detailed design review
DESCRIPTION
P12026: Transcutaneous Power Transmission. Detailed design review. Team Members Nooreldin Amer Michael Carozzoni William Chan Naveen George Devin Prescott Paul Slagle. Presentation Outline. Project Description Review of Customer Needs, Engineering Specifications, and House of Quality - PowerPoint PPT PresentationTRANSCRIPT
DETAILED DESIGN REVIEW
P12026: Transcutaneous Power Transmission
Team MembersNooreldin Amer
Michael CarozzoniWilliam Chan
Naveen GeorgeDevin Prescott
Paul Slagle
Presentation Outline Project Description Review of Customer Needs, Engineering Specifications, and
House of Quality Power Circuit for Motor Armature/Motor Casing CAD Receiver/Generator Casing CAD Generator Selection Power Transmission Test Data Rectifier Circuit Review of Risks System Interface Bill of Materials MSD II Quarter Schedule
Project Description
Team 12026 is currently researching and developing a module for transcutaneous (through the skin) power transmission. Our project involves the transmission of power through a gap using passive magnetic coupling. This unit has potential as a medical device, and is intended as a proof-of-concept for future application in ventricular assist devices (VAD).
Customer NeedsCustomer
Need #Importance Description Comments/Status
CN1 9Transmit power
wirelessly
"Functional prototype paired motor and generator set with passive magnetic coupling." "Delivered system must be āsizedā to be able to yield 100 watts at the motor (receiver)."
CN2 9Lasts long and is
reliable"Estimated design life of 99% reliability at 10+ years with 95% confidence."
CN3 9 Safely implantable Bio-compatible and low heat generation
CN4 3 Light "System weight less than 1 pound."
CN5 3 Small"Inner and outer components of the system must each be the size of a hockey puck or smaller."
CN6 3 Contained Shell containing device to prevent unwanted mass or energy transfer
CN7 3 Comfortable Minimize compressive pressure on tissue
Importance: Sample scale (9=must have, 3=nice to have, 1=preference only).
Engineering Specifications
House of Quality
Power Circuit
Component Part
Rectifier 400V 6A Bridge Rectifier
Transformer 120VAC to 12VDC 0.5A
LM7812 12V output
Test Bench
Parallax BASIC Stamp 2 Module
ā¢ On-board flash ā¢ Vin of 5.5V to 15Vā¢ Cheaper than the Arduino Microcontrollerā¢ Current members experienced in programming
Sample BASIC Code ' {$STAMP BS2} ' {$PBASIC 2.5} FOR counter = 1 TO 50 %start up gradual speed PULSOUT 13, 150
PAUSE 20NEXT FOR counter = 1 TO 50 %start up gradual speed PULSOUT 13, 250
PAUSE 20NEXT FOR counter = 1 TO 50 %start up gradual speed PULSOUT 13, 350
PAUSE 20NEXT FOR counter = 1 TO 50 %start up gradual speed PULSOUT 13, 450
PAUSE 20NEXT DO PULSOUT 13, 650 %Full speed PAUSE 20 LOOP END
DK-LM3S-DRV8312After comparing the DRV8312 to the Phoenix Motor Controller from Castle Creations, the DRV8312 has more options and better headroom with supply voltages up to 50V. This also has a higher PWM operating frequency of up to 500 kHz. This is a more robust controller and a better fit.
Case Material
PVC Material Properties
Outside Sub Assembly Preliminary Model
Motor (Blue): EC-i 40 Brushless Outside Shell(Red/Yellow): PVCShaft Mount (Green): AluminumArmature (Orange): PVCMagnets (black/red): NeodymiumMotor Mount (Grey): PVC
Length: 2inOD: 3in
Weight: 0.75lbMax RPM: 9390
Number of Magnets: 6
ANSYS Simulation Armature/Receiver
PVC Material Properties used for ANSYS
Density 1300 kg/m^3
Modulus of Elasticity 2.90E+09 MPa
Poisson Ratio 0.41
Yield Strength 51.5 MPa
RPM: 20000Material: PVCMax Stress (12 Mag)=8.72 MPa (Pass)Max Stress (6 Mag)= 8.88 Mpa (Pass)
Receiver CAD Model
Height: 35.5 mm [1.4 in]Diameter: 76.2 mm [3 in]Gear Ratio: 3.09:1, 30mm Pitch HelixEpoxy Sealed, USP Class VI
Receiver CAD Model
Receiver CAD Model
Receiver CAD Model
Tooth Profile
Receiver CAD Model
Receiver Sealing
Motor Efficiency
Generator Efficiency
MATLAB Implementation
MATLAB (contād)
MATLAB (contād)
MATLAB (contād)
Generator Selection
Maxon EC22, brushless, 100 Watts, sterilizable
Chosen forOperating point at 8.07 mNm and 45098 rpmLow heat dissipation (0.56 W @155Ā°C)High power output (31 W @155Ā°C)High operating speed (max. 60,000 rpm)High max. ambient and max. permissible
winding temperature (135Ā°C and 155Ā°C, respectively)
Generator Comparison
EC 16 EC 22s
Heat [W] 5.3 4.8
Power [W] 32.9 33.8
Cost [USD] 288 546
Size [mm] 16x56 22x62.7
Max Ambient Temp [Ā°C]
100 135
Operating Torque [mNm]
12.27 14.72
Operating Speed [rpm]
29670 24725
No Load Speed 39200 32700
Magnetic Simulations
Armature/Receiver Testing
Armature/Receiver Testing
Three Phase Rectifier Circuit
Three Phase Rectifier Output Waveform
Output Voltage Regulator
š š=š ššš (1+š 2+š 3
š 1)+š¼ššš (š 2+š 3 )āš šššš
Combination of Rectifier and Voltage Regulator
Review of Risks
ID Risk Item Effect Cause
Likelihood
Severity
Importance
Action to Minimize Risk Owner
Describe the risk briefly
What is the effect on any or all of the project deliverables if the cause actually happens?
What are the possible cause(s) of this risk?
L*S What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring?
Who is responsible for following through on mitigation?
1High Heat Generation Not meeting specifications,
Low generator efficiency, improper heat dissipation, 3 3 9
Research into generators, dissipating heat properly DP
2High Operating RPM failure Unsafe testing condition Power requirements 2 3 6
Extra layer of safety during testing, gearing DP
3Breakdown Torque/Slippage Lose transmission of power
Large air gap, weak magnet strength, 2 3 6
Ramp-up algorithm, fail-safe mechanism WC
4Low Power Transmission
Not meeting power transmission requirement
Heat specification causing a bottleneck 3 2 6
Research into generators, proper heat dissipation MC
5Low Motor Efficiency
Possible too much heat generation, not meeting other specifications
Lack of research into motors, 2 2 4 Do research regarding motor, NG
6 Large device Not meeting specification,
Trying to meet specification, not enough research 2 2 4
Research components, negotiate with customer, PS
7Failure of parts due to Transience Higher stress Going from 0 to x RPM, 1 1 2
Ramp-up algorithm, factor of safety NA
Likelihood scale Severity scale1 - This cause is unlikely to happen 1 - The impact on the project is very minor. We will still meet deliverables on time and within budget, but it will cause extra work2 - This cause could conceivably happen 2 - The impact on the project is noticeable. We will deliver reduced functionality, go over budget, or fail to meet some of our
Engineering Specifications.3 - This cause is very likely to happen 3 - The impact on the project is severe. We will not be able to deliver, or what we deliver will not meet the customer's needs.
Interface with 12022ā¢Final dimensions of generator and motor from 12026 (housing)ā¢12026 provides 2 interior thermocouples and provides access to themā¢12026 provides hall effect sensors and provides access to them ā¢12022 provides power to the hall effect sensors and generator side. ā¢12026 provides access to measure on both input and output
Interface with 12022Measurement Unit of Measure 12022 Measurement Range 12026 Operating Range
Input Power to Motor W 0-200 0-50
Output Power from Generator W 0-200 0-35
Thickness of Transmission Material m 0-0.05 0-.025
Contact Force N 0-178 0-112
External Motor Temperature Ā°C 0-100 35-100
Internal Generator Temperature Ā°C 0-100 35-100
External Generator Temperature Ā°C 0-100 35-100
Generator Housing Torque N-m 0-1 0-1
Motor RPM RPM 0-30000 0-15k rpm
Generator RPM RPM 0-50000 0-32k rpm
Bill of MaterialsSubassembly Item Name/Type Owner Amount Units
Cost per indiv. Unit
Net Cost Component Supplier Supplier P/N
Motor Control Phoenix-35 Brushless Motor Control DP 1 ea. $99.95 $99.95 Castle Creations PHX-35 Arrival Date: 2012-03-09Motor Maxon EC-i 40 Brushless PS 1 ea. $323.60 $323.60 Maxon EC-i 40
Motor Casing 3" Dia Motor Casing PVC PS 1.75 inch $1.60 $2.80 McMaster Carr 8745K63 Budget#4-40 3/8" set screw PS 2 ea. $0.15 $0.31 McMaster Carr 92313A017 Unit Cost: $1,613.40#8-32 1/2" set screw PS 6 ea. $0.12 $0.73 McMaster Carr 92313A194 Team Budget: $1,059.952.75" Dia Motor Mount PVC PS 0.75 inch $1.60 $1.20 McMaster Carr 8745K631" Dia Armature Mount Aluminum PS 0.125 inch $1.44 $0.18 McMaster Carr 86985K431#8-32 1/4" cap screw PS 2 inch $0.11 $0.22 McMaster Carr 91251A1903" Dia Motor Lid PVC PS 1 inch $1.60 $1.60 McMaster Carr 8745K63
Generator Casing 3" Dia Generator Lid DP 1 inch $1.60 $1.60 McMaster Carr 8745K633" Dia Generator Casing DP 1.5 inch $1.60 $2.40 McMaster Carr 8745K63Machining Cost DP 1 ea. $200.00 $200.00 First Cut N/A
Generator Maxon EC-16 60W WC 1 ea. $287.71 $287.71 Maxon EC-22Rectifier Power Amplifier NA 5 ea. $5.52 $27.60 Digi-Key LM675T-ND
Voltage Regulator NA 3 ea. $1.40 $4.20 Digi-Key LM340T-15-NDResistor 270k NA 6 ea. $0.36 $2.16 Digi-Key P270kWCT-NDResistor 100k NA 4 ea. $0.36 $1.44 Digi-Key P100KWDKR-NDSchottky Diode NA 16 ea. $0.40 $6.40 Digi-Key 1N5819HW-FDICTCapacitor 1uF NA 6 ea. $0.37 $2.22 Digi-Key PCE3912CT-NDCapacitor 0.22uF NA 4 ea. $0.36 $1.44 Digi-Key PCE3078CT-ND4Potentiometer NA 3 ea. $0.52 $1.56 Digi-Key MCP4013T-502E/CHCT-NDPCB NA 2 ea. $65.00 $130.00 PCB Express Unknown
Receiver Rotor DP 1 inch $1.60 $1.60 McMaster Carr 8745K63M4 Insert, SS DP 10 ea. $1.30 $13.00 Yardley Products Corp 4007Q9-9SSNeodymium Magnets DP 6 ea. $1.01 $6.03 Rochester MangetsRing Gear DP 1 ea. $329.00 $329.00 Arrow Gear 10P16R32Pinion Gear DP 1 ea. Arrow Gear 10P32L16Main Bearing DP 1 ea. $19.60 $19.60 McMaster Carr 2337K561M4 Bolts 8mm DP 10 ea. $2.81 $2.81 McMaster Carr 92855A408Motor Collar DP 1 ea. $3.60 $3.60 McMaster Carr 8992K881Pinion Bearing DP 1 ea. $6.79 $6.79 McMaster Carr 7804K124Motor Clips DP 4 inch $3.35 $3.35 McMaster Carr 9083K361Epoxy DP 5 oz Epotek OG116-31Overmold DP 5 oz Epotek 337
Armature Neodymium Magnets NG 6 ea. $1.01 $6.03 Rochester Mangets UnknownPVC Magnet Housing DP 1 inch $1.60 $1.60 McMaster Carr 8745K63
Power Supply Bridge rectifier NG 1 ea. $0.92 $0.92 Digi-Key SBR05M60BLPDICT-NDCapacitors NTE Electronics NG 5 ea. $1.36 $6.80 Pic Center NEV4700M25IIDRV8312 NG 1 ea. $55.00 $55.00 texas instruments DRV8312DDWRParallax BASIC Stamp 2 Module NG 1 ea. $47.25 $47.25 DIYbin PLX-BS2-ICtransformer NG 1 ea. $10.00 $10.00 Digi-Key 595-1178-NDLM7812 NG 1 ea. $0.69 $0.69 Digi-Key LM7812ACT-ND
Purchasing
Schedule for MSD II