dhara amin, michael brennan, eric diblasi, andrew smith team litecure
TRANSCRIPT
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Dhara Amin, Michael Brennan, Eric DiBlasi, Andrew Smith
Team LiteCure
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• LiteCure: Manufacturing company for medical devices involving advanced laser technology for the health care and veterinary industries.
• Products: Deep tissue therapy units that use laser technology to accelerate the body’s natural healing process.
• Products are typically housed on a cart to allow the device to be transported from one patient to another in clinical settings
Background
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Motivation
Current LiteCure Cart
LiteCure is in need of a custom cart design that solves several problems surrounding their current cart design.
Issues:• Poor fiber optic and power cord
management• Lack of accessory storage and securing of
those accessories• Aesthetic image of the cart• Ease of use and functionality
improvements
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Project ScopeTo design an aesthetically pleasing utility cart for LiteCure’s deep tissue therapy unit that coincides with their desired image and allows users to easily access and store all components of the unit in a clinical setting.
Deliverables For Sponsor
• Full Drawing Package of Final Concept• Manufacturing Details• Assembly Details• Prototype
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Product Line
15 Watts 9 watts
12 watts 10 watts
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Hand Piece and Fiber Optic Cord
Hand Piece Fiber Optic Cable:• 3 meter length• Minimum bend radius of 3 inches
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Product Accessories
Patient Glasses Operator Glasses Laser Head Attachments
“Doggles” (Veterinary Use) UPS System Foot Pedal (10 Watt Unit)
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Benchmarking
Cutting Edge K-Laser
Anthro CartUD PT Clinic
Anthro CartVet Hospital
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1. Compatible with product line2. Aesthetically pleasing3. Low cost4. Easy to use5. Safe
Design Requirements
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Product Compatibility Need/Want Metric Test Target Value
Support Weight of Laser Unit and all Accessories
Weight Capacity (lbs)
Failure Testing: Statics Calculation
>= 50 lbs
Accommodate each unit of product line
Platform dimensions (in)
Platform can accommodate largest unit (16.25 x 10.5 in)
>=16.25 x 10.5 in
Storage space for all accessories: (Safety Glasses, Head Attachments, Foot Pedal, UPS)
- Is there storage for all required accessories?
Y
Stores Fiber Optic Cable - Is there storage for Fiber Optic Cable?
Y
No blockage of Vents - Are all vents open to air flow?
Y
Height Inches Measurement 30 inches
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Aesthetically PleasingNeed/Want Metric Test Target Value
Company Image - Survey Customer Review
Geometry - Survey Customer Review
Futuristic - Survey Customer Review
Material Selection - Survey Customer Review
Surface Finish - Survey Customer Review
Casters - Survey Customer Review
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Low CostNeed/Want Metric Test Target Value
Manufacturing Price Per Cart
Machining/Forming/Material Cost ($)
Quotes/cost calculations
$500-$700
Packaging Shipping Weight (lbs) Shipping Volume (in^3)
Packaging weight and volume calculations
35 to 50 lbs
< 3 ft^3
Number of Tools Required For Assembly
Number of Tools (#) How many tools are required?
1
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Easy to UseNeed/Want Metric Test Target Value
Quick and Easy Removal and Replacement of Fiber Optic cable
# of wraps, wrapping radius (in), time to wrap (s)
Time Test, Survey 5 wraps, >=3” wrapping radius, <30 seconds, Customer Review
Easily roll and transition over different floor mediums
Pulling Force (static and dynamic) (N)
Rolling Test Passes Test (exceeds or meets current cart results)
Accessory Placement Time to remove and store accessories (s)
Time Test, Survey ~ 30 seconds, Customer Review
Cable Management: Fiber Optic, Power, UPS, Foot Pedal
# of hanging cords, time to wrap (s)
Time Test, Survey 0, <30 seconds, Customer Review
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Easy to UseNeed/Want Metric Test Target Value
Easy to Clean - Can cart be cleaned with bleach, cleaning spray, or wipe?
Y
Easy to Assemble Time to assemble (mins)
- 5-15minutes
Ergonomics: Shelving - Survey: Are the shelves easily accessible and/or adjustable?
Customer Review
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SafetyNeed/Want Metric Test Target Value
Stability Tipping Angle (Degree)
Tipping Test: At what angle does fully loaded cart tip?
10 degrees
Avoid Sharp Edges/Corners Number of Sharp Edges (#)
- 0
Locking Wheels Number of Locking Wheels (#)
Count number of locking wheels
Minimum of 2
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Preliminary Designs
Sponsor Feedback
Final Design
Final Prototype
Testing
Design Details
Mockup
Our Process
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Basic Component Design• Platform:
– Where the units sit• Structure:
– Body of the cart• Base:
– Bottom of the cart: Where UPS sits• Caster Selection:
– Caster size, type, and vendor• Accessory Design:
– Compartments for: Fiber Optic Cable, Safety Glasses, Foot pedal, Head attachments
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Structure Design
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Structure Design
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Platform Design
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Base Design
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Caster SelectionStructure and Wheel Material
Single Wheel Caster
Twin Wheel Caster
Thermoplastic Polyurethane Polyolefin
Thermoplastic Elastomer
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Caster SelectionFastening Type:
Top Plate Threaded Stem Grip Ring Stem
Other Considerations:• Wheel Diameter: 3 or 4 inches• Locking Wheels: yes or no• Swivel: yes or no• Load Capacity: at least 50 lbs• Warranty: at least 2 years
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Manufacturing Research• Anthro:
• Materials used for shelving• Capabilities of a wood laminate design • Cart structure material• Minimal welds in design
• Extreme Machining:• Press breaking capabilities• Tube bending practices• Water and laser cutting capabilities
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2nd Iteration Design
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3rd Iteration Design
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• Chose C-shaped structure• Added a locker• Incorporated the feel and lines of the LiteCure devices• Material: Carbon steel sheet metal
4th Iteration Design
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Mockup• Material: Wood• Casters: 4-inch and 3-inch• Standard hardware• Mockup used for the following
purposes:• Perform tipping and rolling test • Evaluate casters• Perform field test (in PT clinics)
Results:• Increase length and decrease width of
platform• Front door design
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Customer Review• Design: UD PT Clinic and LiteCure office used mock-up for three
days and took survey. • Customer review measures:
Ease of Use Aesthetics
• Easy accessory placement• Easy shelf accessibility• Adequate storage• Easy to transport• Adequate cord
management• Quick/Easy Wrapping and
Removal of Fiber Optic Cable
• Cord Management
• Adequately display company logo
• Futuristic feel• Appropriate Geometry• Appropriate material
selection (sheet metal)• 4-inch casters preferred
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Customer ReviewResults:• Aesthetically appealing• Functional • Satisfactory cord and fiber
optic cable management
Survey Scale: 1 –Strongly Disagree , 2 –Disagree, 3 –Neither Disagree nor Agree, 4 –Agree, 5 –Strongly Agree
Customer Review results for the questions asked about cord and fiber optic cable management. The mean values for the question are
represented with correlating standard deviations.
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Mechanical Testing: Tipping
Worst Case 4 – inch Casters 3 – inch Casters Current LiteCure CartSideways Tipping Angle
11 degrees 15 degrees 15 degrees
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Stress Analysis
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Final Design
• Material: 14 Gauge & 16 Gauge Carbon Steel
• Casters: 4 inch diameter• Fasteners: PEM fasteners• Features: Back locker, front door• Storage space: 1.9 ft^3• Height: 30 inches• Weight: 65 pounds
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Final Design: Aesthetics
• C – Shaped cart with curves and lines similar to LiteCure devices
• Color scheme can be used for both product lines
• Space for logo• Finish: Powder coated paints• Larger 4 inch casters
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Final Design: Platform
• One size platform for multiple devices
• Refined dimensions• Perimeter around device • Hole for cord management
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Final Design: Structure
• Wide base for stability• PEM fasteners attach all parts • Flanges on shelves add strength• Converged to aesthetic design
based on sponsor feedback
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Final Design: Additional FeaturesFront Door: • Easy access to goggles and head
attachments• Goggles stored in mesh bag on front
door• Speed controlled hinge
Back locker• Easy access to all shelves• UPS and miscellaneous storage space• Rotating latch
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Final Design: Additional Features
Fiber Optic Management• Hook design• Quickly drape cord over hook• Secure hand piece on device
Power Cord Management• Hole in top platform• Hole in back locker door• Internal guide for cords
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Cost AnalysisQuote of 1 Cart (machine shop)
• $1460 • Does not include: PEM Fasteners, McMaster Hardware, Casters, Front
Handle, and Fiber Optic Cable Management Hook.
Quote for 1000 number of units (machine shop)• $200 - $225 a unit
Hardware Cost: About $31 a unit
PEM Fastener Cost: About $30 a unit
Casters Cost: About $34 a unit
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User InstructionsAssembly• PEM fasteners press fit in to side
panels• Detailed instructions for assembly• Only 1 tool needed: Wrench
Packaging• Cart can be broken down in to
smaller, flat parts• Box dimensions: 27.5 in x 27.75 in
x 6 in
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Design Validation
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Path Forward• Give LiteCure drawing package and assembly instructions. • LiteCure can take design to manufacturing company for start of mass production. • Small changes may need to be made to the design in order to be manufactured by
a specific company.• More testing to sheet metal prototype: accelerated wear and overload testing