TRANSCUTANEOUS ENERGY TRANSFER SYSTEM

TRANSCUTANEOUS

ENERGY

TRANSFER

SYSTEM

GOALS OF DETAILED DESIGN

REVIEW

Source:

http://www.nuclearcardiologyseminars.net/images/anterio

r.jpg

We are seeking customer approval of our design and approval to spend money.

Inform the customer of our decision making process.

MISSION STATEMENT TETS TEAM P13021

To design and produce a commercially viable Transcutaneous Energy Transfer system with the ability to power a left ventricular assist

device (LVAD). This TETS device will use a magnetic coupling to enhance the patients quality

of life while operating in a safe, efficient, reliable and user friendly manner.

Source:

http://www.nuclearcardiologyseminars.net/images/anterio

r.jpg

WORK BREAK-DOWN

STRUCTURE MSD II Work Breakdown

Name Role in meetings

Mike Brown ME ME Technical LeadDesign Housing

(Generate Prints)

Source Bio-

materialsMachine Assist

Andy Hladky ME Note TakerUpload Meeting

NotesRunning Tests

Assembly &

Manufacturing

Charles Borton ME Systems Integration Manufacturing Testing

Ian Dominick ME Purchasing Magnetic Coupling

Paul Blaszczynski EE EE Technical Lead

User Interface

(Zigby, Motor

control)

Separated

Generator Lead

Kyle Pickard EE Heat GenerationRectification

Ciruits

Abdoulaye Diaw EE Battery & Charging

Ariel Christopher ID Graphics DesignManage Power

Points

Human Factors &

Design for

Usability

Renderings

Alexander Turner IE Project ManagerInternal External

Communications

Manage Edge

Website

Testing plans

(DOE)

Tasks & Focus

CUSTOMER NEEDS ENGINEERING NEEDS and SPECS

ENGINEERING METRICS ENGINEERING NEEDS and SPECS

HOUSE OF QUALITY ENGINEERING NEEDS and SPECS

Customer Needs Cu

sto

me

r W

eig

ht

Ou

tpu

t P

ow

er

Vo

lta

ge

Pro

du

ct

Lif

e

Wa

ter

Pro

of

Th

ick

ne

ss

Pro

du

ct

Lif

e

Th

ick

ne

ss

Wa

ter-

tig

ht

Tim

e t

o S

tart

Op

era

tio

n

Re

lia

bilit

y

He

at

Ge

ne

rati

on

Ele

ctr

ica

l In

su

lati

on

Lig

htw

eig

ht

(Sy

ste

m)

Sm

all

Co

nta

ct

Pre

ss

ure

Transmit Power

Wirelessly9 9 9 3 3

Complete

System9 3 3 3 3 1 1 3 3 3

Lasts Long and

is Reliable9 9 9 9 3 9

Implantable 9 3 9 3 3 9 9 1 3 3

Product is

Sealed/Safe9 9 3 9

Easy to

Use/Customer

Friendly

9 3 3 3 3 9 3 3

Small 3 9 9 1 9

Light 3 1 9 1

Comfortable 3 1 3 3 3 3 1 3 9

User Interface 3 9

Ta

rge

t V

alu

es

50

Wa

tts

12

~1

5 V

olts

> 1

0 Y

ea

rs

IP6

8

< 0

.02

54

m (

1in

)

5 y

ea

rs

< 0

.05

08

m (

2in

)

IP4

3

5 S

eco

nd

s

99

% R

ela

ibility

< 4

0 m

W/c

m2

0 A

mp

s

< 0

.45

kg

< 0

.07

62

m (

3in

)

25

N/c

m2

138 108 135 270 93 108 63 90 117 189 117 198 42 66 81

7.60% 5.95% 7.44% 14.88% 5.12% 5.95% 3.47% 4.96% 6.45% 10.4% 6.45% 10.91% 2.31% 3.64% 4.46%

4 8 5 1 10 8 14 11 6 3 6 2 15 13 12

Relative Weight

Rank

Engineering Metrics

Internal Assembly External Assembly

Raw Score

Output Power (From generator/stator)

• Tools: Multimeter (or Oscilloscope), Configurable Load

• Independant: rpm, gap, angle, medium (if shown to affect torque)

• Dependant: Amperage out, Voltage (Level & Freq.) out

Time to start operation:

• Tools: Stopwatch

• Independent: Range of motion, One hand vs. two handed

• Dependant: Time to start, Qualitative

TEST PLAN

Flux:

• Tools: Calorimeter (Styrofoam cooler, heating element, thermocouple)

• Independent: Wattage generated, RPM

• Dependant: ΔTemp

• Confounding: Ambient temp

Product life: Mechanics of failure, FMEA

Waterproof: Bubble test (Shows air-proof)

Dimensions: Calipers

Reliability: Failure Mechanics, Benchmarking

Weight: Scale

Contact Pressure: Test rig for last years device. (vary with gap)

TEST PLAN

FUNCTIONAL DECOMPOSITION ENGINEERING NEEDS and SPECS

FEASIBLILITY ANALYSIS PRO’S AND CON’S

Magnetic Coupling Separated Generator

Experimentation Validates No Moving Internal Parts

Known Improvements Small

Low Internal Heat Generation

No Magnetic/Attractive Forces

Scalable

Heavier Higher External Heat Generation

Very strong attractive force Distance Dependant Power Output

More Rotating Mass Large Input Power

Heat Generation 6.6 W of heat at 30 watts 5.4 W at 30 Watts (assume 12V)

Max Power Generated 30 watts 50 watts

Pros

Cons

Key Quantitative

Specs

SYSTEM PROPOSAL

RISK ASSESSMENT

RISK ASSESSMENT NON-TECHNICAL

Our Proposal

The Stator presents the best possibility to meet and beat customer specifications, by generating highly scalable power with less heat generation.

The Motor – Generator pair provides a path that has less risk, while still having the ability to complete the task.

Our team proposes to pursue both, with the intention to provide a meaningful comparison within the context of the TET - Device

Motor

• Maxon EC 45 Flat 50W

• Has max RPM of 10000 rpm and a relatively small depth, 24mm for the motor and an additional 17mm for the shaft, which could be shaved down to be only as long as the magnetic coupler is deep. Being just under 2 inches

Motor Housing

Motor Housing Thermal Analysis •External temperature is less 29C

•Safe for patient to hold after steady state operation

•Maximum heat flux is 17.3mW/cm2

•Only at extreme boundary conditions - high estimate

Motor Controller/ UI

• ESC- HobbyKing SS30A Weight: 22g Size: 24x52x6mm Cells: 2-3S (Auto Detect) Max Current: 25A Burst: 30A BEC: 3A

B-Field Calculations

Stator Calculations

Stator Heat Calculations Power through * (1-efficiency) = Heat generated

30 watts * .22 = 6.6 Watts

Heat generation for the Stator is a factor of the

Joule Heating, which can be calculated as

follows:

Per stator:

Current- I = W/V = 0.833

lossy of copper- rho = 1.72E-8

length of cable- 10m

Cross Sectional Area- 26awg = 1.28824934E-7

Number of stators- N = 6

=5.56Watts

Separated Generator Receiver Housing

Generator Receiver Housing

Receiver Housing Impact FEA

Thermal Analysis

Assumptions:

• Body Temperature (Environment) is 37˚C

• Heat distribution on outside of device will be modeled via FEA

• Heat transfer method inside body is conduction

• All energy inefficiencies result in heat generation

• Device is surrounded my muscle tissue which is at equilibrium between perfusion and heat generation

Critical Values

The purpose of our thermal model is to ensure this device will not harm the patient.

With a factor of safety of 2, our maximum heat flux through the tissue is 40mW/cm2

Data

• Reference Temperatures[C]: • Body Temp= 37 C • Ambient Air Temp= 25 C

• Conduction Coefficients : • Internal Organs and Muscle = 0.500 W/m*K • Skin and Fat=0.300 W/m*K • High Density Polymer=0.22 W/m*K (P13021 only) • Steel=50 W/m*K • Aluminum=204 W/m*K • Clothing=0.029 W/m*K • Convection Coefficients [W/m*K]: • Air=10.000

Conduction

Internal Environment

(Abdomen Muscle)

Engineering Model

Device

Boundary Temp: 37˚C

•The Device will be implanted in abdomen muscle

•Assuming a worst case scenario, the device will be surrounded by muscle tissue in all directions for an “infinite” thickness.

•An ANSYS model which includes the boundary temperature of 37˚C and all muscle properties will show worst case temperature and flux conditions

Generator Housing Thermal FEA

Stator Housing Thermal FEA

Torque Graphs

Breakaway Torque Test Results

20 8.723453 5.99 5.9549 19.938664 19.872739 19.725036 24.921568 24.9 24.896241

15 5.936889 6.644 7.1024 19.966121 20.039976 19.889522 35.705872 41.3 40.929263

10 11.876832 8.7775 8.6658 24.779658 24.740295 24.937439 35.6192 40.9 41.154175

Gap (mm)RPM / Breakaway Torque (mN·m)

2000 4000 6000

Pull Force Graph

Magnetic Coupling Simulation

Matlab Code • uo=4e-7*pi; % Permeability of the magnets

• M=1.6e6; % Magnetization of the magnets

• R=(.5/2)*(2.54/100); % Magnet Radius

• t=.25*(2.54/100); % Magnet Thickness

• th=(pi/4); % Theta (Angle between magnets)

• gap=[0:0.0005:.030]; % Gap between the arrays

• DR=(0.835-R*100/2.54)*(2.54/100); % Magnet ring radius

• s=sqrt((DR*th)^2+(gap).^2); %Linear distance between magnets

• n=8; % Number of magnets

• w=[0:100:12000]; % RPM

• for i=1:length(s)

• phi_o(i)=atan((gap(i))/(DR*th));

• Fo(i)=((pi.*uo)./4).*(M.^2).*(R.^4).*((1./(s(i).^2))...

• +(1./(s(i)+2.*t).^2)-(2./(s(i)+t).^ 2)); %Force Between Magnets

• Fy_o(i)=Fo(i)*cos(phi_o(i)); % Pull Force for single magnet

• To(i)=DR.*Fo(i)*cos(phi_o(i)); % Torque for single magnet

• end

• T=n*To; % Torque with 8 magnets

• F=n*Fy_o; %Force with 8 magnets

• figure(1)

• plot(gap,F,'-r'); %changed for gap

• hold on

• title('Pull Force');

• legend('Force');

• xlabel('Gap Distance in Meters');

• ylabel('Force [N]');

• grid minor

• hold off

• hold off

• figure(2)

• subplot(2,2,1);

• plot(gap,T)

• grid minor

• xlabel('Distance in Meters');

• ylabel('Torque [N*m]');

• title('Torque Available');

• Torquereq1=(50./w).*(60./(2.*pi)); % Torque Required for 50 watts of power (P=T*w)

• subplot(2,2,2);

• plot(w,Torquereq1)

• grid minor

• xlabel('RPM');


• title('Torque Required for 50W');

• Torquereq2=(30./w).*(60./(2.*pi));

• subplot(2,2,3);


• grid minor

• xlabel('RPM');



• Torquereq3=(10./w).*(60./(2.*pi));

• subplot(2,2,4);


• grid minor

• xlabel('RPM');



Rectification

• Ripple of 2.5%

Soldering Breadboard

for Rectifier

Conversion to Useful energy

• According to simulations after the rectification from either method of power transfer we will not need a Buck converter (Step down circuit) but if we do, this one would be adequate.

Battery Charger

• Can handle an input from 9V to 36V DC.

• Input pins for thermal warning from battery

• Optimal efficiency is input of 12-18V

• Can handle an upper charge current of 1.2A

Battery

• Li-Ion 2600mAh

• Dimensions 70mm X 55mm X 18mm

• Weight: 5.3 oz

• Max charge current: 2A

• Overcharge protection

What it Looks Like

Empathy Research

Empathy Research

Empathy Research

Empathy Research

Empathy Research

Empathy Research

Empathy Research

External Mounting

What we need to get there

• BOM PART 1

Part Name Material Manuf. Method Manufacturer Manufacturer

Part #

Distributor Distributor Part # Quantity

Needed

Unit MFG

Time (hrs)

Total MFG

Time (hrs)

Quantity

Ordered

Unit Price Total Price Lead

Time

Owner Comments

AC/DC converter NewEgg 9SIA0YE08B

2624

1 $45.00 $45.00 1 Week Paul

ESC HobbyKing HK-SS30A 1 $6.00 $6.00 1 Week Paul

ESC - Connectors (10) HobbyKing AM1001A 2 $1.60 $3.20 1 Week Paul

Outside motor Maxon Motor EC 45 Flat

50W

MaxonMotor 251601 1 $105.60 $106.50 2

weeks

Abdoul

housing(2 Pieces) HDPE Manual

Machining

McMaster

Carr

8671K79 1 25 25 $23.15 $23.15 1 week Charles

magnetic array 416 SS/

NdFeB

Made Magnetic

Technologies

Ltd

MTD-0.6-

0000

1 1 $41.00 $47.14 1 Week Ian Have began

testing with

this component

Mounting Fabric Elastic by hand Joann fabric 1 $20.00 $20.00 1 day Ariel

Buckles/velcro Plastic/

Metal

by hand Joann fabric 1 $10.00 $10.00 1 day Ariel

batteries AA Wegmans 6 $1.00 $6.00 1 day Abdoul

Xbee SparkFun WRL-08665 1

$23.00

$23.00

1 Week

Paul

Xbee - Shield SparkFun BOB-08276 1

$3.00

$3.00

1 Week

Paul

Arduino SparkFun DEV-11021 1

$1.00

$1.00

1 Week

Paul

headers - Male SparkFun PRT-00116 5

$1.50

$7.50

1 Week

Paul

headers - Female SparkFun PRT-00115 5

$1.50

$7.50

1 Week

Paul

2mm Sockets SparkFun PRT-08272 2

$1.00

$2.00

1 Week

Paul

LCD display Digikey NHD-12864WX-

T1TFH

1 $16.00 $16.00

1 Week

Kyle

Housing (2 Pieces) HDPE Manual

Machining

McMaster

Carr

8671K79 1 25 25 $23.15 $23.15 1 week Charles

Wire 1 $0.00

1 day

Kyle Found on

campus

P13021 Transcutaneous Energy Transfer System

Bill of Materials

OUTSIDE

UI

What we need to get there

• BOM Part 2 Housing ABS

(PEEK)

Manual

Manufacturer

Acrylonitrile

Butadiene

Styrene

(Poly Ether

Ether

Interstate

Plastics

1 30 30 (3.5,3.5

,2.5)

43.83

(296.17)

$43.83 1 week Charles Price/Availabilit

y of implantable

material

Grommet- housing Silicon

hose/pas

te

(maybe

paste)

1 $0.00 1 week Charles Paste idea from

Dr. Day

magnetic Hub array 416 SS/

NdFeB

Made Magnetic

Technologies

Ltd

MTD-0.6-

0000

1 1 $41.00 $47.14 1 week Ian Have began

testing with

this component

Motor Maxon EC 45 Flat

30W

200142 1 $74.00 $74.00 2

Weeks

Kyle

o-ring

EPDM O-

Ring

AS568A

Dash

Number 039

McMaster

Carr

9557K128 1 pkg $11.20 $11.20 1 week Ian 1 package

includes 50 o-

rings

Diodes Vishay BY500-400-

E3/54

Digikey BY500-400-

E3/54GICT-ND

6 - - $0.53

$3.18

1 Week Kyle

Rectifier PCB Advanced

Circuits

1 $0.00 3

weeks

Kyle Needs circuit

design

Rectifier PCB Advanced

Circuits

1 $0.00 3

weeks

Kyle Nees Circuit

design

Diodes Vishay BY500-400-

E3/54

Digikey BY500-400-

E3/54GICT-ND

6 - - $0.53

$3.18

1 week Kyle

Housing ABS

(PEEK)

Manual

Manufacturer

Acrylonitrile

Butadiene

Styrene

(Poly Ether

Ether

Keytone)

Interstate

Plastics

1 30 30 (3.5,3.5

,2.5)

43.83

(296.17)


y of implantable

material

o-ring

EPDM O-

Ring

AS568A

Dash

Number 039

McMaster

Carr

9557K128 1 Above $0.00 1 Week Ian


hose/

paste

(maybe

paste)

1 $0.00 1 Week Charles Paste idea from

Dr. Day

Heat Sink 6061 Al Manual

Machining

McMaster

Carr

1610T31 1 4 4 $16.51 $16.51 1 Week Andy

Ferous plate sheet

metal

Manual

Machining

1 2 2 $0.00 1 day Paul Spare Parts

Mag Wire Mag Wire Hand

Wrapped

6 plus

spare

2 14 $0.00 $0.00 1 day Paul Material at

school

Inside

Motor/gen

erator

Inside

Separated

Generator

What we need to get there.

• BOM Part 3

Housing ABS

(PEEK)

Manual

Manufacturer

Acrylonitrile

Butadiene

Styrene

(Poly Ether

Interstate

Plastics

1 30 30 (3.5,3.5

,2.5)

43.83

(296.17)


y of implantable

material

O-ring 1 $0.00 1 week Ian Size unknown


hose/pas

te

(maybe

paste)

1 $0.00 1 Week Charles Paste idea from

Dr. Day

Voltage Regulator 3.3 SparkuFun COM-00526 1 3 $2.00 $6.00 1 Week Paul

Xbee SparkFun WRL-08665 1 0

$23.00

$23.00

1 Week

Paul

Li-ion battery charger CircuitBo

ard

premade SilverTel AG112 Semiconducto

r Store

1 $12.50 $12.50 2

Weeks

Paul

Battery All-Battery AT: Tenergy Li- 2 $26.00 $52.00 Unsure Abdoul

Battery housing ABS

(PEEK)

Manual

Manufacturer

Acrylonitrile

Butadiene

Styrene

(Poly Ether

Ether

Keytone)

Interstate

Plastics

1 30 30 (3.5,3.5

,2.5)

43.83

(296.17)

$43.83 1 Week Charles Not sure of size

of battery

130 $774.17 $0.00

Inside

Battery

Charger

Internal

Battery

Totals

Legend

Ready to order

Do not know all info. and estimate time is

XX hrs.

Know what needs to be done and have XX

hrs of work

How we plan to get there

Week 1 Owner DOE & Analysis Other Tasks Other Tasks Owner

Rectification Designed & Build Kyle

Drawings for Charger & Battery Housing Mike Review for Manufacturability Charles

Motor Generator Pair bench test Ian Alex Build/find test rig Charles, Joe

Stator Bench test Paul Alex

Battery and Charger bench test Abdoul Assist with Battery Andy

Locating belt Designed Ariel

Modify Magnetic Array Charles Setup Assist Ian

Week 2 Owner DOE & Analysis Other Tasks Other Tasks Owner

Wireless communication & Display test Paul

Battery Charger & Battery Boxes Charles Setup Assist Andy, Ian

Test the Generator & Stator with rectifier Kyle (Comparison, Alex)

Battery Charger Status Call Abdoul

UI housing Engineerinig Drawing Mike User Experience/Manufacture Ariel, Charles

Week 3 - Functional Demo Owner DOE & Analysis Other Tasks Other Tasks Owner

Test the External Motor Through Battery Kyle Alex Set up Assist Abdoul

Drawings for External Housing Mike User Experience/Manufacture Ariel, Charles

Programming LCD for user display Paul

Presentation for Demo & Writing Paper Alex,Ian,Ariel,Andy

UI Housing Manufacture Charles Set Up Assist Andy, Ian

CITATIONS Bonfield, Tim. "Device to Help Hearts." Cincinnati Enquirer (November 7, 1999)

"How Artificial Heart is Made." Madehow. N.p., n.d. Web. 13 Dec. 2012.

U.S. National Library of Health and Medicine, ed. Medlineplus. N.p., n.d. Web.

13 Dec. 2012.

Cirtec Medical Systems, ed. Active Implants. N.p., n.d. Web. 13 Dec. 2012.

Cover photo: http://cdn.medgadget.com/img/he3sfe.jpg

Documents

TRANSCUTANEOUS ENERGY TRANSFER SYSTEM