• Change to steppers,

servos• Analysis

• Pill speed• V-channel angle

• Test parts prior to installation

• Feedback loop

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Problem Solving Example 1Problem:

Stepper motors heat up to 130°F if powered constantlySteps to solve this Problem:I. Step 1 - Identify solutions

a. Option 1: Have fans blowing on stepper motorsb. Option 2: Use relays to operate motors non-continuously

II. Step 2 - Evaluate optionsa. Option 1 Pros: Minimal rewiring

Cons: Doubles power draw of motor systemb. Option 2 Pros: Solves root cause of problem; less power draw

Cons: Significant rewiring; additional Arduino pinsIII. Step 3 - Choose and implement solution

a. Problem is significant safety issue, and neither option is high-cost, so implement BOTH solutions

b. Fans and relays added to system; testing ensured functionality

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H-bridge short caused safety doors to not function properly

Steps to solve this Problem:I. Step 1 - Identify solutions

a. Option 1: Have both doors open and close togetherb. Option 2: Allow one door to be functional and always leave the second openc. Option 3: Order new H-bridge

II. Step 2 - Evaluate optionsa. Option 1 Pros: Can be done immediately

Cons: Doesn’t serve original design aspect b. Option 2 Pros: Can be done quickly

Cons: Results in potential lower reliabilityc. Option 3 Pros: Completely fixes problem

Cons: Costs more money and could cause delaysIII. Step 3 - Choose and implement solution

a. Chose and successfully implemented Option 3

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Once servos added to system, photoresistors behaved strangelySteps to solve this Problem:I. Step 1 - Isolate problem

a. Used LED to determine where problem was local or globalb. Determined problem was global - nothing was working right

II. Step 2 - Determine root causea. Consulted EE student with more experienceb. Determined servos were starving system of power, causing irregular

voltage across photoresistors (and everywhere else)III. Step 3 - Identify and implement solution

a. Separated servos from rest of circuit to give them their own powerb. Now everything behaves normally

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Development

Added fans, shortened screws, added base supports

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Modern Tools

Used Solidworks to optimize design and minimize material needed for 3D printing

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Fabrication and Assembly

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Electronics, hardware, and

supports fabricated

28Electronics and hardware assembled

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All components assembled

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Final Assembly

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Validation

Prototype Requirement Method of Validation Test for

ValidationValidation Status

1 Weigh less than 20 pounds

Place final device on scale and record final weight

Specification Test

Pass: 19.4lbs.

2 Be less than 24 in x 24 in x 18 in in size

Measure final product with a tape measure or other measuring device.

Specification Test

Pass: 13in x 17.5 in x 14.75 in

3Machine must take less than 30 minutes to generate one pill

Using a stopwatch or other timing device the dispense device will be timed on how long it takes to sort and dispense one pill

DispenseTest

Pass: 12 min 02 sec

4 Back up battery must last more than 2 days

Disconnect the machine from a power source and run it under normal conditions, at end of 2 days machine must still be functioning at full capacity.

N/A forPrototype

N/A forPrototype

Part 1 of 6

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Validation



5The noise of the machine while it is sorting must be less than 70 dB

The machine will be placed on a stand and a decibel meter will be placed next to it to as the machine is sorting to determine its loudness.

Noise TestConditional Pass: See Test

6Alert noise clearly audible from 20 feet

No notable decrease in volume from 20’ when compared to immediately next to the device Noise Test

Pass: Clearly Audible from 25' 3"

7 System reliability must be greater than 95%

95% dosage delivery rate over the 100 pills trial Dispense Test Conditional

Pass: See Test

Part 2 of 6

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Validation



8The dosage must be be accurate 99% of the time

The correct dosage amount must be given 99 times out of 100 runs Dispense Test Pass: 100%

accuracy

9 Cost less than $150 (Production)

Production model overall cost will be valued at less than $150 Cost Analysis Prototype Cost:

$583.2410

Prove ability to handle up to 6 pill containers

One pill container will work well and a system will be introduced to prove the implementation of multiple containers

Dispense Test Pass

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Must be able to program full dosage in less than 10 minutes

An individual unfamiliar with the device or the technology used within it will be timed while setting up the medication to determine if the system is easy enough and fast enough and that it takes them less than 10 minutes

Dispense Test (prove ability to receive user input)

N/A for Prototype

Part 3 of 6

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Validation



12

Must be able to retrieve dosage in less than 5 seconds

Once dosage has been sorted and dispended and the user has been notified of its readiness it must take less than 5 seconds for the user to retrieve their medication. This will be timed using a stopwatch.

Dispense Test Pass: 4 seconds

13

Must be able to sort any pill between Zyrtec (small, pressed pill) and Nyquil (large, gel capsule)

A variety of pills will be placed in different hoppers and the machine must sort all of them equally as well, with high accuracy. In addition, mechanical analysis (kinematics, dynamics, structural analysis, etc.) will be performed on key components.

Dispense Test (proved versatility) Pass

14

Must run on standard outlet (120V) or standard batteries (AA)

The device will be configured to accept these power supplies, and perform at the same level

Dispense Test Pass

Part 4 of 6

35

Validation



15

Any font must be greater than 20pt size

When programming the user interface a font size greater than 20pt will be used

N/A for Prototype

N/A for Prototype

16

Inside must be accessible in less than 30 seconds

Utilizing a stopwatch an individual unfamiliar with the product will be timed as they attempt to open the device

N/A N/A

17

Must require no tools to access inside

The device will be designed so that no tools will be required to open up the Medisense dispenser. A system of latches will be implemented.

N/A N/A

18

Time to clear a stuck pill must be less than 1 minute

An individual unfamiliar with the Medisense device will be timed as they attempt to clear an obstructing pill from the device

N/A N/A

Part 5 of 6

36

Validation



19

Maintenance interval must be greater than 6 months

The parts within the Medisense device must have a high durability to ensure that they will not need regular care and maintenance

N/A for Prototype

N/A for Prototype

20

Must survive a drop from 4 feet, 3 times

The machine will be dropped from a height of 4 feet 3 times then checked to ensure it is still sorting and dispensing pills properly.

N/A N/A

21

Lid must withstand pulling force of 100 lbs

Pull on lid with a force greater than 100 lbs while using a force meter to verify

N/A for Prototype

N/A for Prototype

Part 6 of 6

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Testing Example

M&M Percent Gobstopper Percent Total Percent

Pass 50 89.29% 50 98.04% 100 93.46%

Fail 6 10.71% 1 1.96% 7 6.54%Total 56 --- 51 --- 107 ---M&M Gobstopper0

10

20

30

40

50

60

50 50

6 1

Dispense Test

Pass Fail

Candy Used

# o

f Tr

ials

3816 18 20 22 24 26 28 30 32 34 360

200400600800

10001200

Labor Budget Chart 489

Cumulative Semester Actual

Project Timeline (Weeks)

Cum

ulat

ive

Labo

r (h

ours

)

Team Performance

2 4 6 8 10 12 14 16 180100200300400500600700

Labor Budget Chart 488

Cumulative Year Actual

Project Timeline (Weeks)Cu

mul

ativ

e La

bor

(hou

rs)

On schedule - Never missed a deadline

Under budget - $583.24 out of $600

Team - 10/10

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Lessons Learned

• Team must be easily compatible• Other teams struggled which resulted in setbacks

• Importance of a clear set of deliverables being determined and agreed upon by the team.• Clear deliverables allow everyone to know what must be done

• Cohesion of the systems must be considered early on• Most additional work was caused by considering electrical

system later

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Summary

• Prototype functionally dispenses two different medications• Wide range of medications can be sorted

and dispensed• Prototype never distributes an incorrect

dose• Team worked well together to finish the

project on time and under budget• Prototype can be scaled to accommodate

more medication and produced at a lower cost

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Thank You

Questions?

Documents

Final ABET Presentation