eps - project - Universitat Politècnica de Catalunya (UPC)

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EPS - PROJECT
TITLE: PAEDIATRIC AND NEONATAL LUNG SIMULATOR
STUDENTS:
ZULKIFLY ABDULLAH
ANNA BASIURAS
ALEXANDRA DUMAN
LAURA VISCARRI GARCIA
SUPERVISORS: MARTA DÍAZ (EPSEVG)
JOSÉ MATAS (EPSEVG)
PEDRO BROTONS (SANT JOAN DE DÉU HOSPITAL)
DATE: 9th of June, 2014
EPS/IDPS 2014
PAEDIATRIC AND NEONATAL LUNG SIMULATOR
TITLE: PAEDIATRIC AND NEONATAL LUNG SIMULATOR
FAMILY NAME: Abdullah
FIRST NAME: Zulkifly
HOME UNIVERSITY: EPSEVG
SPECIALITY: Mechanical Engineering
FAMILY NAME: Basiuras
FIRST NAME: Anna
HOME UNIVERSITY: Lodz University of Technology
SPECIALITY: Biomedical Engineering
FAMILY NAME: Duman
FIRST NAME: Alexandra
HOME UNIVERSITY: Polytechnic University of Bucharest
SPECIALITY: Industrial Design Engineering
FAMILY NAME: Viscarri Garcia
FIRST NAME: Laura
HOME UNIVERSITY: EPSEVG
SPECIALITY: Industrial Design and Product Development Engineering
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PREFACE
The report in front of you has been written for the Lung Simulator (LS) project, carried out
within the 2014 European Project Semester (EPS). The goal of this report is to give to all
interested parties an overview of the proposed solution and how it has been developed after
one semester (between February and June 2014).
The project has been supplied by the ’Children’s Hospital Sant Joan de Déu’, represented by
Pedro Brotons, and university ’Universitat Politècnica de Catalunya (UPC)’, represented by
Marta Díaz. This year was the first year of cooperation with the hospital within EPS
programme. The project team consisted of Anna Basiuras, Alexandra Duman, Zulkifly Abdullah
and Laura Viscarri.
We would like to thank all who had a positive contribution making this project and the final
report possible. Our special thanks go out to our supervisor and two other professors at the
UPC: to Marta Díaz who has offered her unique vision and guidance throughout the entire
semester, to José Matas for his endless supply of knowledge and to Cristobal Raya who offered
his assistance and provided us with laboratory equipment during the prototype testing.
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ABSTRACT
The aim of this project was to design a paediatric and neonatal lung simulator that
would cover hospital’s needs, basically offering innovatory ventilation solutions
through a compact, simple and low-cost product used for educational purposes.
The proposed solution is able to represent various clinical scenarios via four
adjustable features that have the possibility to be remotely controlled: air leakage,
air resistance, bag compliance and spontaneous breathing generation which till
now was only available in the most expensive and heavy lung simulators
The spontaneous breathing generation represents the parameter shown through
the prototype, which is made up out of a rigid structure obtained from the 3D
Printer, an improvised bellow, a polyurethane foam case and a cylinder supplied by
a professor. The testing was possible in a laboratory of the university because an air
source and a proportional valve were needed.
In hopes of a continuation of the project and manufacturing, recommendations for
future students and next steps are enclosed in the final part of the report.
Key words: lung simulator, mechanical ventilation, paediatric and neonatal patients,
spontaneous breathing generation
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INDEX
PREFACE ........................................................................................................................................ 2
ABSTRACT ...................................................................................................................................... 3
1.
2.
INTRODUCTION ..................................................................................................................... 8
1.1.
ABOUT THE COMPANY .................................................................................................. 8
1.2.
PROBLEM STATEMENT AND BRIEF ................................................................................ 8
1.3.
PROJECT GOAL AND OBJECTIVES .................................................................................. 9
1.4.
CONDITIONS AND CONSTRAINTS .................................................................................. 9
RESEARCH: STATE OF THE ART ............................................................................................ 10
2.1.
2.1.1.
TYPES OF SIMULATION IN MEDICINE .................................................................. 10
2.1.2.
EFFECTIVENESS OF SIMULATION IN LEARNING .................................................. 13
2.2.
3.
SIMULATION IN MEDICAL STUDIES AND RESEARCH ................................................... 10
PAEDIATRIC LUNG SIMULATOR ................................................................................... 16
2.2.1.
INTRODUCTION TO HUMAN RESPIRATORY SYSTEM........................................... 16
2.2.2.
LUNG SIMULATOR ............................................................................................... 32
REQUIREMENTS ANALYSIS .................................................................................................. 49
3.1.
CONTEXT OF USE ......................................................................................................... 49
3.1.1.
USERS’ PROFILE ................................................................................................... 49
3.1.2.
TASKS ................................................................................................................... 50
3.1.3.
ENVIRONMENT AND SOCIAL CONTEXT ............................................................... 51
3.2.
STAKEHOLDERS’ SPECIFICATIONS ............................................................................... 55
3.2.1.
3.3.
4.
HOSPITAL’S CURRENT DEVICES ........................................................................... 56
REQUIREMENTS DETERMINATION .............................................................................. 60
DESIGN PROCESS ................................................................................................................. 63
4.1.
IDEATION OF THE CONCEPT ........................................................................................ 63
4.1.1.
MIND MAP........................................................................................................... 63
4.1.2.
SKETCHING .......................................................................................................... 64
4.1.3.
PRODUCT CONCEPT............................................................................................. 65
4.2.
THE BAG ...................................................................................................................... 67
4.2.1.
CONCEPTS DESIGN .............................................................................................. 67
4.2.2.
CALCULATIONS AND RESULTS ............................................................................. 69
4.3.
SPONTANEOUS BREATHING CONTROL SYSTEM ......................................................... 71
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4.3.1.
CONCEPTS DESIGN .............................................................................................. 71
4.3.2.
4.3.3.
MECHANISM TO CONTROL THE SPONTANEOUS BREATHING ............................ 74
4.4.
COMPLIANCE CONTROL SYSTEM ................................................................................ 79
4.4.1.
CONCEPTS DESIGN .............................................................................................. 79
4.4.2.
4.4.3.
MECHANISM TO ADJUST THE COMPLIANCE ....................................................... 82
4.5.
RESISTANCE CONTROL SYSTEM................................................................................... 83
4.5.1.
CONCEPTS DESIGN .............................................................................................. 84
4.5.2.
4.5.3.
MECHANISM TO CONTROL THE RESISTANCE ...................................................... 87
4.6.
5.
LEAKS CONTROL SYSTEM ............................................................................................ 91
4.6.1.
CONCEPTS DESIGN .............................................................................................. 91
4.6.2.
4.6.3.
MECHANISM TO CONTROL THE LEAKS................................................................ 92
4.7.
CASE AND PRODUCT APPEARANCE ............................................................................. 96
4.8.
THE REMOTE CONTROL ............................................................................................. 101
4.8.1.
SELECTION OF THE SYSTEM............................................................................... 101
4.8.2.
INTERFACE DESIGN ............................................................................................ 103
MATERIALS AND MANUFACTURING PROCESS .................................................................. 105
5.1.
BAG ............................................................................................................................ 105
5.1.1.
REASONS FOR CHOOSING THE MATERIAL ........................................................ 105
5.1.2.
PROPERTIES ....................................................................................................... 107
5.1.3.
MANUFACTURING PROCESS ............................................................................. 108
5.2.
RIGID STRUCTURE ..................................................................................................... 109
5.2.1.
5.2.2.
PROPERTIES ....................................................................................................... 109
5.2.3.
5.2.4.
SIMULATION ANALYSIS OF RESISTANCE............................................................ 111
5.3.
TUBE .......................................................................................................................... 115
5.3.1.
5.3.2.
PROPERTIES ....................................................................................................... 115
5.3.3.
5.4.
ELEMENT TO CONTROL LEAKS .................................................................................. 117
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5.4.1.
5.4.2.
PROPERTIES ....................................................................................................... 117
5.4.3.
5.5.
5.5.2.
PROPERTIES ....................................................................................................... 119
5.5.3.
REASONS FOR CHOOSING THE MATERIALS ...................................................... 121
5.6.2.
PROPERTIES ....................................................................................................... 121
5.6.3.
CASE........................................................................................................................... 124
5.7.1.
5.7.2.
PROPERTIES ....................................................................................................... 124
5.7.3.
5.8.
CAP ............................................................................................................................ 126
5.8.1.
5.8.2.
PROPERTIES ....................................................................................................... 126
5.8.3.
PROTOTYPE TESTING ......................................................................................................... 128
6.1.
COMPONENTS OF THE PROTOTYPE .......................................................................... 128
6.2.
FUNCTIONING OF THE SYSTEM ................................................................................. 130
PRODUCT DEVELOPEMENT ............................................................................................... 132
7.1.
MARKETING MIX ....................................................................................................... 132
7.1.1.
PRODUCT ........................................................................................................... 133
7.1.2.
PLACE................................................................................................................. 134
7.1.3.
PRICE ................................................................................................................. 134
7.1.4.
PROMOTION ...................................................................................................... 135
7.2.
8.
ELEMENT TO CONTROL COMPLIANCE ...................................................................... 121
5.6.1.
5.7.
7.
ELEMENT TO CONTROL RESISTANCE......................................................................... 119
5.5.1.
5.6.
6.
COST STRUCTURE ...................................................................................................... 135
7.2.1.
COST EQUATIONS .............................................................................................. 135
7.2.2.
COST CALCULATIONS......................................................................................... 137
7.3.
COMPARISON BETWEEN EXISTING LUNG SIMULATORS ........................................... 139
7.4.
SWOT ANALYSIS ........................................................................................................ 140
CONCLUSIONS ................................................................................................................... 141
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9.
BIBLIOGRAPHY................................................................................................................... 143
9.1.
WEBSITES................................................................................................................... 143
9.2.
LITERATURE ............................................................................................................... 145
9.3.
TABLES AND FIGURES ................................................................................................ 146
9.3.1.
TABLES ............................................................................................................... 146
9.3.2.
FIGURES ............................................................................................................. 146
10.
TABLE OF FIGURES......................................................................................................... 148
11.
TABLE OF TABLES.......................................................................................................... 151
12.
APPENDIX ..................................................................................................................... 152
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1. INTRODUCTION
Simulation in medicine as a way of teaching the future professionals is one of the most
effective ways for students to acquire both theoretical and practical knowledge. This project is
focused on simulating, in medical education, the scenario of a paediatric or neonatal patient
that needs to be assisted by mechanical ventilation. The aim of including simulation classes for
the students is to allow them to learn how they must interpret the graphs and signals emitted
by the ventilator to which the patient is connected. To ensure that the simulated scenario is as
close as possible to the real one, there is the need of designing a lung simulator that behaves
as the real ones, representing standard clinical situations.
1.1.
ABOUT THE COMPANY
Children’s Hospital Sant Joan de Déu is the institution that has required the design of a new
paediatric lung simulator. It is one of the leading medical centres in Europe for childhood and
adolescence and offers a comprehensive and multidisciplinary approach to health care from
birth through 21 years of age. The paediatric centre of the University of Barcelona is
associated with the Clinic Hospital being the hospital alliance most well-known in Spain and
one of the international references for highly specialized hospital care, teaching and research.
Currently is attending annually more than 25,000 inpatient admissions, 200,000 outpatient
visits and 115,000 emergencies. The hospital performs each year more than 14,000 surgical
procedures and is attending around 4,000 births.
The institution promotes innovation among professionals and gives them support so that they
can carry out their ideas, patent them and make the prototype. At the moment the hospital
has developed twelve patents that have generated two spin-offs.
1.2.
PROBLEM STATEMENT AND BRIEF
Current accurate lung simulators in the market are too expensive and sophisticated to be
incorporated in a simulation room for educational needs, and the simplest ones are not
reliable enough to teach different clinical situations of the patients. Demanding to have a
complete lung simulator, Sant Joan de Dèu Hospital has facilitated a briefing for the project
with the main features that the designed lung simulator must accomplish to cover their
current needs:
-
Portable device, transportable in a small suitcase.
-
Two lung sizes: Neonatal lungs (25-50 ml) and paediatric lungs (125-250 ml).
-
Ability to generate pre-defined common clinical scenarios with several degrees of
severity of lungs failure: Decrease of compliance, increase of resistance and creation of
leaks.
-
High precision and reliability
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-
1.3.
All features remotely controlled (this requirement was added later after the first
meeting with the hospital supervisors in April)
PROJECT GOAL AND OBJECTIVES
The aim of the project is to design a reliable, cheap and portable neonatal and paediatric lung
simulator, which will be used for educational and research purposes.
The principle objectives that wanted to be achieved in this project are the ones shown below:
-
Represent the main lung capabilities designing the corresponding internal mechanism.
-
Make the product Eco-friendly reducing the impact of its Life-cycle.
-
Deliver a compelling user experience that raises customer approval ratings by 100%
over the previous product release. (UCD principles)
- Increase the knowledge acquired by students through a reliable lung simulator.
1.4.
CONDITIONS AND CONSTRAINTS
The conditions for this project include the coordination between the members of the team and
supervisors from the hospital and the university and an agreement with Sant Joan de Déu
Hospital about our scope of the project.
For the development of this project the constraint of time has to be considered, due to the
fact of it being a project that must be done in 14 weeks and the constraint of the team’s
background, taking into consideration that in some parts external collaboration was necessary.
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2. RESEARCH: STATE OF THE ART
2.1.
SIMULATION IN MEDICAL STUDIES AND RESEARCH
Medical simulation is a branch of simulation technology applied in education and training in
different medical fields. Its main purpose is to train medical professionals to reduce accidents
during surgery, prescription, and general practice. Currently, it is used to train students in
anatomy and physiology during their medical courses to become health professionals.
Although it is widely recognized the difficulty to represent through simulation the functioning
of a human organ or function, technological advances have made possible to simulate
practices from yearly family doctor visits to complex operations such as heart surgery.
A thorough amount of studies have shown that students engaged in medical simulation
training have overall higher scores and retention rates than those trained through traditional
means. The main purpose of medical simulation is to properly educate students in various
fields through the use of high technology simulators.
2.1.1. TYPES OF SIMULATION IN MEDICINE
Medical simulation includes three ways of training depending on the devices used to develop
the session: human simulation, mechanical simulation and virtual simulation.
HUMAN SIMULATION
It uses a trained role-player to act the part of a patient with a specific medical condition. The
role-players are often professional actors, sometimes working under equity contract.
Human surrogates are well-versed in the symptoms and behavioural effects of patients
suffering from a variety of health problems, from coronary and respiratory diseases to stressrelated conditions and depression.
In general, they have read the histories of real
patients with the conditions they are simulating,
and they memorize scripts written to reflect the
complaints and symptoms.
They are also trained to evaluate the student’s
performance and to provide instruction that will
enhance the learning experience. Due to ethical
constraints, a major limitation of human surrogacy
is the inability for students to perform invasive
procedures and other therapeutic interventions
that could be harmful to the role-player.
Figure 1. Example of Human simulation
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MECHANICAL SIMULATION
It allows students to use mock (i.e., artificial) parts adequately mimicking the experience that
would be gained from interacting with a real patient’s body, organs, or tissues.
The classic mechanical simulator is probably Resusci Anne, an instructional mannequin used
successfully for many years to train students in airway management, assessment of vital signs,
other lifesaving procedures, and related skills for working in teams.
The anatomical mock-ups are made from synthetic materials. Due to advances in materials
science, the full- and partial-body mannequins have become remarkably realistic in
appearance.
Concurrent advances in engineering, miniaturization, and computer controls have also
produced impressive improvements in the numbers and types clinical scenarios that can be
replicated by mechanical simulators.
Figure 2. Resusci Anne mannequin
VIRTUAL SIMULATION
It employs the latest advances in computer technology and visual interfaces to create
acceptably realistic learning experiences. Medical applications of virtual simulation commonly
employ the tools and techniques of popular video game platforms, such as Sony Play Station
and Microsoft Xbox.
At the most basic level, students in the health professions can use keyboard commands or joy
sticks to interact with images of problems that would be encountered in clinical practice.
SIMULATED VISION: 3D PHOTOREALISM
The sensation of realistic vision in virtual
simulation can be produced in several different
ways.
The most common is a head-mounted display
that presents the wearer with a stereoscopic
display via a separate view for each eye.
Figure 3. Virtual dental implant training simulator
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The second most-common approach to realistic visualization is the use of special lenses to
create a stereoscopic view by merging two offset images in different colours projected on a
flat screen. It is a high-end application of the optical technique used in theatres where viewers
watch a movie through cardboard glasses with special lenses that sort the on-screen images
into the right and left eyes.
Finally, a few medical simulations have been created with direct projection of images on to the
users’ retina or with holographic displays using laser light. Both approaches produce stunning
images, but they are extremely expensive and dependent on equipment that is not widely
available.
SIMULATED TOUCH: HAPTICS
To develop many medical skills, students need to be able to feel what they are doing as well as
to see it. Knowing how much pressure to apply when inserting a needle or how hard to push a
catheter into a body opening can make the difference between success and failure when a
procedure is performed for the first time on a real patient. Therefore, successful medical
simulation must accurately convey two types of physical sensation:


Proprioception is the response felt within
the student’s body when applying a force. It
is, for example, the sensation of resistance
felt when pressing a scalpel against tissue or
the muscular tension experienced when
holding a heavy instrument in one hand.
Tactility is the body’s response to touch.
Tactile sensations are feelings like the
relative texture of skin (e.g., smooth to
rough, dry to moist), the elevated forehead
temperature of a patient with a fever, or
the surface distortion caused by a subdural Figure 4. NeuroTouch is the world’s most
advanced virtual reality neurosurgical simulator
mass.
Medical simulation must be able to give the learner a sense of force and touch consistent with
the experience that will be encountered in treatment of a real patient. It must also convey
these sensations in realistic sequence and alignment with procedures being performed.
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2.1.2. EFFECTIVENESS OF SIMULATION IN LEARNING
HOW TO MEASURE THE EFFECTIVENESS OF SIMULATION
The application of medical simulation should provide meaningful assessment of the students’
learning and the ability to reproduce the knowledge acquired in the lessons to the care of real
patients. Therefore, simulation training must be done pointing the same goals as in traditional
lessons. It is essential to identify measurable learning objectives to select the optimal teaching
methodologies and appropriate approaches to assess the students.
Although simulation lessons are more costly than traditional ones, it offers some instructional
advantages that can justify any extra expense under the right circumstances:
-
Standardized teaching and evaluation can be assured in medical simulation.
-
Variations in instructors’ teaching abilities and grading practices are not a problem
because an identical system can be used for all students in all settings.
-
To varying degrees, all three forms of medical simulation can be structured to respond
constructively to different errors that students are likely to make. Corrective tutorials
related to a student’s thought processes and actions can be embedded very effectively
in virtual simulations.
-
Mechanical and virtual systems can also evaluate students’ responses to hazardous
conditions that would not be allowed in learning environments where humans were
present, for instance: dealing with an accidental release of mercury, responding to the
explosion of a medical gas.
To ensure the effectiveness of simulation it is needed to take into account human factors that
influence the interaction between the user and the simulation device:
-
All the required equipment for the simulation must be user-friendly so that an
instructionally valid learning experience is not diminished by a dysfunctional manmachine interface, such as malfunctioning equipment or ergonomically harmful
positioning to use devices.
-
The technology should adapt to variations in users’ knowledge, skills, and approaches
to learning rather than requiring the users to adapt to the technology.
-
Portability, versatility, ease of use, and other non-economic factors must also be
considered.
Research and evaluation of simulation as a teaching tool are beginning to mature in the health
professions. Leaders in the field are creating a body of refereed journal articles to validate or
invalidate medical simulation as an educationally effective and economically efficient
alternative to traditional instruction.
Many presentations at recent conferences on medical simulation have included comparisons
of the new approach with traditional methods of instruction.
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ADVANTAGES OF SIMULATION
The use of simulations in medical education involves important advantages from an
educational point of view, and converts simulation based on the ideal tool to overcome new
challenges in medical education.
It has been shown that the use of simulations shortens the time needed for learning skills,
especially because it enables the students training as many times as necessary to acquire the
skills trained.
Based training simulation allows the students to make mistakes without real impact. The
trainee is able to face challenging situations in a safe environment where errors are allowed
and learn from them without harming the patient. Indeed, mistakes are learning experiences
and offer great opportunities to improve through learning from them and from other students’
errors.
This way of teaching allows the learning of practical experience in different types of
environments, from the simplest and common ones to the most complex and unusual.
The simulations based teaching allows the student to receive feedback in real-time from the
teachers and peers and reflect on the action allowing a formative assessment type.
Recent studies have supported the efficacy of screen-based and realistic simulators in
enhancing technical, behavioural, and social skills in medicine. Identified learning outcomes
involving simulation include:

Improving Communication
Simulations help students learn communication techniques due to the perception of student
that their communication improved and simulations increased their confidence in
communication.

Understanding Classroom Material
Skills are part of the material taught in the classroom. Students improve their understanding of
the course material as a result of participating in clinical simulation scenarios. This is a benefit
of incorporating simulation into nursing and medical programs because when students
understand classroom material, they have the opportunity to synthesize knowledge from
other sources.

Developing Critical Thinking
Synthesizing knowledge is one of the steps of critical thinking. Simulation is one of the best
ways to help students develop critical thinking taking into account that during simulation
classes, students are allowed to think spontaneously and actively in comparison with
numerous theoretical lectures that are more passive. Simulation let the students to make
decisions independently and take risks. This process helps them gain the critical thinking skills
needed in their profession.
On the other hand, students have the opportunity to apply theoretical knowledge in a safe and
realistic setting during simulations in order to develop a systematic approach to solving
problems.
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
Facilitating Teamwork
Problem solving can effectively be done in teams. Collaborating with team members is also a
characteristic of medical experts. Within the team, nursing and medical students have the
opportunity to assume leadership roles during simulation, which is important to facilitate
teamwork, as empirical evidence shows that individual performance does not provide
optimum safety. Nursing students learn teamwork during simulations by functioning as a
single, disciplined team. Multidisciplinary healthcare teams can also benefit from simulation
experiences.
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2.2.
PAEDIATRIC LUNG SIMULATOR
2.2.1. INTRODUCTION TO HUMAN RESPIRATORY SYSTEM
Before moving on to neonatal and paediatric lung description, the basic introduction to
general aspects of respiratory system is necessary. The information presented in this chapter is
mostly based on articles from websites of University of Nevada, Stanford School of Medicine
and Paediatric Health Library of University of Minnesota Amplatz Children's Hospital.
Human body contains a pair of lungs with one lung on both left and right side of the chest. The
lungs are soft, made up of sections called lobes and protected by the ribcage. The left lung is
composed of upper and lower lobe, as well as the lingula which is a small remnant next to the
apex of the heart. The right lung has three lobes: upper, middle and lower.
Figure 5. Human respiratory system: general view
Figure 6. Human respiratory system: lungs
The primary function of the respiratory system is supplying oxygen to the bloodstream and
expelling waste gases, mostly carbon dioxide, from the body. The system is responsible for
gaseous exchange between circulatory system and the outside world. Air is taken in via the
upper airways (the nasal cavity, pharynx and larynx) through the lower airways (trachea,
primary bronchi and bronchial tree) and into the small bronchioles and alveoli within the lung
tissue.
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BREATHING PROCESS
Breathing in is called inspiration; it is a process when air fills the airways in the lungs. Oxygenrich air reaches the balloon-like air sacs – alveoli – at the end of the airways. Oxygen passes
into the blood vessels surrounding the sacs. The blood then carries the oxygen to all parts of
the body. As the body uses oxygen, it produces carbon dioxide, a waste gas, which the blood
carries back to the lungs. While breathing out, carbon dioxide leaves the body through the
airways, windpipe, and mouth or nose. Breathing out is called expiration.
During inhalation and exhalation, the action of breathing in and out is caused by changes of
pressure within the thorax, as compared with the outside environment.
When a person inhales the intercostal muscles and diaphragm contract in order to expand the
chest cavity. The diaphragm flattens and moves downwards and the intercostal muscles move
the rib cage upwards and out. This increase in size reduces the internal air pressure so air from
the outside (now with higher pressure than inside of thorax) rushes into the lungs to equalize
the pressure.
When we exhale, the diaphragm and intercostal muscles relax and return to their resting
positions. This reduces the size of the thoracic cavity, thereby increasing the pressure and
forcing air out of the lungs.
Figure 7. Inhaling and exhaling process
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RESPIRATORY TRACT
Air containing oxygen enters the body through the nose and mouth. From there it passes
through the pharynx or throat on its way to the trachea (windpipe). The trachea divides into
two main airways called bronchi upon reaching the lungs; one bronchus serves the right lung
and the other serves the left. The bronchi subdivide several times into smaller bronchi, which
then divide into smaller branches called bronchioles.
Figure 8. Human respiratory system: bronchi
These bronchi and bronchioles are called the bronchial tree because the subdividing that
occurs is similar to the branching of an inverted tree. After about 23 divisions, the bronchioles
end at alveolar ducts. At the end of each alveolar duct, there are clusters of alveoli (air sacs).
Finally, the oxygen transported through the respiratory system is transferred to the
bloodstream at the alveoli.
The trachea, main bronchi, and approximately the first dozen divisions of smaller bronchi have
either rings or patches of cartilage in their walls in order to keep them from collapsing or
blocking the flow of air. The remaining bronchioles and the alveoli do not have cartilage and
are very elastic which allows them to respond to pressure changes as the lungs expand and
contract.
Bronchi and bronchioles are accompanied by blood vessels from the pulmonary arterial
system. These blood vessels also branch into smaller and smaller units ending with capillaries,
which are in direct contact with each alveolus. Gas exchange occurs through this alveolarcapillary membrane with oxygen moving into and carbon dioxide moving out of the
bloodstream.
Diffusing capacity measures the ease with which gas exchange takes place between the alveoli
and capillaries. Certain lung diseases affecting the alveoli and capillary walls can interfere with
diffusion and reduce the amount of oxygen reaching the bloodstream.
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2.2.1.1. Anatomy and physiology of children respiratory system
There are several changes in anatomy and physiology of the children respiratory system when
compared with the adult respiratory system. They will be explained in this chapter together
with their consequences.
A child’s respiratory system is similar to an adult’s one. However, some structures differ in size
or position. For example, an infant’s tongue takes up more space in the mouth and an infant’s
larynx is located in a higher position in the neck than it is in an adult.
Below is a list of anatomy parts with their functions:














The mouth and nose are the openings through which air enters and exits the body.
Sinuses are air-filled chambers within the bones of the face. They help keep the nose
moist and free of dust and bacteria.
The pharynx is the cavity behind the mouth.
The larynx is the upper part of the windpipe, which contains the vocal cords.
The windpipe (trachea) provides a pathway for air to enter and exit the lungs.
Epiglottis is a flap that covers the trachea during swallowing in order to prevent food
from entering the lungs.
The lungs are a pair of organs made of spongy tissue. They have five sections, or
“lobes,” three in the right lung and two in the left. The lungs allow the body to receive
oxygen and get rid of carbon dioxide.
Bronchioles (airways) are stretchy “branches” that transport air throughout the lungs.
Bands of muscles surround each bronchiole. Bronchioles get smaller as they go deeper
into the lungs.
Alveoli are clusters of balloon-like air sacs at the ends of the airways.
Blood vessels are tubes that carry blood to the lungs and throughout the body. Tiny
blood vessels surround the air sacs, allowing an exchange of oxygen and carbon
dioxide.
The pleural space is an area between the lungs and chest wall, lined on both sides by
tissue called pleura.
The diaphragm is a muscle in the abdomen that helps with breathing.
Mucus is a sticky substance made by cells in the lining of the airways. It traps dust,
smoke, and other particles from air breathed in.
Cilia are tiny hairs on the cells of the airway lining. They sweep mucus up the airways
and to the throat. In Cilia mucus gets swallowed or coughed out.
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Figure 10. Alveoli and mucus
Figure 9. Parts of respiratory system of a child
The most important differences between adult and child anatomy are presented in table
below:
Anatomy part
Child
Adult
Tongue
Large
Normal
Epiglottis shape
Floppy, omega-shaped
Firm, flatter
Epiglottis level
Level of C3-C4
Level of C5-C6
Trachea
Smaller, shorter
Wider, longer
Larynx shape
Funnel-shaped
Column-shaped
Narrowest point
Sub-glottic region
At the level of vocal cords
Lung volume
250 ml at birth
6000 ml
Table 1. Anatomy differences for adult and child
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OTHER PHYSIOLOGICAL CONSEQUENCES
When children grow and their spine elongates, the airway enlarges and moves more caudally.
Their airway is poorly developed in terms of cartilaginous integrity which allows more laxity
throughout the airway. As a result of the narrow airway in children, the resistance is
significantly increased according to the formula: R ~ 8l / r4 (where: R = Resistance, l = Airway
length, r = Airway radius). Thus, even small change in the airway radius will increase the
resistance four times and, as a result the work of breathing for an infant, e.g. in case of a small
amount of post-extubation sub-glottic edema.
Due to poor cartilaginous integrity children have more complaint trachea, larynx and bronchi
which may result in increased work of breathing due to dynamic airway compression.
Paediatric patients have more compliant chest walls which is also increasing the work of
breathing since the outward pull of the chest is greater.
Moreover, the respiratory muscles of paediatric patients require a significant amount of
oxygen and metabolite. In particularly stressful situation, the work of breathing may
correspond up to 40% of the cardiac output.
Another issue to consider is Forced Residual Capacity (FRC) which acts basically as a respiratory
reserve. FRC is defined as the residual volume plus the expiratory reserve volume and occurs
when the outward pull of the chest wall equals the inward collapse of the lungs. In general,
children have smaller FRC which may change when paediatric patients begin to develop
respiratory distress.
There are two situations where the reduced FRC is most important. Firstly, if the patient is in
supine position (lying down), the FRC could be smaller, up to 30% in comparison with sitting
patients. The influence on FRC is caused by the fact that the abdominal contents push up on
the diaphragm in a supine patient. There are also a few factors applying specifically for the
paediatric patient which include a compliant chest wall, small thoracic cage and large
abdominal contents. Secondly, the reduced FRC has great impact during pre-oxygenating a
patient prior to intubation. It decreases the amount of time allowed to establish an
endotracheal tube prior to desaturation.
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2.2.1.2. Lung Test Parameters
There are several lung function tests and they are used for the following purposes:


To determine how much air lungs can hold, how quickly the air is moving in and out of
the lungs and how well the lungs put oxygen into and remove carbon dioxide from
bloodstream.
To diagnose lung diseases, measure severity of lung problems and control how well
lung treatment is working.
Less common are gas diffusion tests which measure the amount of oxygen and other gases
that cross the alveoli per minute. These tests evaluate how well gases are being absorbed into
the bloodstream from the lungs.
Most common lung function test is called spirometry. During the test, a patient breathes into a
mouthpiece attached to a recording device (spirometer). The information collected by the
spirometer is usually printed out on a chart called a spirogram.
The most common lung function parameters measured with spirometry are:

Forced Vital Capacity (FVC): The amount of air that can be exhaled with a maximal effort
after a maximal inhalation

Tidal Volume (TV): The volume of air that is inhaled or exhaled with each breath during
quiet, relaxed breathing.

Expiratory Reserve Volume (ERV): The maximal amount of air forcefully exhaled after a
normal inspiration and expiration. The amount of exhaled air should be greater than the
amount inhaled.

Inspiratory Reserve Volume (IRV): The maximal amount of air forcefully inhaled after a
normal inhalation.

Residual Volume (RV): The amount of air remaining in the lungs after the deepest
exhalation possible.

Vital Capacity (VC): The maximum amount of air that can be exhaled after the fullest
inhalation possible. Vital capacity is the sum of the tidal volume, the inspiratory reserve
volume, and the expiratory reserve volume.

Total Lung Capacity (TLC): The sum of the vital capacity and the residual volume.
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2.2.1.3. Malfunctioning and diseases
AIR LEAKS IN THE NEWBORNS
One of the malfunctions of the lungs is air leaks. It takes place when alveoli rupture (break)
which causes air to leak into the space between the lungs and the chest wall. These air
leaks result in problems with breathing and can lead to lung damage. Below the circumstances
due to which the air leaks may occur are listed:







Being on a ventilator (breathing machine) for a breathing problem. The pressure of the
air provided by the ventilator could cause alveoli to rupture.
Meconium aspiration syndrome, a health problem that causes the lungs to become
irritated, damaged, and overinflated (filled with too much air).
Respiratory distress syndrome, a common problem in premature babies that is a result
of immature lung development and causes difficulty in breathing.
Vigorous crying, which causes the alveoli to rupture. Some babies cry hard enough to
do this at birth, or soon after.
Lung problems that require the baby to work harder to breathe.
Congenital problems, such as an underdeveloped lung.
Unknown causes.
There are three main types of air leaks. Their characteristics are presented below.

Pulmonary interstitial emphysema (PIE): Tiny ruptures occur in the alveoli, allowing
air to leak out into the lung tissue. This puts pressure on the surrounding alveoli. Too
many of these tiny leaks can lead to the more severe problems (pneumothorax and
pneumomediastinum) which are described below.

Pneumothorax (collapsed lung): Air gets trapped between the chest wall and the lung.
This trapped air puts pressure on the lung, preventing it from inflating. Thus, the baby
has trouble breathing.

Pneumomediastinum: Air leaks into the chest, into the space between the two lungs.
The trapped air puts pressure on both lungs.
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Figure 12. Air leak treatment
Figure 11. Collapsed lung in infant
The treatment of air leaks in children depends on severity of air leaks. If the baby is not having
breathing problems, treatment probably isn’t needed since a small air leak may heal by itself.
For more severe cases, possible treatments include the following:



A needle or catheter (small, flexible tube) is inserted into the space between the lungs
and the chest wall in order to draw air out. This process helps remove the air that
leaked out, so breathing can return to normal. If a lot of air leaked out, though, further
treatment may be needed.
A chest tube is inserted into the space between the lungs and the chest wall. The chest
tube is attached to a suction device that pulls out the trapped air, so the lungs can
expand once again. This allows the tear to heal. However, it may take a few days for
the tear to heal. The chest tube will stay in during this time.
The baby may need breathing support (such as supplemental oxygen or a ventilator)
until the air leak heals.
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CHILDHOOD ASTHMA
WHAT IS ASTHMA?
D
Asthma is a chronic (long-term) lung condition in which the airways are inflamed and
narrowed, making it harder to breathe normally.
WHAT ARE THE SYMPTOMS OF ASTHMA?
Children with asthma typically suffer from at least two of the following symptoms:




Wheezing (a whistling noise in the chest).
Shortness of breath.
A tight feeling in the chest (children may say their chest or tummy hurts).
Coughing.
Figure 13. Childhood bronchial asthma
Other signs and symptoms of childhood asthma include:





Trouble sleeping caused by shortness of breath, coughing or wheezing.
Bouts of coughing or wheezing that get worse with a respiratory infection, such as a
cold or the flu.
Delayed recovery or bronchitis after a respiratory infection.
Trouble breathing that may limit play or exercise.
Fatigue, which can be caused by poor sleep.
Symptoms normally come and go, often unpredictably. There is a wide variation in the
severity, frequency and duration of symptoms. One child’s experiences can be very different to
another’s.
Many children find their symptoms are worse at night and that they are provoked by particular
irritating substances or circumstances known as ‘triggers’.
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CAUSES
The underlying causes of childhood asthma aren't fully understood. Developing an overly
sensitive immune system generally plays a role. Some factors thought to be involved include:
Figure 14. Evolution of the disease



Inherited traits.
Some types of airway infections at a very young age.
Exposure to environmental factors, such as cigarette smoke or other air pollution.
Increased immune system sensitivity causes the lungs and airways to swell and produce mucus
when exposed to certain triggers. Reaction to a trigger may be delayed, making it more
difficult to identify the trigger. These triggers vary from child to child and can include:





Viral infections such as the common cold.
Exposure to air pollutants, such as tobacco smoke.
Allergies to dust mites, pet dander, pollen or mould.
Physical activity.
Weather changes or cold air.
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EOSINOPHILIC LUNG DISEASES
Eosinophils are a type of white blood cell. High numbers of eosinophils (eosinophilia) are
generally associated with allergies or are a response to being infected by a parasite, known as
an infestation.
It can affect the airways, resulting in asthma or allergic Broncho pulmonary aspergillosis
(ABPA), a complication of sensitisation to a fungus called aspergillus.
Sometimes it affects the alveoli (tiny air sacs) inside the lungs that are involved in the exchange
of oxygen and carbon dioxide as we breathe in and out or even the lung vessels (Churg Strauss
syndrome).
This type of lung disease is rare in children, except when it is caused by parasites. Usually the
diagnosis is made by detecting too many eosinophils in the blood and seeing shadows on a
chest X-ray, which are due to collections of eosinophils in the lungs.
The most common parasites that cause eosinophillic lung diseases are ascaris lumbricolides,
toxocaria canis and filaria. The immature forms of the parasites, called larvae, move through
the lungs. Symptoms include sudden onset or gradually developing symptoms of
breathlessness, wheeze, cough or fever. In cases caused by parasites, the liver, spleen and
lymph nodes – the small, oval glands that form part of the immune system and remove
unwanted bacteria and particles from the body - often also become enlarged.
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OBSTRUCTIVE SLEEP APNOEA
DESCRIPTION OF OSA
Obstructive sleep apnoea (OSA) is the term used to describe the most common breathing
disorder that happens during sleep.
Obstructive = there is obstruction of the airway in the nose, throat or upper airway.
Sleep = it happens when your child is asleep.
Apnoea = this is a Greek word that means ‘without breath’ – there is not enough air going
down into the lungs.
When a person goes to sleep, the muscles relax, including those in the throat. In some
children, especially those with enlarged tonsils or adenoids, the relaxed muscles cause
narrowing, which can reduce the airflow. This can cause snoring and irregular breathing.
If the throat obstructs (closes) completely, a child might temporarily stop breathing. This is
called ‘apnoea’. If the throat partially closes, breathing is reduced. This is called ‘hypopnoea’.
When breathing is interrupted or reduced, there may be a fall in the level of oxygen in the
blood. Sensors in the brain will tell the body to re-start or increase breathing. Breathing often
re-starts with a gasp or snort.
When the problem is severe this can happen many times each night and disturb the quality of
sleep. This causes irritability, poor concentration and sometimes drowsiness the following day.
HOW COMMON IS IT AND WHAT ARE THE RISK FACTORS?
OSA is quite common and may affect up to 1 in 30 children. It affects boys and girls equally.
The following factors increase the likelihood that children will be affected.
Common factors:
 Large tonsils and adenoids.
 Obesity.
 Family history of OSA.
 Down’s syndrome.
 Sickle cell disease.
Rarer factors:
 Craniofacial malformations such as an abnormally small chin, large tongue or cleft
palate.
 An extremely narrow upper airway.
 Rare diseases of the nerves or muscles, which cause loss of upper airway tone because
of poor muscle strength.
 Problems with control of breathing.
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PULMONARY HYPERTENSION
Figure 15. Pulmonary hypertension
PULMONARY HYPERTENSION IN NEW-BORN BABIES
Pulmonary hypertension is when the blood in the arteries of the lungs is at an abnormally high
pressure. It occurs in about 0.2 per cent of live births.
The changes that normally happen to the circulation at birth do not occur and circulation
continues in the same way as before birth. This means that blood flows in the wrong direction
through the new-born baby’s heart. It is a very serious situation and requires early surgical
treatment, because not enough oxygen reaches the baby’s vital organs.
PH in new-born babies is sometimes due to asphyxia (lack of oxygen) during birth, infection,
congenital heart disease or incomplete development of the lungs. When there is no known
cause it is referred to as primary pulmonary hypertension.
PULMONARY HYPERTENSION IN CHILDREN
When PH occurs later in childhood it’s usually a complication of a severe lung problem, such as
cystic fibrosis, lung fibrosis (scarring) or the sleep disorder obstructive sleep apnoea. It can also
cause complications with diseases of the nerves and muscles or congenital heart disease.
It can also happen as a result of an abnormality in the lung arteries themselves, for example
clots in the blood vessels in the lungs or a clot (embolism – pleural emboli) travelling through
the circulation from elsewhere. Occasionally, emboli are not formed from clots of blood, but
are clumps of infected material that have broken off and travelled in the blood from an
abscess somewhere else in the body.
Lung clots may also be due to abnormalities in the blood’s clotting function and very rarely PH
is due to an abnormal overgrowth of tiny vessels (invasive pulmonary capillary
haemangiomatosis).
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RESPIRATORY SYNCYTIAL VIRUS
Respiratory syncytial virus (RSV), which causes infection of the lungs and breathing passages, is
a major cause of respiratory illness in young children.
Infants most at risk from RSV are:





Premature babies in the first few months of their life
Babies born very early who need additional oxygen for more than one month after
birth
Babies with congenital heart disease
Babies with immune problems
Babies with cystic fibrosis
SYMPTOMS
Signs and symptoms of respiratory syncytial virus infection typically appear about four to six
days after exposure to the virus. In adults and older children, RSV usually causes mild cold-like
signs and symptoms.
These include:





Congested or runny nose.
Dry cough.
Low-grade fever.
Sore throat.
Mild headache.
In severe cases:





Figure 16. RSV-Respiratory syncytial virus
High fever.
Severe cough.
Wheezing — a high-pitched noise that's usually heard on breathing out (exhaling).
Rapid breathing or difficulty breathing, which may make the child prefer to sit up
rather than lie down.
Bluish colour of the skin due to lack of oxygen (cyanosis).
Infants are most severely affected by RSV. They may markedly draw in their chest muscles and
the skin between their ribs, indicating that they're having trouble breathing, and their
breathing may be short, shallow and rapid. They may cough. Or they may show few, if any,
signs of a respiratory tract infection, but will eat poorly and be unusually lethargic and irritable.
Most children and adults recover from the illness in one to two weeks. But in young babies,
infants born prematurely, or infants or adults who have chronic heart or lung problems, the
virus may cause a more severe — occasionally life-threatening — infection that requires
hospitalization.
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RESPIRATORY DISTRESS SYNDROME
This affects babies who are born too early (premature) whose tiny, immature lungs are unable
to inflate properly and deliver enough oxygen to the body.
It happens as a result of a combination of factors: being born early and a lack of a substance
called surfactant. This helps the lungs to expand and keeps them inflated, preventing the air
sacs inside the lungs from collapsing. If your baby doesn’t have enough surfactant in their
lungs, air sacs will collapse every time they take a breath, causing their oxygen levels to fall.
Neonatal respiratory distress syndrome is the leading cause of death in babies, accounting for
20 per cent of the deaths in new-borns. The more premature the baby, the more likely it is he
or she will have respiratory distress syndrome. It is twice as common in boys as girls and more
likely to occur:



After Caesarean section.
If there is lack of oxygen before birth.
If the mother is diabetic.
It usually presents immediately after birth. Symptoms include blue skin and very distressed
breathing, characterised by fast, shallow and irregular breaths. The baby’s chest often draws
inwards when they take a breath, which may be accompanied by a grunting sound. Levels of
oxygen in the blood are very low, so treatment is needed urgently and involves administering
carefully controlled oxygen, usually with the help of a ventilator or breathing machine.
Surfactant can be given as a treatment down the breathing tubes.
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2.2.2. LUNG SIMULATOR
2.2.2.1. Description and elements
Mechanical ventilation has revolutionized the treatment of critically ill and post-operative
patients by making it possible to ventilate and oxygenate patients with markedly reduced lung
function. It has facilitated advances in cardiac surgery, improved the survival of premature
infants, and helped the recovery of trauma victims. Technological advances have resulted in
the development of increasingly sophisticated modes of artificial ventilation, permitting the
successful ventilation of very ill patients. Enhanced monitoring modalities have improved the
safety of mechanical ventilation, allowing it to become a frequently used life-sustaining
therapy.
Yet like many rapidly advancing technologies there comes a time when it becomes necessary
to rethink the direction and contemplate the consequences of what is being done. Mechanical
ventilation is undergoing such a re-examination, from both scientific and economic
perspectives. Many principles have been questioned, and the answers have often reversed
what were previously considered basic tenets. This article reviews some of these issues and
examines what has prompted this review process and the changes in practice that have
ensued.
A mechanical lung simulator is described (an extension of a previous mechanical simulator)
which simulates normal breathing and artificial ventilation in patients. The extended
integration of hardware and software offers many new possibilities and advantaged over the
former simulator. The properties of components which simulate elastance and airway
resistance of the lung are defined in software rather than by the mechanical properties of the
components alone. Therefore, a more flexible simulation of non-linear behaviour and the
cross-over effects of lung properties is obtained. Furthermore, the range of lung compliance is
extended to simulate patients with emphysema. The dependency of airway resistance on lung
recoil pressure and trans mural pressure of the airways can also be simulated. The new
approach enables one to incorporate time-related, mechanics such as the influence of lung
viscosity or cardiac oscillation. The different relations defined in the software can be changed
from breath to breath.
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PEDIATRIC AND NEONATAL LUNG SIMULATOR
The main parts of the lung simulator system, including all the devices that can be involved, and the parameters they should be able to show
and control are represented in the next figure:
1.2 DISPLAY
INTERFACE
3 BODY (MANNEQUIN)
1 VENTILATOR
1.1 CONTROL
INTERFACE
2 LUNGS (BAG)
- Flow rate
- Spontaneous breathing
- Pressure
- Resistance of airways
- Real time monitoring of
respiration curves
- Leaks of air
- Compliance (lung elasticity)
- Volume of air
2.1 REMOTE/ MANUAL
CONTROL OF LUNG
PARAMETERS
Main elements
Input and output elements
Communication
Controlled parameters
Figure 17. Elements of a Lung Simulator system
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1.
VENTILATOR
In its simplest form, a modern positive pressure ventilator consists of a
compressible air reservoir or turbine, air and oxygen supplies, a set of valves and tubes, and a
disposable or reusable "patient circuit". The air reservoir is pneumatically compressed several
times a minute to deliver room-air, or in most cases, an air/oxygen mixture to the patient. If a
turbine is used, the turbine pushes air through the ventilator, with a flow valve adjusting
pressure to meet patient-specific parameters. When overpressure is released, the patient will
exhale passively due to the lungs' elasticity, the exhaled air being released usually through a
one-way valve within the patient circuit called the patient manifold. The oxygen content of the
inspired gas can be set from 21 percent (ambient air) to 100 percent (pure oxygen). Pressure
and flow characteristics can be set mechanically or electronically.
Mechanical Ventilator aims to avoid fatigue in patients while keeping the gas exchange vital for
life. Typically, during Mechanical Ventilation, the patient inspiratory effort triggers a ventilator
that pumps a mixture of air (Oxygen + other gases) through the central airways into the lungs
inflating them and increasing the intraalveolar pressure. When the ventilator stops the central
airway pressure decreases and air passively flows from the higher pressure lungs to the lower
pressure central airways.
Triggers that can be used when the ventilator is not automatically are:



1.1.
Pressure trigger- the patient effort reduces the pressure till a certain sensitivity
value that, when surpassed, activates the ventilator.
Flow trigger-the activation of the ventilators take place when the flow, nduced
by the pacient effot, surpass a cutoff value.
Electrical activity of the diaphragm-the ventilator is activated when the
integrated electrical activity of the diaphragm surpasses a treshhold.
CONTROL INTERFACE
Computer control of mechanical ventilators includes the operator-ventilator interface and the
ventilator-patient interface. New ventilation modes represent the evolution of engineering
control schemes. The various ventilation control strategies behind the modes have an
underlying organization and understanding that organization improves the clinician’s
appreciation of the capabilities of various ventilation modes.
Through the control interface certain parameters must be controlled, such as resistance,
compliance, spontaneous breathing and leaks. The interface must be user centred for an easy
and understandable use.
All modern ventilators use closed-loop control to maintain consistent pressure and flow
waveforms in the face of changing environmental conditions. Closed-loop control is
accomplished by using the output as a feedback signal that is compared to the operator-set
input. The difference between the two is used to drive the system toward the desired output.
For example, pressure-controlled modes use airway pressure as the feedback signal to control
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gas flow from the ventilator. Manufacturers typically do not use flow at the airway opening as
a feedback signal, because they do not trust the flow sensors available for that purpose.
Instead, they measure flow inside the ventilator, near the main flow-control valve.
Closed-loop control uses a sensor to measure the output of the effector. This signal is passed
to a comparator (represented by the circles) that essentially applies a simple equation:
error=input-output. If the error in the effector output is large enough, an error signal is sent to
the controller. The controller then adjusts the effector so its output is closer to the desired
input (i.e., makes the error smaller). The advantage of closed-loop control is that the output is
continuously and automatically adjusted so that disturbances are not a problem. The greater
complexity of that system makes it more expensive to build and maintain.
Figure 18. Schematic diagrams of closed-loop control of a mechanical ventilator. A: Pressure control. B: Flow
control. C: The flow signal is integrated to provide a signal for volume control. D: Flow/volume control
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1.2.
DISPLAY INTERFACE
Figure 19. Display
The main components of the display interface are the monitoring patients’ part and the
ventilator settings part. Through the first part certain parameters can be observed such as
resistance, compliance and leaks shown with the orange, green and blue lines. In the right side
of these lines the current value can be observed and if the values go out of the pre-set interval
the numbers will be written in red. With the ventilator settings you can modify the value of
different parameters and set them according to the patient’s profile.
2.
LUNGS
The lungs from the mechanism are represented by a bag that imitates the volume of
the real lungs. It is designed to simulate the physical conditions of neonate and
paediatrical lungs with widely adjustable resistance, compliance, leakage and
spontaneous breathing.
There are different types of devices to simulate the human lungs but all of them must
be able to change the named clinical parameters, and to have and outlet to connect
the ventilator tube that will provide the lung simulator of air.
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3. BODY (Mannequin)
Figure 20. Premie HAL S3009
With the mannequin, which has inside the lung simulator, several things can be noticed:
breathing when the chest rises and lung sounds that are synchronized with selectable
breathing patterns, circulation and colour change shown through multiple heart sounds, rates
and intensities, the possibility to view ECGs with physiologic variations generated in real-time,
the rate and depth of respiration can be controlled, bilateral, brachial and femoral pulses that
vary with blood pressure and pulses are synchronized with ECG.
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PEADIATRIC AND NEONATAL LUNG SIMULATOR
2.2.2.2. Functionalities
LUNG PERFORMANCES
The following parameters are the main functions that a Lung simulator must cover in the
system in order to simulate the breathing behaviour of the respiratory system.
1. Spontaneous breathing
Natural spontaneous ventilation occurs when the respiratory muscles, diaphragm and
intercostal muscles pull on the rib cage open, creating a negative inspiratory pressure. This
leads to lung expansion and the pulling of air into the alveoli allowing gas exchange to occur.
Therefore, spontaneous respiration occurs by negative inspiratory force.
Once a patient is intubated, the endo-tracheal tube (ETT) is connected to the ventilator.
Depending on the type of ventilator, positive pressure ventilation is provided either by a
pneumatic or electric device. The compressed air entering at the alveolar level allows for gas
exchange.
The significant difference between spontaneous respiration and mechanical ventilation is that
during spontaneous respiration, air is pulled into the lungs whereas during mechanical
ventilation, air is pushed into the lungs. This difference impacts cardio-pulmonary dynamics, as
well as the integrity of lung tissue with the potential for long-term injury.
2. Airway resistance
-
It is all about a measure of the impedance to airflow through the Broncho pulmonary
system and the reciprocal of airway conductance.
For examples, in asthma and in smokers, the airway resistance is increased.
The airway resistance testing can be able to evaluate the airway responsiveness, airflow
resistance or closures and the characterisation of the type of lung disease.
In physiology, the obstruction or turbulent flow in the upper and lower airways can cause
the resistance to the flow of gases during the ventilation.
It also could be defined as the ratio of the difference in pressure between the mouth,
nose, or other airway opening and the alveoli.
There are some factors that influence the airway resistance which are lung volume and
bronchial smooth muscle activity.
3. Lung compliance
-
-
It is a measure of the ease of expansion of the lungs and thorax.
It can be determined by pulmonary volume and elasticity.
When the compliance is decreasing, it means that there is a greater change in pressure
needed for a given a change in volume, such as in atelectasis, edema, fibrosis, pneumonia
and absence of surfactant.
At the base of the lung, the compliance is higher than at the apex of the lung.
The lungs are going to be stiffer and having a greater tendency to collapse if the
compliance is low.
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-
There are two distinctive curves with different phases of respiration as shown in the
following diagram:
o
o
Inspiratory compliance curve
Expiratory compliance curve
Figure 21. Example of lung compliance graphically
-
-
Normally, the occurrence of the lung compliance is caused by elastic forces of the lung
itself and also due to the elastic forces of the fluid that lines the inside walls of alveoli and
other lung air passages.
The compliance of the whole system is measured while expanding lungs of totally relaxed
or paralysed person.
4. Leaks of air
-
The presence of system leaks must be synchronised by the ventilators used during the
paediatric ventilation.
The leak compensation is significantly impacted by the lung mechanics and model size.
Usually, the leak is going to be minimised as much as possible in clinical practice.
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2.2.2.3. Analysis of existing solutions
This section is focused on analysing a selection of lung simulators systems that are currently in
the market, from the simplest ones to the most sophisticated and complete ones, to have an
overview of the latest innovation in this field in each of the elements. The purpose is to detect
the most interesting features that can be included in the design of the proposed solution
before having been specified all the requirements.
BENCHMARKING OF LUNG SIMULATOR’S ELEMENTS
To have the view of all the different elements of a lung simulator system that exist in the
current market and their characteristics, it has been done a selection of three examples of
common and interesting ventilators, lung simulators and mannequins. The diagram bellow
illustrates all the lung simulator system as it has been presented in the description of a Lung
simulator section.
3 BODY (MANNEQUIN)
1.2 DISPLAY
INTERFACE
2 LUNGS
(BAG)
1 VENTILATOR
1.1 CONTROL
INTERFACE
- Flow rate
- Pressure
- Real time monitoring
of respiration curves.
- Leaks of air
- Volume of air
2.1 REMOTE/ MANUAL
CONTROL OF LUNG
PARAMETERS
Figure 22. Parts of lung simulator
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1. VENTILATOR
RESPIRONICS V200 Philips
The Respironics V200 critical care ventilator provides state-ofthe-art ventilation modes with synchrony options that reduce
work of breathing and streamline patient care. As a busy
clinician, you will appreciate the V200's design and its range of
treatment modalities for all patient populations. The V200
supports care in any environment by connecting to Philips
patient monitors and hospital information systems for a
seamless flow of ventilation information.
For invasive ventilation, the V200 provides instantly
recognizable modes. Behind these modes, the V200 ventilator
employs advanced breath delivery algorithms (Auto-Trak, Flow- Figure 23. Ventilator Respironics
V200 from Philips
Trak, and Baby-Trak) to improve patient-ventilator synchrony.
For noninvasive ventilation (NIV), the V200 functions like the BiPAP Vision with Auto-Trak, the
gold standard for NIV. By using spontaneous breathing (S) and timed back-up (S/T) with IPAP
and EPAP settings, the V200 keeps NIV simple, for new and experienced caregivers.
SERVO-U Maquet
It is a mechanical ventilator with unprecedented levels of speed in
sensing and control, with Workflows, to support protective
ventilation strategies. It is provided by a highly intuitive touch
screen. Context based views, dialogues and recommendations with
well-placed shortcuts.
The significance of protective tidal volumes is well documented.
SERVO-U automatically calculates tidal volume per kilogram of
predicted body weight (VT/ PBW) to help the professionals adhere
to ARDSNet protocol strategies. This time-saving new core value is
continuously measured and trended, facilitating adjustment of
ventilation parameters in all modes.
Figure 24. Ventilator SERVO-U
from Maquet
The Edi respiratory vital sign (Electrical activity of the diaphragm), displayed on screen, helps
clinicians track spontaneous breathing efforts. It also supports sedation management in all
ventilation modes as well as in standby. This accurate onscreen information allows appropriate
and timely response to changing breathing conditions.
On screen tutorials help the professionals brush up on their knowledge, and support them
when applying settings and ventilation modes.
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EPS/IDPS 2014
SERVO-U gives the opportunity to share patient information for review, research and
education. The user can either use the built-in 72 hours trend or use the recording feature.
When the recording is made, SERVO-U allows capturing what just happened, with a pre– and
posting recording function.
HAMILTON-C3 VENTILATOR Hamilton Medical
The HAMILTON-C3 has been designed to ventilate adult and
paediatric patients in the critical care environment.
With optional support, the HAMILTON-C3 is also able to ventilate
infants and neonates. The unique Ventilation Cockpit™, with its high
definition widescreen, provides exactly the needed information and
helps to focus on what’s important. The Dynamic Lung and the Vent
Status window assist the doctor in immediately identifying the
patient’s lung condition and assessing the weaning process.
Adaptive Support Ventilation (ASV) makes ventilation intelligent by
providing optimal support with each breath for virtually all patients.
This ventilator has been designed with built-in, hot
swappable batteries and a turbine-giving the maximum
independence and flexibility to accompany your patient
everywhere.
Figure 25. Ventilator
HAMILTON-C3
Interesting features:
 A 12.1 inch high-resolution widescreen display for more information at a glance.
 A unique Ventilation Cockpit that is designed to improve safety through intuitive
operation and monitoring.
 Proven closed-loop ventilation that automatically applies lung-protective strategies –
reducing the risk of operator errors and promoting early weaning.
 A single, versatile source of invasive and non-invasive ventilation for adults, paediatrics
and neonatal ICUs, emergency and recovery rooms, sub-acute care, and intra-facility transport.
 Integrated turbine and hot-swappable batteries providing maximum mobility for up to
6.5 hours.
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2. LUNGS (BAG)
BABI.PLUS Neonate Lung Simulator
Figure 27. Babi.plus lung simulator with the
optional manometer
Figure 26. Example of the simulator functioning
with a manual ventilator
This is an ideal neonate test lung for equipment testing, product demonstration and medical
personnel training. Test lung has been designed to simulate the physical conditions of a
neonate lung. It is calibrated in accordance to different compliances and various airway
resistances for neonates thanks to changeable silicone elbow come with four airwaysimulation resistors: 90, 145, 300 or 600cmH2O/L/s.
Each lung also has the option of including shell panel to simulate lung compliance.





Anatomical design and two different lungs for more precise simulation.
Great compliance consistency.
Pressure monitoring port for accurate pressure measure.
Made of high performance engineering plastic and silicone rubber. Each unit has been
calibrated to ensure the resistance and compliance conforms to specifications for
different applications.
Lightweight, easy and convenient for use and storage.
SPONTANEOUS BREATHING
NO
RESISTANCE OF AIRWAYS
90, 145, 300 or 600cmH2O/L/s
LEAKS OF AIR
NO
COMPLIANCE (LUNG ELASTICITY)
YES (innacurate)
WEIGHT
0,5 Kg
SIZE
-
PRICE
-
PARAMETERS
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TL2 PRO TEST LUNG
TL2 Pro Test Lung is an advanced training and testing system
capable of simulating a wide range of patient conditions.
Some of its features include the ProLeak, ProCompliance, and
ProBreath controls that allow independent leak, compliance and
lung selection settings for the ultimate in flexibility and
performance.





Figure 28. Lung simulator TL2 PRO
3 leak settings: no leak, low leak and high leak.
TEST LUNG
Single or double lung breath delivery.
Variable secondary lung resistance.
Independent lung compliance control, with more tan 20 combinations.
Soft sided carrying case included.
PARAMETERS
NO
YES
LEAKS OF AIR
YES
YES (inaccurate)
WEIGHT
0,4 Kg
SIZE
-
PRICE
250€
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ADULT/PEDIATRIC DEMO LUNG
Ventilator graphics and advanced modes of ventilation offer the
opportunity for improved treatment of ventilator patients.
However, they also demand more sophisticated skills of today’s
clinicians.
The Adult/Paediatric Demonstration Lung Model allows
teaching about the dynamics of patient-ventilator interaction in
a very visual fashion. Using the Lung Model, it can be easily set
up real-world scenarios, including ET-tube and lung leaks as well
as spontaneous breathing.
Figure 29. Lung simulator DEMO
LUNG
This lung model is ideal for teaching, training, and ventilator
demonstrations where the ability to quickly change patient
parameters is essential for the success of instruction.

Easy to set up: simply open the lid and select settings.

Quickly demonstrate the effects of changes in compliance, resistance, and leaks.

Two-bellows system provides realistic simulation of compartmentalized lung problems
(leaks, resistive anomalies).

Pressure gauges show differences between airway and lung compartment pressure.

Peak pressures recorded by drag pointers.
YES
YES
LEAKS OF AIR
YES
YES
WEIGHT
7-8 Kg
SIZE
291x 248x 165 mm
PRICE
1950€
PARAMETERS
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3. BODY (MANNEQUIN)
NEWBORN HAL® by Gaumard
Figure 30. Newborn HAL mannequin
Newborn HAL® is a mannequin of 40 week newborn, along with breathing, pulses, colour and
vital signs and responsiveness to hypoxic events and interventions. Also included are trending,
crying, convulsions, oral and nasal intubation, airway sounds and extra tablet PC for control.
The features of this model are numerous and corresponding to different kinds of simulations,
i.e. connected with respiratory and circulatory system or with speaking patterns. Below there
is a list of selected advantages of Newborn HAL® in terms of breathing and airways, based on
informative brochure about the product.
AIRWAYS
BREATHING
Multiple upper airway sounds synchronized
Control rate and depth of respiration
with breathing
Automatic chest rise is synchronized with
Nasal or oral intubation
respiratory patterns
Chest rise and lung sounds are synchronized
Right mainstream intubation
with selectable breathing patterns
Accommodates assisted ventilation including
Depth of intubation detected by sensors
BVM and mechanical support
Possibility of airway obstruction
Block right lung, left lung, or both lungs
Ventilations are measured and logged
Detection and logging of ventilations and
compressions
Head tilt/ chin lift
Simulated spontaneous breathing
Jaw thrust
Variable respiratory rates and
inspiratory/expiratory ratios
Possibility of using simulated suctioning
Remains fully functional even while in transit
techniques
20 preprogramed scenarios modifiable by the
Bag-Valve-Mask Ventilation
instructor even during the scenario
Placement of conventional airway adjuncts
Create your own scenarios - add/edit
Table 2.Newborn HAL mannequin selected features
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PediaSIM® by HELSIM
Figure 31. PediaSIM mannequin
PediaSIM is a complete reproduction of an actual six-year-old child. Paediatric patient
mannequin measures in at 122 cm tall, weighs 38 17.2 kg and is fully operational in the supine,
lateral and sitting positions. It was designed to support a wide range of clinical interventions,
taking into account differences that make paediatric medicine uniquely challenging, like
distinctions in anatomy, reactions to drugs, types of injuries and underlying physical
conditions. PediaSim operates on the basis of delicately calibrated mathematical equations
which reflect those of the paediatric patient; this highly developed paediatric patient models
generate realistic and automatic responses to clinical interventions and drug administrations.
Simulated Clinical Experiences:










Acute Respiratory Failure
Asthma
Asystole
Bradycardia
Hypovolemic Shock
Multiple Trauma
Pulseless Electrical Activity (PEA)
Supraventricular Tachycardia/Ventricular Tachycardia
Toxidromes
Ventricular Fibrillation
AIRWAY TRAUMA
AIRWAY FEATURES
Swollen Tongue
Upper Airway Obstruction
Laryngospasm
Bronchial Occlusion
Esophageal, Nasal and Oral
Intubation
Oropharyngeal Intubation
Nasopharyngeal Intubation
Bag-Valve-Mask (BVM) Ventilation
Laryngoscopic Procedures
Endotracheal Tube Intubation
Table 3. PediaSIM mannequin selected features
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CHILD HEART AND LUNG SOUND TRAINING MODEL PP00020 by Simulaids
Child Heart and Lung Sound Training Model can be used to
play back the recorded voice, lung and heart sounds of a real
4 year old child, with having the ability of choosing sounds
and their rate. The sounds are then emitted from 10 lung
and 1 heart speaker locations that student can auscultate
with a stethoscope. The manikin also features a speaker jack,
allowing you to broadcast the sounds to the whole class of
students.
Figure 32. Child Heart and Lung
Sound Training Model
LUNG SOUNDS INCLUDED
VOICE SOUNDS INCLUDED
Asthma
Cough
Bronchial
Crying
Coarse crackles
Gasp
Fine crackles
Gurgling
Normal breath sounds
Sneeze 1
Pneumonia, lobar
Wheeze
Table 4. Child Heart and Lung Sound Training Model selected features
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3. REQUIREMENTS ANALYSIS
3.1.
CONTEXT OF USE
The aim of the project is to design a neonatal and paediatric lung simulator, which will be used
for research and educational purposes.
The different users profile and stakeholders determine the specifications that the new lung
simulator has to accomplish depending on their purpose and context of use.
The purpose of a lung simulator is to represent real scenarios in a simulated environment. Its
application during medical and nursing studies it is useful to teach the future professionals to
understand and to know how to interpret the data and graphs shown through the ventilator
where the patient with a respiratory disease is connected through intubation or a mask. The
function of the lung simulator is to behave as the patient lung being able to represent different
diseases and grades of severity.
REAL SCENARIO IN THE HOSPITAL ROOM
SIMULATION CLASS WITH THE LUNG SIMULATOR
Figure 33. Illustration of the purpose of the lung simulator in its context of use
3.1.1. USERS’ PROFILE
Taking into consideration the fact that the proposed lung simulator will be a device used by
several profiles of users, it is necessary to present a description of each target group that is
going to use the product: university professors, medical and nursing students, doctors and
researchers.
-
MEDICAL PROFESSORS: Qualified people from 23 years of age and older with medical
studies who work in public and private Spanish universities. Regardless of their
personal culture, they can only teach in English or Spanish. Their classes have an
extension of time of about 2 hours and they can be in charge of theoretical or practical
classes. It is mandatory for them to continue training and acquiring knowledge through
research to be updated being able to give students the latest information in their field.
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-
MEDICAL AND NURSING STUDENTS: Generally, students are aged between 18 and 30
years and their nationality is Spanish, although it has to be taken into account that
foreigners students are also include in this target group. They usually are familiar with
new technologies and use to work with electronic devices and new applications. This
user profile has the motivation of learning new skills in medicine and to apply their
knowledge in practical scenarios to prove their knowledge. They want to learn the
specific technical vocabulary during lectures.
-
DOCTORS AND RESEARCHERS: This type of user is a professional who
practices medicine and is concerned with promoting, maintaining or restoring
human health through the study, diagnosis, and treatment of disease, injury, and other
physical and mental impairments. They may focus their practice on certain disease
categories, types of patients, or methods of treatment. They must have
detailed knowledge of the academic disciplines, such as anatomy and physiology,
underlying diseases and their treatment and also a decent competence in its applied
practice. Doctors use and understand the proper medical technicalities.
3.1.2. TASKS
PROFESSORS
STUDENTS
DOCTORS AND
RESEARCHERS
-
To control the lung simulator
To transport the device
To generate real clinical scenarios and show real diseases
To transmit theoretical knowledge through the simulator
To evaluate the students
-
To develop practical and analytical skills
To understand the data obtained from the simulation
To learn how to interact with a ventilator
To learn the different paediatric respiratory diseases
To be able to identify different diseases through the simulator
behaviour.
-
To apply the ventilator part of the simulator to real patients
To be able to show real diseases with the simulator
To be able to update the simulator with new diseases, varying
parameters
To compare data from different medical scenarios
To transport the simulator to different places
To save the results obtained.
-
Table 5. Tasks to do using the simulator by the different users
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3.1.3. ENVIRONMENT AND SOCIAL CONTEXT
CURRENT AND MAIN ENVIROMENT FOR THE SIMULATOR
Figure 34. Darwin Simulation Centre of Sant Joan de Déu Hospital
DARWIN SIMULATION LAB OF SANT JOAN DE DÈU HOSPITAL
The Darwin simulation centre of Sant Joan de Déu Hospital's main objective is to improve the
training of health professionals in the paediatric and obstetric field, by providing a simulation
environment where they can plan and practice a wide range of diagnostic and therapeutic
interventions without involving patients.
In order to provide medical students and professionals with the proper and most realistic
scenarios, the simulation Lab has the following resources:
-
Real physical spaces
Multidisciplinary Training
Advanced simulators
Learning methods "problem-based" by addressing specific and real clinical cases
Basic-Advanced / individual- team training
The centre focuses its training in different aspects:
-
Training in technical skills
Training in teamwork
Training in decision-making
Relational skills
Currently, the following areas of the hospital are used in the simulation program:
-
Emergency Room (ER)
Neonatology
Anaesthesiology
Intensive care
Obstetrics
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Darwin simulation lab materials and tools
The simulation centre occupies an area of about 150 m2, located in the vicinity of Sant Joan de
Deu Hospital, in the teaching building. There are multipurpose spaces that allow training in
multiple specialties and areas that recreate real clinical environments and have the audiovisual equipment such as surveillance cameras and microphones, advanced recording system,
projectors and screens for debriefing. The simulation area has the ability to record their
activity in audio and video and also make video streaming and broadcast anywhere in the
world.
The equipment and tools in the lab are:
-
Two multipurpose rooms for advanced simulation: Box paediatric ICU; Neonatal ICU;
Box of emergency; Delivery Room.
A specific room for individual skill training and coaches of various techniques.
A control room.
A room for viewing and debriefing.
The space is equipped with simulators, venting and the medical support equipment required:
-
Material for advanced training in clinical settings for all paediatric ages’ simulation.
Advanced simulation equipment to recreate obstetrics scenarios.
Respirators and lung simulators for training in paediatric and neonatal ventilation.
Simulators for training of basic life support.
PEDIATRIC AND NEONATAL LUNG SIMULATION IN THE DARWIN SIMULATION LAB
Currently, the hospital has a ventilator connected to a source of air, and its monitor to control
the clinical parameters that must be shown through the screen.
On the other hand, there is a lung simulator, which is inaccurate to simulate children lungs. It is
composed by a rubber bag that simulates the lung. It will be analysed below to detect all the
problems that it has.
Figure
Hospital’s
35. Hospital’s
ventilator
ventilator
monitor
monitor
Figure 36. Current lung simulators of the Hospital
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OTHER POSSIBLE ENVIROMENTS
-
TRANSPORT (PUBLIC AND PRIVATE): There are some ways to transport the lung
simulator from the manufacturers to the hospital or university which could be a public
or private transport. For example, as the lung simulator is portable, so it can be easily
transported or brought by the users via public transport such as train, bus, airplane
and taxi or in some cases like the professor or doctor can migrate it via private
transports which are their own vehicle and the ambulance from the hospital. Although
the lung simulator is portable, it needs an intensive care in order to ensure it is in a
good condition and to avoid it from being broken or malfunctioned. So, the users
themselves need to be really aware where to put it when they are transporting it from
a place to another. Another aspect to bear in mind is the transport by plane, and all
the controls that the device must pass in the airports.
-
LABORATORIES OF THE UNIVERSITY:
When it is talked about the laboratories
of the medical university, they need to
have a high safety providing that there
are many medical equipment especially
the lung simulator which is going to be
used in some practical by the students
or the professors in those laboratories.
The professor or the person that is in
charge and responsible for that
Figure 37. Example of a University Laboratory
particular laboratory also needs to
oversee and watch all the actions from the students during the practical session. So,
the situation could be under control and all the expensive medical equipment could be
in good condition as usual. Besides, the laboratories should always be neat and orderly
so the students and professors could do the work in comfort.
-
CONFERENCE ROOMS: As is widely known, a
conference room is quite extensive in order to
ensure all the people from the conference are
in good comfort. In addition, it should be
completed with all facilities to assist the people
in that particular conference to explain about
the given topics or give their speech. This
conference room could be in either hospital or
university for the professors to have a
conference with their students or for the
doctors to have a conference with other
professional doctors or researchers.
53
Figure 38. Example of a University conference
room
EPS/IDPS 2014
Taking into account the environment of the simulation lab and the other possible
environments, there are some aspects to bear in mind for the design of the lung simulator:
PORTABILITY
ACCESSIBILITY
-
Low weight
Compact design
Avoid metallic materials
Protection of the device
-
Easy to control all the lung parameters, both remotely and
manually.
-
Compatibility in connexion between the current ventilators.
Wireless connexion between the simulator and the remote
control.
Compatibility of the remote control connexion in different
environments.
CONNEXION
-
MANTEINANCE
-
Easy to clean
Exchangeable components
Table 6. Requirements for the lung simulator according to the environment
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3.2.
STAKEHOLDERS’ SPECIFICATIONS
The stakeholder of the project is the Children’s’ Hospital Sant Joan de Déu, represented by
Pedro Brotons, R&D Project Manager from the Innovation and Research Department and José
M. Quintillá Martínez, the Coordinator of the Simulation Centre from the Emergency Service.
1.2 DISPLAY
INTERFACE
1 VENTILATOR
1.1 CONTROL
INTERFACE
2 LUNGS
(BAG)
- Flow rate
- Pressure
- Real time monitoring
- Leaks of air
of respiration curves.
- Volume of air
2.1 REMOTE/ MANUAL
CONTROL OF LUNG
PARAMETERS
HOSPITAL’S NEEDS
HOSPITAL’S CURRENT DEVICES
Figure 39. Scheme of the whole system divide in: current devices and needs
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3.2.1. HOSPITAL’S CURRENT DEVICES
-
Lung simulator: SMART LUNG
Smart Lung is one of the lung simulators in the current market produced by Imtmedical
Company located in Switzerland. This kind of lung simulator has been bought recently by The
Paediatric Hospital Sant Joan de Déu, Barcelona for educational purposes to assist all the
medical students to get familiar with the simulation before they work in the real situation.
Compliance
Air bag
Airway resistance
Leak
Tube connector
Figure 40. Current hospital simulator: SMART LUNG
Parts
Description
Compliance
It can be adjusted by easily moving the slider according to the degrees of lung
compliance they like to be simulated without an adapter.
Air bag
It is used to represent the real lungs of the patient and to show how the lungs
work and move depending on those performances (compliance, leak and
resistance). It is not replaceable with different bag sizes.
Airway resistance
It is designed to be able to simulate the lungs with different airway resistances
that can be simulated simply by turning the connector.
Tube connector
It has to be connected by the tube to the ventilator before the simulation is
started to give out the results and parameters that are needed to be measured.
Leak
The leakage can be adjusted by turning the side screw and it requires no
adapter. It also enables the ventilators for premature babies or mask
ventilation to be checked.
Table 7. Main parts of the SMART LUNG
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Smart Lung for Adult
Resistance
Compliance
Volume
Leak
Weight
Dimensions (L x W x H)
Price
5, 20, 50, 200 mbar/L/s
10, 15, 20, 30 mL/mbar
0 – 600 mL (with 1L bag)
0 – 10 L/min
325 g
300 x 115 x 40 mm
620€
Table 8. Main parameters of the Smart Lung for adult
Smart Lung for Infant
Resistance
Compliance
Volume
Leak
Weight
Dimensions (L x W x H)
Price
5, 20, 50, 200 mbar/L/s
1, 2, 3, 5 mL/mbar
0 – 200 mL (with 0.5L bag)
0 – 10 L/min
285 g
275 x 115 x 40 mm
620€
Table 9. Main parameters of the Smart Lung for infant
The problem of this lung simulator is that good test lungs take up a lot of space. It is also
expensive and complicated to be used. The main problem is that is not able to be controlled by
a remote. For example, whenever the doctor does not want to be in the simulation room, he
cannot control this lung simulator from the outside to adjust the leak, compliance, resistance
and especially the spontaneous breathing of the patient. In addition, the results obtained from
this lung simulator are not quite precise as for instant there is some air passages come through
the simulator.
-
Ventilator: SERVO-I Maquet
Since the introduction of the first SERVO ventilator in 1971, SERVO has
become the worlds’ number one ventilation brand. A close
partnership with the medical community ensures that SERVO
ventilators meet the needs of clinicians, across the spectrum of
patient types and treatment situations.
SERVO-I Infant offers a wealth of features and functionalities for
treating neonatal and paediatric patients. Its unparalleled sensitivity
helps clinicians to deliver the best care for the smallest patients.
Robust, easy to use and highly mobile, SERVO-i Infant is designed to
react to needs of the dynamic neonatal and paediatric intensive care
environments.
Figure 41. Ventilator SERVO-I Maquet
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EPS/IDPS 2014
SERVO-I offers one platform for treating the range of patient types and conditions. Available in
Infant, Adult and Universal configurations, this future-proof modular system can be easily
upgraded with new functionality to keep up with the clinician’s changing needs.
SERVO-i Infant delivers the performance needed for treating neonatal and paediatric patients.
With one ventilator, the clinician can treat a wide range of conditions in patients at differing
levels of stability. The system has a range of ventilation modes and treatment extension
features that help clinicians address specific needs for a variety of patient characteristics.
Performance
Sensitive control
SERVO controller
valves
SERVO-I
expiratory flow
sensor
Sensitive trigger
Inspiratory Cycle
Off
Auto mode
Time Constant
Valve Controller
Adjustable rise
time
Non-invasive
support
Leakage
detection
Description
High speed in sensing and control is a key element in providing optimal
treatment for neonatal and paediatric patients.
SERVO-I responds to the smallest deviations from set values which are
regulated several hundred times during each breath.
A Y sensor measurement option with an airway adapter dead space of less than
0.75 ml and weight of 4 grams allows the clinician to monitor pressure and flow
readings as close to the patient as possible.
This gives a fast response time ensuring the comfort of the patient.
The adjustable Inspiratory Cycle Off ensures an appropriate ventilator response
even when leakage is present.
This allows automatic patient interaction for shorter weaning times and better
patient comfort.
It reduces expiratory resistance, continuously calculating the elastic and
resistive forces of the respiratory system.
This helps reduces work of breathing by allowing a range of flow responses.
SERVO-I offers features for non-invasive ventilation via mask or endotracheal
tube retracted above the vocal cords, combined with Pressure Support or
Pressure Control Ventilation modes.
It triggers an alarm if leakage is excessive. Display of leakage fraction shows
how well the patient interface fits.
Table 10. Parameters of SERVO-i Infant
Taking into account that the tube from the ventilator changes depending on the type of
mechanical ventilation, the hospital has a tube connector to adapt the tube to each one:
-
Neonatal ventilation: 14 mm of diameter.
-
Children ventilation: 22 mm of diameter.
-
Non-invasive ventilation: 25 mm of diameter.
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HOSPITAL’S NEEDS
The requirements that have been decided by the hospital are shown below:

Portable device, transportable in a small suitcase: The hospital requires us to develop
and design a lung simulator that is more portable than the existing ones and it can be
transported or located in a small case, so it could be easier to be handled and brought
to the simulation class or conference without any problems.

Two lung sizes:
- Neonatal lungs (25-50 ml)
- Paediatric lungs (125-250 ml)
It is mandatory to design a lung simulator of two different sizes of lung. One of them is
for neonatal and the other one is for paediatric patients and they have specific range
of volume of 25-50 ml and 125-250 ml respectively.

Ability to generate pre-defined common clinical scenarios with several degrees of
severity of lungs failure:
- Decrease of compliance
- Increase of resistance
- Leaks in neonatal and paediatric scenarios
The other requirement from the hospital is to design a lung simulator which should be
able to simulate some common scenarios of the lung of a patient by considering the
compliance, air resistance, leaks and the simulation of spontaneous breathing, when
the patient starts breathing by himself.

High precision and reliability: The lung simulator that is going to be designed should
be more precise and reliable as we were told by the hospital in order to obtain a result
from the simulation that is more accurate.

Remote control: The most important thing to take into account is that the lung
simulator must be able to be controlled by a remote control as at this very moment,
none of the lung simulators in the market is able to do so. The main purpose to make it
so is because in many occasions, doctors or medical professors decide not to be inside
the simulation room with the students and adjust the lung simulator manually due to
they don’t want to influence the learning process and decisions of the students . So, by
making this lung simulator controlled remotely, it could be much easier for them to do
the simulation from a different room instead of doing it manually in front of the
students. However, just in case of malfunction of the remote control, the lung
simulator also needs to be designed to make it able to be used manually.
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3.3.
REQUIREMENTS DETERMINATION
Once the context of use and the hospital’s current problems have been specified, a list of
requirements attending different features of the lung simulator has been done. The following
scheme shows the parts of the system that need to be mandatory included in the development
of the lung simulator.
2 LUNGS
(BAG)
- Leaks of air
4 REMOTE/ MANUAL
CONTROL OF LUNG
PARAMETERS
Figure 42. Parts of the lung simulator system that have to be designed
On one hand, there is the need of designing a new bag that represents the lungs. There is the
possibility to design a simulator that includes two bags representing both lungs, or only one
bag considering that in numerous occasions it is only needed the representation of the whole
respiratory process to detect the constraints that the patient has to be able to adapt the
ventilator to his/her demands, independently the lung in which the problem appears. The bag
has to be able to simulate the presented main parameters that represent the different
problems that a patient intubated or connected to a ventilator could have.
On the other hand, it is necessary to control the system remotely ensuring a realistic situation
for the students that have to interpret the data shown by the ventilator’s screen without
seeing the professor how is he changing the lung simulator parameters taking into account
that this can influence their decisions and the evaluation wouldn’t be as reliable as it should
be.
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STORYBOARD OF USE
1. Connection of the lung simulator
2. Connection of the ventilator to the air
source
3. Adjustment of ventilator’s
parameters by the professor
4. Accommodation of the professor and students in respective rooms
5. Adjustment of lung simulator parameters that modify the graphs in
the ventilator screen for students’ interpretation
6. Disconnection of all the devices
7. Package and carry of the lung simulator
Figure 43. Storyboard of use
This storyboard illustrates the whole use of the lung simulator that we want to propose
according to the studied requirements.
The first step is to connect the lung simulator to the ventilator, and then, the ventilator to the
air and oxygen source, that is already installed in the Darwin Laboratory and in the hospitals’
rooms.
To start the simulation session, the ventilator’s parameters, such as, rate flow of the air,
pressure or the weight of the patient that is simulated to be connected must be adjusted by
the professor.
The following step is the accommodation of the students and the professor in their respective
rooms. Students stay in the Darwin Laboratory and the professor is situated in a room next to
the lab that allows seeing what is happening in the other side without being seen by the
students. From this side, the professor adjusts the lung simulator parameters that modify the
graphs in the ventilator screen for the students’ interpretation.
The final steps are: to disconnect all the devices and then package and carry or store the lung
simulator in its own case to be protected from knocks and avoid damaging the device.
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MAIN FUNCTIONALITIES AND CHARACTERISTICS
According to the analysis done of the context of use and form the stakeholders’ specifications
it can be conclude a list of features that each part of the lung simulator must accomplish to
start the design process.
LUNGS (BAG)
General features:
-
Low weight.
Compact.
Easy to assemble and disassemble.
Compatible connection with SERVO-I ventilator and others.
Size bags of 25-50 ml and 125-250 ml.
Inclusion of a case.
Parameters to control:
- Decrease of compliance.
- Increase of resistance.
- Leaks in neonatal and paediatric scenarios.
- Spontaneous breathing.
- Accuracy and reliability.
REMOTE CONTROL
Connexion and control:
-
Wireless device.
Compatibility in the remote connexion in different environments.
At least 2 hours of autonomy.
Proper control of the device between different rooms.
Interface:
-
User Centred Designed interface for an easy and understandable use.
Accurate adjustment of Resistance and compliance.
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4. DESIGN PROCESS
In this section the whole process to develop the final product is presented. It includes the
design of each element that has to be included in the lung simulator: from the bag and each
specific element controlling different parameters to the interface design in order to control the
device remotely.
There are included the best two design options of design, the proper calculations for
dimensioning and adjusting the different elements to their constraints and the final design of
every element with its corresponding mechanism, that has been selected to have the product
prepared for the future implementation of the electronic part in order to control all the
parameters remotely.
4.1.
IDEATION OF THE CONCEPT
4.1.1. MIND MAP
After having specified all the requirements that the product must accomplish, the ideation
process was started. It consisted of brainstorming ideas and making a Mind Map including the
main aspects to consider in the design in order to arrive at the end with the most complete
concept of the lung simulator.
Figure 44. Mind Map
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4.1.2. SKETCHING
After brainstorming all the aspects that the lung simulator had to take into consideration, it
was started the sketching phase to decide the general shape of the device.
It was thought in many shapes for the simulator but it was really conditioned by all the
mechanisms that had to be included in to control remotely the bag. For this reason the final
appearance will be explained after presenting all the mechanisms.
Here are shown the 4 main ideas that were considered to develop:
Figure 45. First sketches of the system with two lungs
The first ideas were focused on including two lungs wanting to represent the system as the
human; however after discussing this aspect with doctors it has been concluded to design the
lung simulator using only a bag that represent both lungs as the important function of the
simulator is to behave as the whole breathing process. This issue allows the product being
more compact and easy to control.
Figure 46. First sketches of the system with one lung
These two sketches represent the two studied shapes to use for the simulator. It was thought
in revolution volumes for ergonomics reasons in order to make the simulator more portable,
avoiding edges. Another issue that was taken into consideration was the ease to remove the
bag in order to change from the children size to the neonate size.
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4.1.3. PRODUCT CONCEPT
The following scheme represents the final shape that was chosen for the product. It points the
main elements that will include and where will they be located. In the next sections it will be
described each element designed to do all the required functions; this is a general scheme to
understand the entire concept.
Figure 47. General scheme of the concept
MAIN ELEMENTS
- BAG: Is the part that simulates the lungs, with its proper volume. It has to be elastic and
resistant to the air pressure that goes inside through the ventilator tube where is connected to
generate the breathing movement of the bag.
- STRUCTURE: It has been thought about a rigid structure to contain the bag inside to ease the
generation of the spontaneous breathing, it will act as the diaphragm of the human body
respiratory system. Considering the low rigidness of the bag it is necessary a more rigid
support to open the bag to simulate this spontaneous breathing in order to be detected by the
ventilator.
- TUBE: A cylindrical tube represents the airway of the lung and it is where the tube coming
from the ventilator will be connected.
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- LEAKS CONTROL: The element to control the leaks will be placed in the tube due to the
facility to generate a leakage in the connection between the ventilator and the simulator
before arriving at the bag.
- RESISTANCE CONTROL: Taking into account that the change of resistance in the human body
is generated in the airways it has been decided to place the system to control this resistance in
the tube.
- COMPLIANCE CONTROL: System applied directly in the bag to adjust the stiffness of it.
- BOX: Due to the remote control of the simulator, all the mechanisms and electronic
components to control each of the parameters need to be placed inside a compact box.
- CAP: An easy open and close cap to access easily to the components inside in case that the
lung simulator had to be repaired.
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4.2.
THE BAG
RIGID STRUCTURE
ELASTIC BAG
The bag is the main element of the lung simulator providing that is the one that represents the
lungs of the patient simulated.
There is the need to design an elastic bag that behaves as the walls of the human lung and a
rigid structure that enables to control all the movements that the bag can do when it is
provided by air applying a number of constraints that the lung has to simulate.
4.2.1. CONCEPTS DESIGN
4.2.1.1.
Balloon shape
Figure 48. Bag concept: balloon shape
The first idea of shape for the bag that represents the lungs of the patient was taken from a
common balloon. One of the interesting aspects of this morphology is its amorphous shape,
which is really close to the real lungs. The material applied, an elastomer such as a kind of
rubber, allows also an expansion and contraction of the walls when it is inflated simulating the
inspiration and expiration process.
Considering the application of this bag in the functioning of the whole process of simulation, it
needs to include a system to adjust the capacity of air inside and be applicable in the
spontaneous breathing control. According to this need, it was designed a rigid structure where
the bag is stuck and it can be opened and closed.
This concept pretended to enable the adjustment of the two size lungs required through a
band system included in the rigid structure but it could be misunderstood with the reduction
of the compliance.
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4.2.1.2.
Bellow shape
Figure 49. Bag concept: bellow shape
This concept has been inspired in a kind of foot pump that uses a bellow to inflate many kinds
of inflatable products.
Thanks to the two sides rigid surfaces stuck, the bellow made of silicone can be inflated or
compressed easily. The shape of this model has been calculated according to the ranges of
volume that the two different sizes of lungs must have. This option has independent designs
for each size to adapt the morphology of both to the final lung simulator that contains the bags
inside.
It has a cylindrical connector to fix the tube from the ventilator to the lung simulator in which
the bag has to be provided by the air.
4.2.1.3.
Final shape
NEONATE BAG
CHILDREN BAG
Figure 50. Final shape of the bag for two lung sizes
-
Bellow shape
Morphology that enables to calculate accurately the volume of air that it can contain
within the limits.
- 2 independent bags: 125-250 ml and 25-50 ml
- Easy control of spontaneous breathing thanks to the rigid sides stuck in the bag.
All the information about the dimensions and constructive parameters are available in the
ANNEX.
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4.2.2. CALCULATIONS AND RESULTS
The ranges of volume that the bag has to be able to have are these two:
-
Children: 125-250 ml= cm3
Neonate: 25-50 ml= cm3
It has to be ensured that the size of the bag allows changing the capacity of the bag from the
lowest volume to the higher one, so it was decided to develop two bag sizes that can be
replaced easily in the lung simulator box.
To calculate the size of the bags it has been used the volume equation:
V= A x h
CHILDREN BAG
Vmin = 125 cm3 = 125,000 mm3
Vmax= 250 cm3 = 250,000 mm3
It was decided to fix the minimum h (height) of the bag in 25 mm. So it could be known the
total area for the bag using the lowest volume (125,000 mm3):
It has been used the Trapezium area due to be the profile of the selected shape:
To adjust the size of the area were made various calculations and approximations and finally it
was decided to establish these values: a= 40 mm and b= 80 mm.
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NEONATE BAG
To dimension the smallest bag has been considered the shape of the big one and the height of
the trapezium has been reduced until have:
Vmin = 25 cm3 = 25,000 mm3
Vmax= 50 cm3 = 50,000 mm3
Considering that the minimum h (height) of the bag is 25 mm, the lowest volume is (25,000
mm3):
Calculation of the Trapezium area:
To adjust the size of the area were made various calculations and approximations and finally it
was decided to establish these values: a = 59 mm and b = 67 mm.
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4.3.
SPONTANEOUS BREATHING CONTROL SYSTEM
The spontaneous breathing is referred to the situation when a patient connected to the
ventilator starts recovering his breathing by himself, so the ventilator has to readjust the flow
of air. Thus, the airflow rate has to be synchronised with the breathing rate of the child.
In order to simulate expansion of the patient’s lungs due to its recovering, there is a need of a
specific system. This system forces the simulator bag to open and generates the entrance of air
inside the bag, hence alerting the ventilator that it has to start reducing the flow of air
provided initially.
It is known that the only condition required for the ventilator to detect the beginning of an
spontaneous breathing process is the increase of the bag’s volume of at least 10 ml. This
information was confirmed by the doctors from Sant Joan de Dèu Hospital.
Another function that the system has to be capable to do is to continue generating this
expansion of the bag during 2 minutes to allow the ventilator to adapt to the breathing rate of
the patient.
Considering the different breathing pathologies of patients, the system has to be able to adjust
the rate of breathing from the range of 10-70 respirations per minute.
4.3.1.1.
Cylinder system
Figure 51. Sketches of cylinder system for spontaneous breathing
The idea is that the upper part of the rigid structure will be moved up by the use of a
pneumatic cylinder. That way, the volume of the bag will be expanded slightly, allowing the
ventilator to notice the change of pressure inside the bag and respond by adjusting the airflow.
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4.3.1.2.
Final design
RIGID STRUCTURE
CYLINDER
SPONTANEOUS BREATHING GENERATION
Figure 52. Final design for spontaneous breathing
The structure that allows the bag generating the spontaneous breathing has two guides in
each side of the piece to hold the bag inside and a bracket system to avoid the slippage of the
bag during the generation of the movement.
Figure 53. Structure of the bag
Thanks to the pneumatic cylinder application the system has some advantages:
-
Accurate control of the spontaneous breathing. The user can adjust the breathings per
minute in order to generate different scenarios.
The cylinder takes profit from the air source that all the hospitals’ and laboratories’
rooms have installed.
According to the selected system to generate the expansion of the bag, the height of the bag
with 10 ml more has to be calculated in order to determine the career of the stroke of the
cylinder.
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CHILDREN BAG
AREA OF THE BAG= 5000 mm2
It is took the minimum volume of the bag taking into consideration that is the volume of the
lung before the inhalation.
VOLUME OF THE BAG= 125,000 mm3
To this volume there have to be summed 10,000 mm3 so the volume to work with is 135,000
mm3.
The initial h of the bag was determined in 25 mm, so the stroke of the cylinder only has to
expand the bag with a displacement of 3 mm.
NEONATE BAG
AREA OF THE BAG= 1000 mm2
VOLUME OF THE BAG= 25,000 mm3
To this volume there have to be summed 10,000 mm3 so the volume to work with is 35,000
mm3.
In this case the displacement is of 10 mm and considering that the displacement of the bag is
not flat and generates an angle, the displacement will need to be slightly higher.
The generation of the spontaneous breathing needs to be tested with the mechanical
ventilator in order to prove that the ventilator detects the bag expansion.
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NEEDED CYLINDER STRENGTH
The initial h of the bag was determined in 25 mm, so the stroke of the cylinder only has to
expand the bag with a displacement of 10 mm.
The diagram below shows the amount of force is being applied to the structure. Actually, the
force is directly from cylinder used in this mechanism.
Figure 54. Results of the simulation: displacement of the structure
The image shows the result of the displacement of the structure obtained from the simulation
with the coloured map showing the different grades of displacement.
4.3.3.
MECHANISM TO CONTROL THE SPONTANEOUS BREATHING
As it has been described, the mechanism to generate the spontaneous breathing consists in a
pneumatic cylinder system. To have the proper functioning of the cylinder it is necessary to
choose different pneumatic elements that will control the movement of the piston in order to
be adjusted to the simulator specifications for the spontaneous breathing. There have been
selected two options of system to control this parameter that are presented in the following
page.
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4.3.3.1.
Electrovalve + flow regulator
CYLINDER
AIR SOURCE 3atm (IN HOSPITAL LABORATORY)
FLOW REGULATOR
ELECTROVALVE
INSIDE THE SIMULATOR CASE
Figure 55. Mechanism to generate the spontaneous breathing: electrovalve + flow regulator
This system consists in a double effect cylinder in order to control both movements of the
stroke controlled by a distribution valve 5/2 driven electrically. In order to adjust the flow of
the air to control the velocity of the stroke it has thought about including an electrically
controlled flow regulator.
The problem of this system is that is not as compact as it must be to adapt it inside the case of
the simulator.
4.3.3.2.
Proportional control valve
CYLINDER
AIR SOURCE 3atm (IN HOSPITAL LABORATORY)
PROPORTIONAL
CONTROL VALVE
Figure 56. Mechanism to generate the spontaneous breathing: proportional control valve
In this case the proportional control valve unifies the flow regulator and the electrovalve,
reducing the space used. In this case it is a 5/3 position valve.
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4.3.3.3.
Chosen system
Due to the simplicity of the system with the inclusion of the proportional valve it has been
selected to be implemented in the simulator.
The supplier chosen for all the elements is FESTO. It has been decided to use all the
components of the system from the same company to ensure the compatibility between them.
CYLINDER
To select the cylinder it has been taken into account the career that it has to be at least of 35
mm considering that the neonate bag has to increase this high to generate the spontaneous
breathing.
AND-16-40-A-P-A
Career
Stroke diameter
40 mm
16 mm
Male thread
Normalized
Pneumatic connexion
M6
ISO 21287
M5
Material
Weight
Steel alloy
139 g
Figure 57. Chosen system to generate the spontaneous breathing: cylinder
The chosen cylinder has as the main characteristics to be applied to the simulator the following
ones:
-
Inclusion of position sensors to allow the electronic system that controls the
movement when the stroke of the cylinder has raised the top part. Thanks to this
functionality the system can be programmed to move the cylinder as faster as it is
needed to generate different clinical scenarios.
-
Male threat to include the cylindrical plate in order to distribute the pressure to push
the structure that contains the bag.
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-
Pressure of functioning: 0,6-10 bar. Considering that the pressure of the air from the
air source is close to 3 bar it is ensured the compatibility with the cylinder.
More information about dimensions is specified in the ANNEX.
PROPORTIONAL CONTROL VALVE
This valve has the function of a distribution valve. This valve will control this cylinder through a
5/3 double effect.
The second functionality of this valve is the adjustment of the flow of air that comes from the
air source installed in the hospital which works with 3 atm of pressure, adjusting electrically
with the vary of voltage the flow in order to vary the velocity of movement in the cylinder,
generating thanks to this variation, different breathing scenarios that are between 10-70
respirations/min.
The principle requirements to choose the proportional control valve are the following ones:
-
Pneumatic connection M5 to fit with the cylinder.
Electric control to be programmed from the Arduino board.
Reduced weight and size in comparison with the other presented option.
MPYE-M5
Pneumatic connection
Standard nominal flow rate
Voltage
Functioning pressure
Drive
Weight
M5
100 l/min
17…30 V DC
0…10 bar
Electrical
290 g
Figure 58. Chosen system to generate the spontaneous breathing: proportional control valve
More information about dimensions is specified in the ANNEX.
FITTINGS + TUBING
The complements for the assembly of all the pneumatic system are push-in fittings to enable
an easy connection of all the elements through the normalized tubing for pneumatic
connections.
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According to the selected valves and cylinder the pneumatic connection of the fitting has to be
M5 and the push-in connector with a diameter of 4 mm. From that data is chosen all the tubes
with a section of 4 mm.
QSM-M5-4
PUN-4X0, 75-BL
Figure 59. Chosen system to generate the spontaneous breathing: fittings + tubing
The following image shows the real connection of the described components and their
position inside the lung simulator.
The cylinder is gonna be connected with two tubes; the one for pushing up the stroke and the
other to retunr it back and it will be conected to the hospital’s air source through the indicated
push-in fitting allowing to connect the simulator easily.
It is necessary to add a connector between the simulator and the tube from the air source
because the diamater of that tube is 14 mm. The connector will reduce the diammeter from 14
to 4 mm.
PROPORTIONAL CONTROL VALVE
CYLINDER
Tube
Fitting
Figure 60. Top view of the lung simulator to see the pneumatic elements position and their connections
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4.4.
COMPLIANCE CONTROL SYSTEM
Compliance (C) measures the expansibility of the lungs and describes the elastic features of the
breathing apparatus. It is expressed by relationship of the volume change in the lungs for each
unit change in intra-alveolar pressure, according to the formula:
If additional volume is pressed into an elastic body such as a balloon, that has a certain volume
and is under a certain pressure, the volume changes by the value ΔV and the pressure
increases by the value Δp. The volume change involves complete filling of the lungs from the
beginning to the end of a taken breath. The larger the compliance, the less the pressure
increases at a certain filling volume.
Normal values:
Child age
Compliance [mL/mbar]
Newborn
Infants
Small children
3-5
10-20
20-40
Table 11. Standard values for compliance depending on child age
Compliance values for the Simulator:
Compliance [mL/mbar]
1
2
3
5
Table 12. Values of compliance chosen for lung simulator
4.4.1.1.
Screw system
The first idea of how to control compliance, was to apply screw at the
end of the rigid structure and change compliance by turning it. This
system would have successfully restrained bag movement however it
could be only controlled manually. Due to this and also the fact that this
part of the simulator was occupied by spontaneous breathing system, the
idea of screw system was abandoned.
Figure 61. Sketches of screw system for controlling compliance
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4.4.1.2.
Band system
Figure 62. Sketches of band system for controlling compliance
The second idea consisted of band system with the elastomeric band which surrounds the bag
and is fixed to the rigid structure of the bag on the one side. The band would be rolled into
pulley inside the case with each turn of the pulley corresponding to fixed value of compliance.
By decreasing the length of the band constraining the bag, the bag is allowed to move less and
less freely. The movement of the pulley can be controlled remotely which is why this system is
to be applied to proposed lung simulator.
4.4.1.3.
Final design
BAND
PULLEY
BAG WITH STRUCTURE
COMPLIANCE GENERATION
Figure 63. Final design of the system for controlling compliance
The band with pulley system has been chosen because is the system that can adjust the
stiffness of the bag remotely controlled. Depending on the laps of the pulley, the band will
stretch to pull the bag wall closer to the other.
The structure has 4 grooves where the band passes through. In the top face the band is held
from side to side by the grooves in the guides of the piece.
Top grooves
Base grooves
Figure 64 and 65. Grooves in the rigid structure
Holding point of the band
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The first calculation is about the band length. The band length required for the system can be
divided into a few parts:
1) L1 – The part fixed to the pulley
It corresponds to the half of the circumference of the pulley. Since the diameter of the pulley is
d = 25 mm, this part of the band is equal:
* d * π = * 25 mm * π = 39 mm =
2) L2 – The part between pulley and rigid structure of the bag
Since the distance between the outer part of the pulley and upper part of rigid structure is
equal 109 mm, this part is equal 109 - 25 - 50 mm = 34 mm = L2.
3) L3 – The part surrounding the bag itself
This part consists of twice the distance between the upper and lower part of ridid structure
and the width of the rigid structure itself when the band is to be placed (75.5 mm). This first
part can be calculated due to intercept theorem, since the band is placed in the middle of the
length of rigid structure:
=
Where: C = 180 mm
D = 25 + 10 mm (for maximal expansion of the bag for
spontaneous breathing) = 35 mm
B = 82.4 mm
Then:
=
= 16 mm
Thus, this part is equal 2 * 16 mm + 75.5 mm = 91.5 mm = L3
4) L4 – The safety length
In order to ensure that the band does not restrain in any way the movement of the bag, some
extra length is advisable. 10% of the previously calculated length should be enough to make
sure that the presence of the band does not influence in any manner the behaviour of the bag,
unless the specific value of the compliance is required.
(
(
)
)
Finally the whole length of the band can be calculated:
91.5 + 16.5 = 180 mm
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Therefore, the whole band should have 180 mm of length and 12 mm of width, since this is the
width of the space in pulley where the band will be placed.
The expected values of compliance will be obtained by rotating the pulley by a specific angle.
However, those values can only be obtained experimentally due to the relationship between
change in volume and change in pressure that defines compliance. Therefore, this part of
calculations can be only solved after checking behaviour of the prototype with compliance
control system which is not part of this project.
4.4.3. MECHANISM TO ADJUST THE COMPLIANCE
The main elements to be taken into account in this mechanism are a pulley, a motor and an
elastomeric band. Actually, one side of the elastomeric band will be glued or pasted on the
pulley and the other side will be put across the bag which represents the lung. While, the
pulley will be connected to the motor to ensure that it can be rotated perfectly. Once it is
rotated, the band will be stretched more or less depending on the value of the compliance that
is introduced.
Figure 66. Mechanism to adjust compliance
PULLEY
The pulley that will be used in this mechanism is being shown in the following picture. This
design is the most suitable and compatible to be used to create this kind of scenario or in other
words to control the compliance of the lung simulator. Other than that, it could easily roll up
the elastomeric band once the motor is being rotated.
DC MOTOR
This motor is exactly the same as before but only has different length of shaft which is 35mm.
This length is compatible with the length of the pulley, so it can be positioned very well on the
motor without any difficulties.
ELASTOMERIC BAND
This kind of band is so flexible, so it can be stretched out more without having any problems. It
will be placed across the bag and being pulled up by a pulley controlled by a motor.
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4.5.
RESISTANCE CONTROL SYSTEM
Resistance (R) is a measure of airflow resistance and is defined by the pressure difference
between the beginning and end of a tube (ΔP) and the flow of gas volume per time unit (V):
For the pulmonary airways, ΔP corresponds to the difference between atmospheric pressure
inside the mouth and the alveolar pressure. In case of children, the airflow resistance is
considerably higher than for adults, due to anatomical and physiological features of the
respiratory organs which were described in section 2.2.1. In the below table there are
presented normal values for the resistance depending on age of a child:
Child’s age
Newborns
Infants
Small children
Airway resistance [mbar/l/sec]
30 - 50
20 - 30
20
Table 13. Typical values of airway resistance
The values of resistance of the proposed Lung Simulator were provided by Sant Joan de Dèu
Hospital’s doctors in accordance to their needs and experience. Those values are shown in the
table below:
Resistance [mbar/l/sec]
5
20
50
100
Table 14. Values of resistance for lung simulator
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4.5.1.1.
Push and pull system
Figure 67. Sketches of push and pull system for controlling resistance
The first idea of controlling resistance was push and pull system presented below. The system
would have been controlled manually by pushing the bar in order to reach proper diameter
corresponding to different values of airflow resistance. This idea was dismissed after the
meeting with the doctors when we learned that hospital would like to have all parameters
controlled remotely.
4.5.1.2.
Wheel system
Figure 68. Sketches of wheel system for controlling resistance
Second option was the ring with the holes of different diameters which would be rotated in
order to represent specific resistance. This system was decided to be used for the product
because of it can be easily controlled remotely.
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4.5.1.3.
Final design
RESISTANCE WHEEL
TUBE
RESISTANCE CONTROL
Figure 69. Final design of the system to control resistance
The resistance piece is going to be the connector between the lung simulator and the
ventilator. In one side is connected the tube of the simulator and in the other the tube from
the ventilator. Between the two sides the diameter of the interior wheel will determine the
resistance value of the airway.
The tube exterior diameter is 20 mm and the interior is 16 mm. These dimensions have been
considered taking into account the total size of the wheel and the resistance holes. The
ventilator tube has not got an important influence on the dimensioning because it is necessary
to use a connector depending on the mechanical ventilation type as it has been specified in the
requirements analysis section of the report.
DIAMETER OF THE HOLES
To calculate the adjusted diameters for each resistance value there have been taken into
account the following parameters:
-
Length of the tube that represents the airway
Diameter of the tube that represents the airway
Flow of air
Usually, the relationship between airway resistance and radius of the tube can be analysed
using the Poiseuille Law. It can be described by following formula:
Where:
µ - fluid viscosity
L - length of the tube
r - radius of the tube
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Thus, for the simple tube the resistance is inversely proportional to the fourth power of the
radius. However, since inside the tube there is a resistance mechanism designed to influence
airflow, the relationship based on Poiseuille Law is no longer valid.
That is why the values of diameters from resistance mechanisms from existing lung simulator
were measured and analysed in order to propose the conceptual design. The results of these
measurements are presented in the table below:
Resistance [mbar l/s]
5
20
50
200
Diameter [mm]
8
6
4
1
Table 15. Diameters for existing lung simulator
The results of measurements were plotted and function fitting them was found using software
Logger Pro. From the graph, the missing value for 10 mbars l/s can be read:
Figure 70. Curve fit for resistance measurements
Therefore, the values of the diameters for different resistances of the lung simulator were
obtained:
Resistance [mbar l/s]
Diameter [mm]
5
8
20
6
50
4
100
2
Table 16. Diameters for proposed lung simulator
Those values need to be checked experimentally due to the fact that measuring airflow
resistance require measuring simultaneously change in pressure and volume in the bag of lung
simulator. Therefore, the values of the resistances for each chosen diameters are only
approximated and exact values would be obtained by testing the prototype with resistance
mechanism.
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4.5.3. MECHANISM TO CONTROL THE RESISTANCE
To control the airway resistance of the lung simulator remotely, the main components that
have to be included are Geneva Wheel and a DC motor to control the system.
Figure 71. Mechanism to control resistance
GENEVA WHEEL (4 steps)
Figure 72. Mechanism to control resistance: Geneva wheel
In general, the Geneva wheel is a gear mechanism that translates a continuous rotation into an
intermittent rotary motion. The rotating drive wheel has a pin that reaches into a slot of the
driven wheel advancing it by one step. Actually, the type of drive wheel that is shown in the
figure above is an exterior drive wheel.
However, the idea for this kind of mechanism is the same but in this lung simulator the drive
wheel that will be used is an interior wheel; it is a little bit different with that shown in the
previous figure. The following picture shows the real mechanism will be used and the motor
will be connected to the driven wheel which is in red. The motor then will rotate the driven
wheel and automatically the drive wheel will be rotated step by step.
Figure 73. Mechanism to control resistance: Specification
The base contains the
wheels and includes
the tubes connectors.
The drive wheel is
controlled by the
motor and
transforms the
continuous
movement in a step
by step one
The driven piece is
moved in a 90º angle
by the drive Wheel. It
has the different
resistance holes.
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In this mechanism, the airway resistance will be measured by using the internal Geneva
mechanism which is being controlled by a motor.

Equations for the Internal Geneva Wheel: The values of a, n, d and p are being
considered given or assumed.
a = crank radius of driving member
n = number of slots
d = roller diameter
p = constant velocity of driving crank, rpm
b = centre distance = am
D = inside diameter of driven member =
m=
(
√
)
ω = constant angular velocity of driving crank, rad/sec =
rad/sec
α = angular position of driving crank at any time, degrees
β = angular displacement of driven member corresponding to crank angle
√
(
Angular velocity of driven member =
)
[(
Angular acceleration of driven member =
Maximum angular velocity occurs at α = 0° and equals
(
)
)
]
rad/sec
Maximum angular acceleration occurs when roller enters slot and equals
rad/sec2
√
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Given parameters
a = 9mm
n = 4 slots
d = 24.4mm
p = 3750 rpm (same as
motor’s velocity)
Figure 74. Internal Geneva Wheel: parameters

Calculations: The calculations of all the parameters needed to be known of the
internal Geneva wheel.
(
√
)
(
)
√
√
√
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DC MOTOR
This kind of motor actually has the shaft of 7mm long and it is
compatible with the Geneva Wheel. The role of this motor is
to rotate the driven wheel.
The motors for all the mechanisms: resistance, compliance
and leaks are from the same model but with different lengths
of shaft. The picture shows an example of a Direct Current
(DC) motor of Model RE-280 which is approximately 45g of
weight and it is made up of ANSI38 (Aluminium).
This kind of motor is the most suitable to be put in the case of Figure 75. DC motor for controlling
the lung simulator because it is very small, so it does not need resistance
more space to be installed and it is really light. These
characteristics are interrelated with those from the hospital; as a result, the simulator would
be portable. These three motors will be connected to the Arduino Uno electronic board, then
it will be programmed in order to control it remotely.
The following table represents the specifications of the motor that will be used for the lung
simulator. The motor has enough power output to be used in those mechanisms. This type of
motor will be needed a nominal voltage of 1.5V, on other word, it needs at least 1.5V of power
supply in order to ensure it will work perfectly. Moreover, the rotation speed of the motor is
sufficient to rotate the motor together with the load.
MODEL
VOLTAGE
NO LOAD
AT MAXIMUM EFFICIENCY
STALL TORQUE
OPERATING RANGE
NOMINAL
SPEED
RPM
CURRENT
A
SPEED
RPM
CURRENT
A
oz - in
TORQUE
g - cm
OUTPUT
W
EFF
%
oz - in
g - cm
Table 17. Motor specification
90
RE - 280
1.5 – 3.0
1.5V CONSTANT
4600
0.12
3750
0.53
0.16
11.53
0.44
56.2
0.86
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4.6.
LEAKS CONTROL SYSTEM
Air leakage in lungs is a major problem in long-term assisted ventilation both invasive and noninvasive that becomes even more important during sleep. This problem causes the reduction
of air volume introduced in the lung cavity. In this section is presented the system to simulate
the leakage of air in three scenarios: Big, small and no leaks during respiration.
4.6.1.1.
Pull and push system
Figure 76. Sketches of pull and push system for controlling leaks
The first idea was the pull and push system with the bar with holes of different diameters. By
placing the bar in different positions, the air would be allowed to escape the tube or not.
4.6.1.2.
Ring system
Figure 77. Sketches of ring system for controlling leaks
Second idea was based on the ring outside of the tube. When the hole in the ring was placed
near the hole in the tube, the leakage occurred. The position of the ring can be controlled
remotely.
4.6.1.3.
Final design
LEAKS RING
TUBE
LEAKS GENERATION
Figure 78. Final design of the system for controlling leaks
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Leakage will be simulated through the position of the leaks ring. This ring has 2 sizes holes to
simulate big and small leaks that will rotate to match with the orifice in the tube of the
simulator to let the air scape from it. The toothed shape of the ring is to allow the control
through a gear.
Due to the fact that the hospital did not requested specific values of leaks in the simulator, the
values of hole diameters were chosen arbitrarily. The ‘big leak’ is when the air is escaping from
the tube by the hole of diameter 10 mm while for ‘small leak’ this value is 5 mm. The option
‘no leaks’ is when there is no hole in the ring near the hole in the tube.
4.6.3. MECHANISM TO CONTROL THE LEAKS
For this mechanism, there are some components which are really important in order to ensure
the system is working perfectly. Those important components are a leaks ring, a motor and
two gears.
Figure 79. Mechanism for controlling leaks
LEAKS RING
By considering how big the leaks could be, this ring is being designed to have two different
sizes of holes or two holes with different diameters whereas one is small and the other is big
hole. The following ring looks like a gear as it will be controlled by two gears indeed. There
have been used 2 gears instead of one because of the motor position inside the box of the
simulator, if it wouldn’t have been this constraint the ring could be controlled only with one
gear.
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DC MOTOR
As one of the two gears needs to be connected to this motor and suits it well, so the shaft of
the motor has the same length of the gears that is 20mm. This motor will rotate and control
the gear, then the leaks ring will be rotated to open the hole that allows the air from the tube
to go out and simulate the leaks.
GEARS
As there is not enough space to place only one gear together with the motor stacked on it on
an upper side, so this mechanism will be using two gears where one of them is being
connected to the motor and the other one will be placed on the top of that gear and at the
same time the upper gear will be positioned into a plastic stick which is a part of the simulator
case. Those two gears are exactly the same size and have the same number of teeth as well as
the leaks ring. When the motor is turning on, for instant it will start to rotate clockwise.
After that, the gear that is connected to the motor will also start to rotate clockwise. Then, the
second gear which is placed on top of the first gear will begin to rotate on the other way or
anticlockwise and lastly, the effect of the rotation of the second gear will let the leaks ring to
rotate clockwise. For example, the motor should be rotating half of a cycle in order to obtain a
small leak or otherwise it should be rotating one half-cycle more to gain the big leaks.

Type of gear: In this mechanism, the simplest gear that would be used is spur gear. It is
a cylindrical shaped gear, in which the teeth are parallel to the axis and it is the most
commonly used gear with a wide range of applications and it is the easiest to
manufature.

Gear trains: The gear train for this mechanism is the single-stage train with an idler as
shown in the following diagram. There are three gears with different diameters shown
in that diagram but in the real situation, it would be three gears with the same
diameter and number of teeth.
Out
Idler
Gear 3 (z3, n3) Gear 2 (z2, n2)
In
Gear 1 (z1, n1)
Figure 80. Mechanism for controlling leaks: gear trains
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
Gear tooth profiles: For power transmission gears, the tooth form most commonly
used today is the involute profile. Involute gears can be manufactured easily and the
gearing has a feature that enables smooth meshing depsite the misalignment of center
distance to some degree. The table below shows the standard values of module sizes
of the gears and the unit is in mm.
Figure 81. Mechanism for controlling leaks: gear tooth profiles
The real specification of the gear that will be used in this leaks mechanism:
All these information are from the
manufacturing process of the gear

Calculation of gear dimensions: Gear dimensions are determined in accordance with
their specifications. Calculations of external dimensions such as tip diameter are
necessary for processing the gear blanks. Tooth dimensions are considered when gear
cutting.
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The following table represents the calculations for standard spur gear like the one that
will be used in this mechanism.
No.
Item
Symbol
1
Module
Pressure
angle
Number of
teeth
Center
distance
Pitch
diameter
Base
diameter
Addendum
Tooth
depth
Tip
diameter
Root
diameter
m
2
3
4
5
6
7
8
9
10
Formula
α
Example
Gear
1.75
20°
Set Value
z
16
(
a
)
28
d
28
db
26.3114
ha
1.7500
h
3.9375
da
31.5000
df
23.6250
Table 18. Calculations for standard spur gear

Calculation of angular speed output: In this case, those three gears have the same
diameter and number of teeth, so the ratio speed, i is equal to 1. This means that their
angular speeds should be the same value. In this mechanism, the speed of the motor
that will be used is 3750rpm.
(
)
It is important to clarify that the motor has to be check in a future step when it will
have to be programmed the electronic instructions to control the motor in order to
stop it every 90º of rotation to position the ring in the desired position.
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4.7.
CASE AND PRODUCT APPEARANCE
CASE SHAPE
130
278
141
Figure 82. Case shape
The general shape of the lung simulator was decided once all the elements to control each
parameter were chosen.
The compactness of the product was the main principle to take into account for the design of
the whole product, for this reason all the elements had to be included in a closed case. The
total dimensions of the device are the ones shown in the picture.
The shape of the case was conditioned by all the elements that had to be placed inside and by
the dimensions and morphology of the bag with its structure, the most important component
of the simulator.
For dimensioning reasons that have already been detailed, the bag shape is a trapezium that is
located in a structure that facilitates the spontaneous breathing generation.
Considering the cylindrical piece to push the structure up, the bag and to give an appearance
similar to the lung it was designed the structure morphology.
Taking care of the compactness aspect and the shape of the structure, the case has been
designed transforming the shape of the structure into a regular volume in order to make the
product portable, avoiding sharp corners. The result is a cylindrical profile that can contain all
the elements inside.
In order to ease the access to the mechanisms that are inside the case it has been designed a
cap with a joint system provided by its own geometry.
CASE
CAP
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Both, structure and case have been designed thinking about the changing of the bag from the
children size to the neonate bag. Because of this all the elements can be removed from the
case slipping them, thanks to the included slots.
In order to remove the bag is only needed to pull it from the structure but this piece can be
also extracted from the case through the same system.
Figure 83. Elements removal
The following image shows a view of all the main elements of the simulator to specify their
position in relation with the rest of components.
Figure 84. Simulator components
COLOR AND TRIM
The main colour of the product, chosen for the case, is white. It has been
taken into consideration to give a clinical and neat aspect to the product for
being intended to be a medical device.
Since the simulator is supposed to be an innovative product in comparison
with the ones in the market thanks to the remote control technology it has
been applied a brightly green providing the product this connotation.
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For the cap of the simulator it has been chosen the same green tonality but with
a different trim. It is transparent in order to contrast with the case that is
completely white and to break the visual weight concentrated in this piece; this
difference of texture provides the product of visual balance.
The visible structure uses a colour mimesis, as it has been done with its shape,
with the human lungs. It has been chosen this maroon to contrast with the white
case and let the user identify easily which part of the simulator represents the
lung cavity.
GRAPHICAL ELEMENTS
The case of the product includes useful graphical information for the user to identify the parts
of the simulator they must interact with.
Figure 85. Graphical elements of the case
In one side of the case there are the elements related with the power source of the device: the
power button and an USB plug to charge the device before being used. The black icons inform
the user about the functions of the elements.
Figure 86. Power icon
On/off button is illuminated when is pressed alerting that the simulator is functioning. Once it
is disconnected the button turns off.
Figure 87. Battery status icons
The information of the battery state will be shown in the remote, but is also indicated in the
simulator using a LED button under the USB groove. The LED will be red if it is out of energy, an
orange flashing light if it starts to be low of battery and green to indicate when it is charged.
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Figure 88. Spontaneous breathing icon
Figure 89. Leaks and resistance icons
The fitting to introduce the tube for the spontaneous breathing generation is pointed by a
pictogram that represents this parameter in order to inform the user. The same method is
applied for the control of the leaks and resistance to ensure that in case the device had to be
controlled manually the user would not confuse the elements. The iconography is explained in
the design of the remote interface description.
INTERIOR MECHANISMS OF THE CASE
The following image shows the position of the mechanical elements inside the box and the
position between them. All the elements are fixed in the box by subjection elements that have
been selected. All of them are extrusions in the box to ensure that they cannot be moved fixed
with screws in their corresponding cover. The dimensions of those pieces are in the technical
drawings in the ANNEX.
LEAKS
RINGWHEEL
GENEVA
ELASTOMERIC
BAND
ELECTROVALVE
MOTOR
RESISTANCE
GEARS
CYLINDER
MOTOR MOTOR PULLEY
LEAKS COMPLIANCE
Figure 90. Interior mechanisms of the case
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Box for electronic
components
Subjection of the elements
Figure 91. Placement of the elements inside the case
The three motors that the simulator has, are attached by extruded parts of the case that
addapts to their shape and is fixed with a piece by 4 screws, as shown in Figure 92. All the
elements that need to be hold are fixed to the case ensuring the proper functioning and also
easy disassembling.
Figure 92. Subjection piece for motors
Figure 93. Bottom view of the case to show subjection elements
Figure 94. Subjection piece for the cylinder
These images show the pieces used to attach the motors and the cylinder in the case.
The screws are M2 0.4 of nominal diameter. The length varies according to the
element to fix.
Subjection pieces technical drawings are in the ANNEXES for more information.
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4.8.
THE REMOTE CONTROL
4.8.1. SELECTION OF THE SYSTEM
TABLET/SMARTPHONE
Figure 95. Design of the remote
In order to control the lung simulator remotely it has been chosen to use a tablet or
smartphone through an application considering that the lung simulator has been designed to
be controlled through ARDUINO.
CONNECTIVITY
Bluetooth is a brand name of a wireless networking technology which uses short-wave radio
frequencies to interconnect cell phones, portable computers, and other wireless electronic
devices over short distances.
Figure 96. Principle of Bluetooth technology
A fundamental advantage of Bluetooth wireless technology is its ability to simultaneously
handle data and voice transmissions. This feature, among other beneficial qualities like low
cost and low energy consumption, means that there are many applications of Bluetooth
technology including:



Wireless control and communication between mobile and hands-free headsets
Wireless networking between multiple computers in areas with limited service
Replacement of conventional wired communication, like GPS receivers, medical
equipment, traffic control devices and bar code scanners
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




For low-bandwidth applications, when a higher USB bandwidth is not desired
Managing short-range data transmission between medical and other tele-health
devices
Mobile phone communication with digital enhanced cordless telecommunication
(DECT)
Identifying and tracking object positions with the real-time location system
Tracking livestock and prisoner movement
Due to the widespread usage of Bluetooth technology in almost the whole globe, any
Bluetooth enabled device can connect to other Bluetooth enabled devices located in close
proximity to each other. The wireless communication between these devices is possible thanks
to the piconets which are short-range, ad hoc networks. Piconets are established in dynamic
and automatic manner depending on if the devices are within radio proximity which means
that connection and disconnection is up to users’ convenience. Each device in a piconet can
simultaneously communicate with up to seven other devices within that single piconet and it is
also possible to one device to belong to several piconets at the same time.
Bluetooth technology operates in the unlicensed ISM band (industrial, scientific and medical
band) at the frequency between 2.4 and 2.485 GHz. It uses a spread-spectrum, frequencyhopping, full-duplex signal at a nominal rate of 1600 hops/sec. The 2.4 GHz ISM band is
available and unlicensed in most countries.
There are two elements required in order to make the lung simulator the Bluetooth enabled
device. One of them is connecting a Bluetooth board to Arduino and the other is Android
application to control the board. Below, the Arduino scheme and picture of one of possible
applications - BlueTerm are presented:
Figure 97. Scheme with Bluetooth board
Figure 98. BlueTerm application
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4.8.2. INTERFACE DESIGN
Simulator battery
Exit icon
Selection of
the resistance
Selection of
the leaks
Selection of
the compliance
Activation and
adjustment of
The spontaneous
breathing
Figure 99. Interface design
ICONOGRAPHY
Figure 100. Iconography of the interface
There has been selected an icon that represents the lungs to be used as the image that
indicates the different parameters to control applying referential points that indicate the
parameter adjusted:
-
RESISTANCE: It has the airways marked because is the part of the lung where the
resistance changes.
COMPLIANCE: Referring to the lung walls because the compliance depends on the
elasticity of the lungs’ bag.
LEAKS: The coloured zone means the air escaping due to the leak.
SPONTANEOUS BREATHING: A child with green narrows that indicates the moment
when the patient starts recovering his breathing.
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-
BATTERY INFO: The energy source of the simulator is a battery, so it is necessary to
inform the user through the interface the level of energy that the simulator has.
EXIT: It closes the application.
FUNCTIONING
Figure 101. Interface:
compliance
The interface is divided in the 4 parameters to be controlled by the user. Once inside
the application, the icons inform about the parameter to control and this has a button
for each established value.
In the case of resistance, leaks and compliance the user only has to tap in the value
that is wanted to be applied in the simulator and the signal will be sent to the device.
For spontaneous breathing, due to be a parameter that can be or not activated there is
an on/off option. When the spontaneous breathing is selected, the user can adjust the
breathing per minute from 10 to 70.
Figure 102. Interface:
spontaneous breathing
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5. MATERIALS AND MANUFACTURING PROCESS
In this section the process for choosing the materials for each component of the lung simulator
is presented, also the most important characteristics, the manufacturing process, the final
weight for each part and what the cost will be, these two final elements will be found in the
Appendix part of the project.
An Eco-Audit analysis will be made to see the impact of these materials on the environment,
specifying that these materials were elected based on their Eco properties and this analysis will
be found in the Appendix as well.
5.1.
BAG
Figure 103. Bag
5.1.1. REASONS FOR CHOOSING THE MATERIAL
The material wanted for the bag is the silicone rubber because of its excellent mechanical,
thermal and electrical properties. It offers good resistance to extreme temperatures, some
properties such as elongation, creep, cyclic flexing, tear strength, compression set, dielectric
strength(at high voltage), thermal conductivity, fire resistance and in some cases tensile
strength can be—at extreme temperatures—far superior to organic rubbers in general,
although a few of these properties are still lower than for some specialty materials.
Silicone rubber is a material of choice in industry when retention of initial shape and
mechanical strength are desired. Silicone rubber is highly inert and does not react with most
chemicals. Due to its inertness, it is used in many medical applications.
Silicone and flour-silicone elastomers have long chains of linked O-Si-O-Si group (replacing the
C-C-C-C- chains in carbon-based elastomers), with methyl (CH3) or fluorine (F) side chains.
Silicones are based on the repetition of silicon and oxygen in the polymer chain; it can be used
as an elastomer or a thermoset.
Additionally, this material had improved fatigue properties as evaluated using a torsion-fatigue
test.
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ADHESIVE
For the lung simulator an adhesive is needed to bind the bags with their surrounding structure,
which together will go in the rigid structure.
The use of adhesives offers many advantages such as the ability to bind different materials
together, to distribute stress more efficiently across the joint, the cost effectiveness of an
easily mechanized process, an improvement in aesthetic design, and increased design
flexibility.
The best choice in this case was considered to be Bisphenol B epoxy resin which is a
thermosetting product known for its excellent surface and sub-surface adhesion, mechanical
properties and chemical resistance. The system is made up of an epoxy resin and a hardener
(catalyst) and it also contains organic solvents, fiberglass and pigments.
RIGID PART SURROUNDING THE BAG
Because the bag comes in two sizes and will be switched according to the doctor’s needs, a
system was required that could facilitate the change in a very fast and easy way. The proposed
solution consists of two rigid sides that will be attached to the bag using the proper adhesive
and these parts will be placed in the rigid structure with the help of the two brackets
positioned on each side of the rigid structure. The concept of the two rigid surfaces glued to
the bag allows a very easy inflation or compression and the size for each one was selected in
order to adapt the morphology of both to the final lung simulator.
The material chosen for the two sides is HDPE, the same as for the rigid structure, in order to
avoid friction. HDPE has excellent mechanical properties and after a stress analysis done with
the program NX it was proven that the shock wasn’t very big and the structure wouldn’t break.
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5.1.2. PROPERTIES
Odourless and tasteless, silicone rubber is prized by many industries for its inherent inertness.
Its attributes make it ideal for the medical industries, where silicone rubber is used in bottle
nipples, conveyor belting, tubing and even implants.
General
properties
Density: 1.3e3
– 1.8e3 kg
(m^3)
Price: 12.9 –
14.2 USD/kg
Mechanical properties
Thermal properties
Processability
Young’s modulus: 0.005 –
0.02 GPa
Glass temperature: -123
- -73.2 ⁰C
Castability: 4 – 5
Shear modulus: 0.002 –
0.0066 GPa
Maximum service
temperature: 227 – 287
⁰C
Minimum service
temperature: -73.2 - 48.2 ⁰F
Moldability: 4 – 5
Yield strength (elastic limit):
2.4 – 5.5 MPa
Tensile strength: 2.4 – 5.5
MPa
Machinability: 2 – 3
Weldability: 1
Compressive strength: 10 –
30 MPa
Elongation: 80 – 300 %strain
Fatigue strength at 10^7
cycles: 2,28 – 4 MPa
Fracture toughness: 0.03 –
0.5 MPa*m^ (1/2)
Table 19. General properties of silicone rubber
Eco properties
The use of silicones, siloxanes and silanes generates energy savings and greenhouse-gas emission
reductions that outweigh the impacts of production and end-of-life disposal by a factor of 9. Also
striking is that a relatively small quantity of silicone, siloxane or silane can lead to a comparatively
large increase in the efficiency of processes and the use of energy and materials. Examples include
high-performance thermal insulation products, foam-control agents for washing, paint additives that
increase the durability of vehicles and construction materials, and silanes used to reduce the rolling
resistance of tyres.
Table 20. Eco properties of silicone rubber
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5.1.3. MANUFACTURING PROCESS
The process through which the bag is obtained is injection moulding due to its several
advantages like a fast production, material and colour flexibility, labour costs low, design
flexibility and low waste.
Figure 104. Manufacturing process of the bag
Injection moulding is a manufacturing process for producing parts by injecting material into a
mould.
Material for the part is fed into a heated barrel, mixed, and forced into a mould cavity where it
cools and hardens to the configuration of the cavity. After a product is designed, usually by
an industrial designer or an engineer, moulds are made by a mould maker (or toolmaker) from
metal, usually either steel or aluminium, and precision-machined to form the features of the
desired part. Injection moulding is widely used for manufacturing a variety of parts, from the
smallest components to the biggest ones.
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5.2.
RIGID STRUCTURE
Figure 105. Rigid structure
The desired material for the structure that surrounds the bag is HDPE (high-density
polyethylene) due to the fact that it exhibits a higher capacity for tolerating surge pressures.
The unique performance characteristic of the HDPE polymer chains disentangling under
sudden stress and then returning at its normal state, provides the HDPE with the ability to
absorb some of the energy generated by the pressure surge.
5.2.2.
PROPERTIES
It is very used in the industry due to its several advantages like the low price, impact resistant
from -40 C to 90 C, moisture resistance, good chemical resistance and readily processed by all
thermoplastic methods.
General
properties
Density:
952 – 965
kg/m^3
Price:
1.76 –
1.94
USD/kg
Composition overview
1.09 GPa
Base: polymer 100%
Shear modulus: 0.377 –
0.384 GPa
Polymer class:
thermoplastic semicrystalline
26.2 – 31 MPa
Polymer type full name:
Polyethylene, high
density
Filler type: Unfilled
Tensile strength: 22,1 – 31
MPa
Compressive strength: 18,6
– 24,8 MPa
Elongation: 1,12e3 – 1,29e3
%strain
cycles: 8,84 – 12.4 MPa
1.82 MPa.m^0.5
Eco properties
Embodied energy; primary
production: 90.3 – 99.9
MJ/kg
CO2 footprint, primary
kg/kg
Water usage: 167 – 185
l/kg
Table 21. General properties of high-density polyethylene
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Because of many advantages of the process like the fact that it is continuous and has high
production volumes, low cost per pound, efficient melting and good mixing the best option, for
this part is the polymer extrusion.
Figure 106. Manufacturing process of rigid structure
Every extrusion process has eight main steps:
1. Pre-treatment of extruded material which includes drying of materials, feeding of
additives and preheating.
2. The material is put into the extruder through the throat.
3. Force the feeders if the process is difficult or needs to be constant.
4. The raw material is conveyed from the feeding zone to the die, in this case it is very
important that the friction between the screw is lower than the friction between the
cylinder.
5. The melted material is pumped through the die into the final form.
6. The next step is to calibrate the extrudate in the final dimensions and form.
7. Post-processing of extrudates.
After the extrusion is finished, the machining process will begin in order to make the hole
through which the tube will go.
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5.2.4. SIMULATION ANALYSIS OF RESISTANCE
Figure 107. Simulation analysis of resistance
The result of the stress distribution on the structure obtained from the simulation where the
structure withstands the maximum stress around the red areas. With that amount of force
applied to the structure, it seems that it would not be broken. In this case, the maximum stress
is 6.09MPa.
CROSS-SECTIONAL AREA OF THE STRUCTURE
-
Material: High Density Polyethylene (HDPE)
-
Young’s Modulus: E = 1000MPa
-
Poisson’s Ratio:  = 0.4
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Figure 108. Cross-sectional area of the structure

Calculation
Section
Moment of Inertia
Shear Modulus
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Bending Moment
M=F·x
Shear Force
Diagram of Moment and Force
Diagram of bending moment
Diagram of shear force
Maximum Normal Stress (Navier’s Law)

M
.y
Ix
(
)
Shear Stress

T
.m
b.I x
(
(
)
)
(
(
)
)
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Diagram of Stress
(
)
Neutral axis
(
)
In order to reach the maximum expansion volume of the bag which is 250ml, the rigid
structure if the lung simulator should be displaced or moved up by 10mm from the original
position by the piston in this mechanism. This means, the piston should be applied by a
sufficient force to achieve that displacement. As shape of the piece is very complicated, so the
calculation of the amount of force that is needed to be applied to the piston cannot be done
theoretically. On the other words, it has to be done by doing the simulation through the
software (Solidworks or NX). During the simulation, the value of force needs to be assumed
until it gives the displacement of the structure approximately 10mm.
Afterwards, once the value of that force is known, the calculation of the stresses, bending
moment and shear force could be done easily by applying those formulas. But before that, to
be able to do that calculation, the moment of inertia and the shear modulus need to be
calculated first.
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5.3.
TUBE
Figure 109. Tube
The best option for this element is considered to be PVC (Polyvinyl chloride) with 20% glass
fibre that has extrusion as its manufacturing process.
PVC is used in many critical applications such as in medical products, for example blood and
intravenous bags as well as many of the tubes and catheters used in hospitals throughout the
world.
5.3.2. PROPERTIES
General
properties
Density:
1,43e3 –
1.5e3
kg/m^3
Price: 2.4 –
2.79
USD/kg
Eco properties
Young’s modulus: 4,69 –6,69
GPa
Base: polymer 100%
production: 54,4 – 60,2
MJ/kg
Shear modulus: 1.71 – 2,44
GPa
Polymer class:
thermoplastic
amorphous
Acrylonitrile butadiene
styrene
production: 2.5 – 2.76 kg/kg
47.4 – 70,6 MPa
Tensile strength: 59.3 –
88,3MPa
Compressive strength: 56.9 –
84.8 MPa
cycles: 23.7 – 35.3 MPa
3.27 MPa.m^0.5
HV: 14.2 – 21.2 HV
Table 22. General properties of polyvinyl chloride
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Considering the shape of this part, the easiest process through which it could be manufactured
is extrusion.
Figure 110. Extrusion process
The extrusion process is a very simple one and that is why it represents a great choice in this
case. It begins with the pre-treatment of the material which includes drying the PVC, adding
additives and preheating it. Next the material is put in the throat of the extruder and the raw
material is conveyed from the feeding zone to the die. The melted material is pumped through
the die into the final form where the calibration of the extrudate takes places and the final
step is the post-processing of the extrudate.
Once the extrusion is done and the tube is out a machining process will start in order to obtain
the hole with which the leak parameter is shown.
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5.4.
ELEMENT TO CONTROL LEAKS
Figure 111. Element to control leaks
The ABS (Acrylonitrile Butadiene Styrene) makes an ideal choice because of its excellent
impact resistance, its good appearance for design purposes, a moderate strength and a good
flow. It is also a recyclable material and easily extruded and injection moulded, two very
important aspects to take into consideration when choosing a material.
5.4.2. PROPERTIES
The final properties will be influenced to some extent by the conditions under which the
material is processed to the final product. For example, moulding at a high temperature
improves the gloss and heat resistance of the product whereas the highest impact resistance
and strength are obtained by moulding at low temperature. The aging characteristics of the
polymers are largely influenced by the polybutadiene content, and it is normal to
include antioxidants in the composition.
General
properties
Density:
1,03e3 –
1.06e3
kg/m^3
Price:
2.84 –
3.13
USD/kg
Eco properties
2.76 GPa
Base: polymer 100%
MJ/kg
Shear modulus: 0.74 – 0.987
GPa
Polymer class:
thermoplastic
amorphous
kg/kg
34.5 – 49.6 MPa
styrene
l/kg
51.7 MPa
Compressive strength: 39.2
– 86.2 MPa
cycles: 15.2 – 20.7 MPa
Table 23. General properties of Acrylonitrile Butadiene Styrene
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ABS is an amorphous thermoplastic copolymer blended from Acrylonitrile, Butadiene and
Styrene. Being an amorphous thermoplastic, it is easily extruded and by this the highest
impact resistance and strength are obtained.
There are numerous advantages to ABS extrusion such as good electrical properties, impact
resistance, combines strength, rigidity and toughness in one material, excellent load stability
and is lightweight.
For the actual manufacturing process there are some easy steps to follow, as I said before.
First, the material is fed into the throat, moved from one zone to the other and pumped
through the die into the final form.
The leaks ring needs to undertake a machining process to get two holes through which air will
pass.
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5.5.
ELEMENT TO CONTROL RESISTANCE
Figure 112. Element to control resistance
For the element that will control the resistance it was chosen the same material as for the
leaks rings, this being ABS, because the two are located on the same tube and need to have
similar characteristics. As it was said before, ABS has many advantages such as dimensional
stability, toughness-even at low temperatures, chemical resistance and that is why it is a
perfect choice for this part as well.
5.5.2. PROPERTIES
The ABS three monomer systems can be tailored to yield a good balance of properties.
Basically, styrene contributes ease of processing characteristics, acrylonitrile imparts
chemical resistance and increased surface hardness and the butadiene contributes
impact strength and overall toughness.
General
properties
Density:
1,03e3 –
1.06e3
kg/m^3
Price:
2.84 –
3.13
USD/kg
Eco properties
2.76 GPa
Base: polymer 100%
MJ/kg
GPa
Polymer class:
thermoplastic
amorphous
kg/kg
34.5 – 49.6 MPa
styrene
l/kg
51.7 MPa
– 86.2 MPa
cycles: 15.2 – 20.7 MPa
4.29 MPa.m^0.5
HV: 10.4 – 14.9 HV
Table 24. General properties of Acrylonitrile Butadiene Styrene
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Due to its light weight the ABS has two possibilities regarding manufacturing, injection
moulding and extrusion. The best option in the case of the element that controls the
resistence is the injection moulding.
The process of injection is very easy to do, in four steps:
1. Granules of ABS are fed to a hopper that
stores them until it is needed.
2. Due to the heater that heats up the tube
until it gets to a high temperature, a screw
thread starts turning.
3. The thread is then turned by a motor
and pushes the ABS granules along the heater
section which melts then into a liquid. The liquid
is forced into a mould where it cools into the
desired shape.
4. The final step consists in the opening of
the mould and recovering the unit.
Figure 113. Manufacturing process for the element
controlling resistance
When the product is cooled, through the machining process, the four holes that show
different resistances will be made.
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5.6.
ELEMENT TO CONTROL COMPLIANCE
5.6.1. REASONS FOR CHOOSING THE MATERIALS
5.6.1.1.
BAND
For this element used in the control of compliance a material with great wear
properties is needed, also it must have good mechanical and impact properties, it
should be self-lubricating and abrasion resistant, extremely durable. For these
reasons and many more, PA (Polyamide) or better known as nylon represented the
optimal solution.
Figure 114. Band
5.6.1.2.
PULLEY
The material used for the pulley is PEEK (Poly ether ether ketone), which
is a semi-crystalline thermoplastic with high tensile strength, stiffness,
good wear resistance, low coefficient of friction, excellent chemical
resistance and very low moisture absorption. This broad range of useful
properties in addition to its ability to retain them over a long period
under elevated mechanical stress and demanding environmental
conditions make it a premium choice for this application.
Figure 115. Pulley
5.6.2. PROPERTIES
5.6.2.1.
General
properties
Density:
1,22e3 –
1.24e3
kg/m^3
Price: 5.26 –
5.79 USD/kg
BAND
Eco properties
Young’s modulus: 3.13 – 3.91
GPa
Base: polymer 85%
production: 107 - 118
MJ/kg
Shear modulus: 1.26 – 1.33 GPa
Polymer class:
Polyamide/nylon 6
Filler type: Glass fiber
15%
kg/kg
l/kg
68.5 – 85.5 MPa
Tensile strength: 63.9 – 78.1
MPa
Elongation: 8.44 – 12.1 %strain
Fatigue strength at 10^7 cycles:
27 – 29.8 MPa
Fracture toughness: 3.94 – 4.36
MPa.m^0.5
Table 25. Properties of Polyamide
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5.6.2.2.
General
properties
Density:
1,3e3 –
1.32e3
kg/m^3
Price: 99.1 –
109 USD/kg
PULLEY
Eco properties
GPa
Base: polymer 100%
production: 101 - 111 MJ/kg
GPa
Polymer class:
Poly ether ether ketone
kg/kg
87 – 95 MPa
Tensile strength: 70.3 – 103
MPa
130 MPa
cycles: 28.1 – 41.2 MPa
4.3 MPa.m^0.5
Table 26. General properties of Poly ether ether ketone
5.6.3.1.
BAND
Nylon is made through a complex two-step chemical and manufacturing process that first
creates the fibre’s strong polymers, then binds them together to create a durable fibre.
The first thing that needs to be done is to combine two sets of molecules. One set has an acid
group on each end and the other set has an amine group, made up of basic organic
compounds, on each end. When these two substances are combined, thick crystallized “nylon
salts” result. These are commonly known as nylon 6, 6 or simply 6-6. The name is based on the
number of carbon atoms between the two acid groups and the two amine groups.
The crystals that result must be soaked in water to dissolve them, then acidified and heated to
create a chain that is nearly unbreakable on a chemical level.
A specially designed machine must be used to get the polymers heated to the right
temperature, and then combine the molecules to form a molten substance that is forced into
a spinneret, separating it into thin strands and exposing it to air for the first time. The air
causes the strands to harden immediately, and once they are hard they can be wound onto
bobbins. The fibres are stretched to create strength and elasticity, which is one of the
material’s main benefits.
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From here the filaments are unwound and then rewound onto another, smaller spool. This
process is called drawing and is used to align the molecules into a parallel structure. The
strands that result are multipurpose threads that can be used for a variety of different
purposes. They can be woven or bound as they are, or they can be combined and further
melted.
After the material has been wound onto the smaller spool, it is ready to be turned into the
band needed for the lung simulator and this is done through the extrusion process explained in
detail before.
5.6.3.2.
PULLEY
Because the pulley needs to have certain dimensions to fit in the proposed case it needs to be
specially manufactured for the lung simulator. The process through which this is done is
injection moulding that represents the best solution due to its several advantages that were
named before.
Plastic material which has the form of small pellets is fed into the unit and after heated
transforming them from a solid state to a liquid one. After reaching the right temperature, the
hot molten plastic is forced into the mould where a screw controls the pressure and speed of
this phase of the process. This phase is called the dwelling phase, which ensures that the
mould cavities are completely filled before cooling begins. The next and final step is the
cooling one after which the object is released and the process begins all over again.
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5.7.
CASE
Figure 116. Case
For the box that will contain all the mechanisms a material very resistant, but also flexible was
needed, so PC (polycarbonate) with 10% glass fibre was considered the best option. Some of
the advantages of this material are: lightweight, polycarbonate has a very high stiffness to
weight ratio; durable, PC has UV inhibitor co-extruded on the outer surface which prevents the
radiations from penetrating the sheet, meaning a longer life and prevention of yellowing and
deterioration; damage resistance, polycarbonate has impact resistance up to 200 times
stronger than glass.
5.7.2. PROPERTIES
General
properties
Density:
1,27e3 –
1.28e3
kg/m^3
Price:
4.99 –
5.49
USD/kg
Eco properties
4.14 GPa
Base: polymer 90%
production: 101 - 111
MJ/kg
GPa
Polymer class:
thermoplastic
amorphous
kg/kg
Yield strength (elastic
limit): 58.6 – 69 MPa
Tensile strength: 48.3 – 69
MPa
– 96.5 MPa
cycles: 19.3 – 27.6 MPa
4.51 MPa.m^0.5
Polycarbonate
Filler type: Glass fiber
10%
l/kg
Table 27. Properties of polycarbonate
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The process used to manufacture the case is injection moulding and there are several things to
take into account when working with this type of machine, like the ones presented next.
Polycarbonate tends to lose heat from the melt to the mould, barrel, nozzle and air faster than
most plastics, which can lead to “delamination” when processing polycarbonate. Due to
thermal diffusivity, polycarbonate temperatures can be difficult to control. Proper
temperature control constants can help reduce the time needed to stabilize the process after
start-up and help melt temperature override. The optimal temperature control system for
polycarbonate products features high density, high response mineral-filled bands and an auto
tune controller. It is very important the temperature control zone used for the end cap of the
barrel.
End cap designs on older machines often have many transitions in the flow path, which can
“shear” the polycarbonate and cause degradation. Such end caps typically don’t seal well
against the higher pressures of a polycarbonate process. Newer designs have only three
consolidated components, including the nozzle tip, and a constant taper flow path for a more a
streamlined delivery.
Polycarbonate products will not mould well on a machine that has the “general purpose”
olefin screw. These screws tend to develop material degradation in the rapid compression
(transition) sections. Screws with moderate feed lengths (7 turns) and long, gentle
compression sections (8-10 turns) may process more efficiently.
Also, the non-return valve (NRV) portion of the screw is not universal. For example, the correct
valve for polypropylene can cause shear heating of polycarbonate products and require “suckback” to seat.
Polycarbonate products tend to adhere to high iron alloys and in pitted metals. Therefore, the
screw should be plated to create a smooth surface and reduce contact with the screw base
metal.
Without careful purging, polycarbonate materials can “weld” together two pieces of steel. The
valve can break off when the screw is turned because it has become “welded” to the end cap.
Or, if the screw is not allowed time to warm up before it is turned, the melted material can
become glue-like and pull the plating off the screw. To avoid these problems, the machine
should be thoroughly purged after manufacturing polycarbonate products.
Drying polycarbonate can be a challenge since the pellets tend to adsorb moisture rapidly from
the plant air during transport to the machine and while waiting to be moulded. Moulding
undried polycarbonate not only causes splay, it destroys some physical properties like tensile
and impact strength. For optimal performance, polycarbonate products should be dried to less
than 0.02% moisture with a desiccant drier.
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5.8.
CAP
Figure 117. Cap
A thing that must be mentioned is that the cap will be removed and put back as often as
needed, depending if the professor will need to check some mechanism or replace a part if it is
broken. The chosen material is the same as for the box, but it will have besides the base of
polymer 5% silicone to give a little flexibility in order to avoid future cracking from overuse.
5.8.2. PROPERTIES
The advantage in combining these two materials is the maintenance of inherent benefits of
polycarbonate-based urethanes, including high pressure resistance; tensile-strength and
superior chemical resistance combined with silicone’s industry recognized advantages such as
heightened elongation, superior elasticity and a low coefficient of friction.
General
properties
Density:
1,45e3 –
1.47e3
kg/m^3
Price: 4.59
– 5.58
USD/kg
Eco properties
GPa
Base: polymer 65%
MJ/kg
GPa
Polymer class:
thermoplastic amorphous
84 – 92.8 MPa
Tensile strength: 105 – 116
MPa
Polycarbonate
Filler type:
Glass fiber 30%
Silicone 5%
kg/kg
111 MPa
Elongation: 3.47 – 3.74
%strain
cycles: 38.8 – 50.4 MPa
5.53 MPa.m^0.5
Table 28. Properties of polycarbonate
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In its natural state polycarbonate raw material is clear granules. Due to its excellent properties
it has many applications, one of them being a casing or in the present case the cap of the box.
The chosen manufacturing process for this part is the injection moulding, because it is more
efficient then extrusion, the material loss is smaller and you can make more parts with the
same mould.
The process was explained before because it was chosen for most parts of the lung simulator
but to sum up, with injection moulding granular plastic is fed by gravity from a hopper into a
heated barrel. As the granules are slowly pushed forward by a screw-type plunger, the plastic
is forced into a heated chamber called the barrel where it is melted. As the plunger advances,
the melted plastic is forced through a nozzle that seats against the mould sprue bushing,
allowing it to enter the mould cavity through a gate and runner system. The mould remains at
a set temperature so the plastic can solidify as soon as the mould is filled.
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6. PROTOTYPE TESTING
In order to provide the project of a practical result, it was developed a first prototype to test
the Spontaneous Breathing function. The purpose for doing this prototype was to test the
proper functioning of the remote control of the pneumatic system controlled through a
Bluetooth application from the mobile phone. Initially it was desired to test the resistance of
the rigid structure but considering that it was not possible to print it with the final real material
the results wouldn’t be as reliable as it must, even though it was printed layer by layer and
with a less resistant material, the structure resists in terms of fatigue the application of the
cylinder strength, what it can ensure the success of the real future piece.
6.1.
COMPONENTS OF THE PROTOTYPE
1.
Rigid structure: This white rigid structure as shown in the figure on the right side is being
printed with a sophisticated 3D printer to be having in the prototype testing of one of the
functionalities of the lung simulator which is the spontaneous breathing mechanism.
Actually, this piece is being placed on a box which represents the case of the real lung
simulator and it is stuck on that box to ensure it will not move during the testing.
2.
Piston: The piston or cylinder that is being used in the prototype is
different with the one that will be used in the real product which
has the series name DSNU-10-25-P-A because there is none of the
unused pistons in the automation laboratory of the university
which is exactly the same as the proposed one. As soon as it is
working without any problems, so it can be used as the real one.
One more difference of that piston is that it has the stroke of
25mm instead of 35mm like the real one. In the prototype, this
piston is placed inside the box which is directly vertically under the
rigid structure and it is connected by two tubes to the proportional
valve to let the air from the compressor enters the piston once the
valve is opened.
Figure 118. Prototyping: piston
3.
Cylinder plate: This object is being placed at the end of the piston
stroke to avoid the stroke from being pushed up towards the
rigid structure directly on the structure’s surface. Besides, it is
also to make the structure being pushed up easily by the piston
by having the cylinder plate on the stroke. Actually, this cylinder
plate is a little bit higher than the one that will be used in the real
product because the length of the stroke is not long enough to
push up the structure until a certain height as wanted as in the
real design. So, by having the cylinder plate with a bit higher, it
could be more helpful.
Figure 119. Prototyping: cylinder plate
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4.
Arduino Uno: Arduino is actually a single-board microcontroller
to create the application of interactive objects or environments
more accessible. The hardware consists of an open-source
hardware board that has been designed around an 8-bit Atmel
AVR microcontroller, or a 32-bit Atmel ARM. The feature of the
current models includes a USB interface, 6 analog input pins, as
well as 14 digital I/O pins that allows the user attaching various
extension boards.
Figure 120. Prototyping: Arduino Uno
The picture beside shows the current model of the Arduino electronic board available in the
market nowadays. This electronic device is one of those low-costs out there. This idea has
been selected to create the system that can be controlled remotely whether by Bluetooth
system or any other system compatible with this kind of electronic board.
Furthermore, in the real situation, this board will be placed into
the case of the lung simulator together with other components
and parts but before that, it will be programmed first according
to how the system will be working to create those scenarios;
resistance, compliance and leaks of the lung simulator.
In addition, the aside picture represents the Arduino and Figure 121. Prototyping: electronic board
other electronic boards which are being connected with a
Bluetooth receiver and after that it will be connected to
proportional valve in order to control the airway to enter the
piston. This board also is being connected to a power supply
with 24V.
The good is the user can connect and control it by installing
the Arduino application available for Android and Apple in the
market store named ‘BlueTerm’. So, the system can be
handled remotely easily.
Figure 122. Prototyping: BlueTerm app
5.
Bag: The bag that is being used in the prototype is totally different
from the real one. In this prototype, the bag is not made from
silicone rubber but paper. It is just to show how actually the real
bag in the final product will be working. This bag is being glued in
between the rigid structure as shown in the figure.
Figure 123. Prototyping: bag
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6.
Box: The box actually represents the case of the lung simulator which is being used to place
the piston with cylinder plate inside it and the rigid structure with the bag on top of it. This
box is used just to assemble some components and to ensure they are placed in correct
position in order to make it works perfectly.
7.
Proportional valve: This kind of valve is used to control the
airway from the compressor to the piston. It is connected
to the piston by two tubes as represented in the figure
which is in colour blue.
Figure 124. Prototyping:
Proportional valve
6.2.
FUNCTIONING OF THE SYSTEM
Figure 125. Prototyping: laboratory system
Firstly, all the components of the lung simulator need to be set up correctly in their position as
the figure shows and the compressor must be turned on to let the air enters the system
through the piston. The Arduino board must be connected to a battery of 9V to supply the
voltage, while the electronic board with the Bluetooth receiver needs another source of power
of 24V for the valve to be functioned perfectly. Then, the two tubes have to be connected to
the piston and the proportional valve as well.
Once all the components are connected properly and all the sources of power are switched on,
the LED from the Bluetooth receiver will be blinking as there is no device connected to it yet.
The only thing to be done is to connect this application to the Bluetooth receiver on the
Arduino by turning on the Bluetooth sign on the smartphones or tablets and then connect
them. When the two devices are properly connected, the LED from the Bluetooth receiver will
stop blinking.
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After that, the application will only detect two capital letters which are ‘E’ and ‘H’. These two
letters have their own meaning which ‘E’ means ‘ON’ and ‘H’ means ‘OFF’. When the letter ‘E’
is being pressed, the piston will be pushing up the rigid structure to a certain height and, once
the letter ‘H’ is selected, the piston will be going down and the system will be going back to its
original position.
The flow of the air that enters the piston can be controlled, whether slower or faster, by
adjusting the two screw adjusters on the piston in order to control the speed of the piston that
pushes up the rigid structure.
Finally, the system needs to be shut down by unplugging the power supplies, disconnecting the
Bluetooth between the two devices, switching off the compressor and keeping all the
components safely once the prototype is not being tested anymore.
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7. PRODUCT DEVELOPEMENT
In the product development chapter a cost analysis is made of the whole system. It is
important to take into account that the calculations in this chapter are done to estimate the
production and sale cost of the LS system and the numbers are estimated.
7.1.
MARKETING MIX
For a product to be successful at the launch time, it is required to address aspects related to
the product marketing innovation. After the cost analysis and market study several things will
be noticed such as the type of approach of the market and suitable market for Lung Simulator,
competition and optimization of the cost for the entire life cycle will be possible, including new
products related to recycling.
The customer must be at the centre of concerns with the elements of marketing mix
surrounding him, the 4P’: product, price, placement and promotion which are presented in the
next figure.
Figure 126. The 4P's description
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The 4P’s show the conception of target market and they must correlate with the 4C of the
buyer in order to obtain a competitive position in the market and a bigger profit.
4P
Product
Price
placement
Promotion
4C
Customer demands and wishes
Customer cost
Convenience acquisition
Communication
Table 29. 4P & 4C
7.1.1. PRODUCT
Sant Joan de Déu Hospital is the company that develops the lung simulator in collaboration
with Universitat Politècnica de Catalunya.
The product is a lung simulator that will be used in educational and research purposes by
doctors and professors who will be able to show the students through the product different
scenarios in which a lung can be used and after seeing these scenarios the students must be
able to detect what disease does the patient have.
The designed concept of the lung simulator was focused on the main requirements that have
been established. It is a portable device developed to simulate the spontaneous breathing,
different scenarios of resistance in the airways, compliance or stiffness of the lungs and
leakage of air, all prepared to be controlled remotely through a tablet application in order to
test the ventilator’s functioning in practical classes for medical students.
It has been designed to be wireless, allowing the simulator to be used without electricity.
The product offers the customer the possibility to use two lung sizes in the simulation
according to his needs due to the practical design of the product. It can be easily transported
and it is very accessible for maintenance. The interface page has a simple graphic and it is very
easy to use.
Figure 127. Final product
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USE
Figure 128. Context of use
Connect the air source with the tube in order to move the interior cylinder and show
the spontaneous breathing generation and connect the simulator to the ventilator’s
external tube.
All the elements are connected to start the simulation class. The simulator has to be
placed in a flat platform.
Students are focused on interpreting the ventilator data while the medical professor
adjusts the parameters remotely in order not to influence their interpretations.
7.1.2. PLACE
The simulator has been developed in one of the laboratories of UPC. The distribution channel
is direct; producer to consumer without any interfering parties. Sant Joan de Déu Hospital is
located in Barcelona, Spain therefore giving it the ability to deliver directly to people who need
to use it. The product will be available to purchase straight from the hospital or through a
virtual store on the internet.
7.1.3. PRICE
The product’s price is flexible and it depends on consumer’s needs. The price varies according
to:
-
The number of bags the customer wants to buy.
If the customer wants insurance.
If the customer wants a special addition to the product or has a specific requirement
regarding of the components.
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7.1.4. PROMOTION
This represents all of the communications that marketers may use in the marketplace in order
to increase awareness about the promoted product and its advantages for the targeted
segment.
There are two ways in which promotions can be realized, online and offline. Through the
online one means that the product can be promoted using webpages, social networks and
advertising, while the offline one refers to events in which the product can be presented, flyers
or banners, articles in magazines or newspaper or a more direct approach in which the
potential customer is contacted directly.
7.2.
COST STRUCTURE
7.2.1. COST EQUATIONS
The cost of production is an economic indicator, its calculation takes place in all economic
units and requires consideration of the relationship between cost and sale price. The
production cost is only a part of the sale price, the part that includes the expenses incurred by
the manufacturer.
(eq.1)
Pv = sale price
Cown= own cost (global cost)
Pf = profit
MATERIAL COST
• Material cost (CM) is obtained by summing the unique cost and overall cost of the material.
CM = CUM + COM
(eq.2)
• Unique cost material CUM is calculated based on the amount of material used (QM) multiplied
by the cost per unit of material (cUM).
CUM = QM + cUM
(eq.3)
• Overall cost of the material (COM): include for example costs of supplies, material storage
space and storage cost.
COM = CUM ∙ (SCOM%)
(eq.4)
SCOM%= Supplement overall cost of materials is generally between 5-20%
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MANUFACTURING COST
The manufacturing cost is obtained from salary expenses of those directly involved in the
production (manufacturing salary costs) and overall manufacturing cost.
CF = CSF + COMa
(eq.5)
They include actual manufacturing costs of the parts and their assembly to achieve the finished
product.
• Salary costs for production (CSF): calculate the salary cost per unit of time and the time
required to manufacture a piece:
CSF = cs ∙ t
(eq.6)
cs = salary cost per unit of time [euro/min; euro/h]
t= time required to manufacture a piece [min or h]
• Overall manufacturing cost (COMa): is calculated based on the manufacturing salary costs and
supplement overall manufacturing cost.
COMa = CSF ∙ (SCOF%)
(eq.7)
SCOF = Supplement overall manufacturing cost is between 200-500%
Supplement overall manufacturing cost is for example energy consumption, equipment cost,
salary of auxiliary production department (e.g. Economic unity or marketing).
PRODUCTION COSTS
• Cost of preparation/ finish of manufacture (CPIF) is the cost of testing devices and represent
3% from production cost.
• Production costs (CP ) include material costs, manufacturing costs and preparation/finish cost
of manufacture. This cost is worth around 68.6% of the own cost and could include the cost of
design and development too.
CP = CM + CF + CPIF
(eq.8)
OWN COSTS
The own cost is obtained from the sum of production costs, research – development costs and
sale costs.
Cown = CP + CRDD + CUV + CRS
(eq.9)
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SALE PRICE
The final price is extremely important because it plays a significant role in maximizing the
profit. From costs plus desired profit the net selling price can be obtained.
SALE PRICE CALCULATED
Own cost
(Cown)
Production cost
(CP)
Research,
develop.and design
(CRDD)
Profit
Unique cost related
with sale
(CUV)
Overall cost for sale
and representative
(CRS)
Figure 129. Sale price structure
7.2.2.
COST CALCULATIONS
MATERIAL COST
*The total material list can be found in chapter Materials and manufacturing process.
The lung simulator can be divided in two parts:
 Internal part € 229
 External part: € 6
(eq. 3) CUM = € 235
(eq. 4) COM = 235 ∙ 5% = € 11.75
(eq. 2) CM = 235 + 11.75 = € 246.75
MANUFACTURING COST
To produce a lung simulator there are required one employee, one employee’s salary being €
20.000/year and the required time for manufacturing is a week.
cs = 9 €/h
t = 30 h
(eq. 6) CSF =€ 270
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(eq. 7) COMa = 270 ∙ 200% = € 540
(eq. 5) CF = 270 + 540 = € 810
PRODUCTION COST
(8) CP = 246.75 + 810 +
CP
CP = 1089.40
CPIF = 32.65
OWN COST
CP =1089.40 => 68.6% from own cost
Research development and design costs => 8.6% from own cost.
CROD = € 136.57
Unique cost related with sale =>3.7% from own cost
CUV = € 58.75
Overall cost for sale and representative =>19.1% from own cost
CRS = € 303.30
The own cost is € 1580.
Although the price is quite high in comparison with the one that is used in Sant Joan de Dèu
Hospital, it has to be taken into consideration that the proposed lung simulator is more
sophisticated allowing a better experience for students in their learning process, including the
possibility of it being remotely controlled which require certain parts that are quite expensive.
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7.3.
COMPARISON BETWEEN EXISTING LUNG SIMULATORS
This table shows a number of significant characteristics about the most completed paediatric
lung simulators that were analysed in this project. This enables to compare the developed
product with the others in the market, especially with Imtmedical smartlung which is the one
used in Sant Joan de Déu Hospital.
Number of
lungs
Compliance
adjustment
Leak
adjustment
Resistance
adjustment
Spontaneous
breathing
generation
Remote
control of
the
parameters
Volume (L)
Resistance
(cmH20/L/S)
Compliance
(mL/cmH20)
Weight (kg)
Price(€)
TL2 PRO test lung
Ingmar Med
Imtmedical
smartlung
SUMLUNG
2
2
1
1
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
YES
NO
YES
NO
NO
NO
YES
2.0
2.0
0.6
0.25 and 0.05
0, 5, 20, 50
15, 25, 50
5, 20, 50, 200
5, 20, 50, 100
5-50 inaccurate
15-80 inaccurate
13, 17, 23, 30
1,2,3,5
0.4
7
0.3
1.7
€250
€1,950
€620
Table 30. Comparison between lung simulators
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7.4.
SWOT ANALYSIS
Weaknesses
Strengths
- The interactive interface is not
completely developed (add
application )
-Lightweight
- The product shows spotaneous
breathing generation
-Lack of electronic background
-All parameters can be controlled
remotely
-Short period of time
-Low cost compared to existing
products with the same features.
-Ergonomic and easy to control
SWOT
Threats
Opportunities
-The competition could launch the
product faster
- This might be the first product on
the market that includes all these
features controlled remotely
- Some competitors can produce
lower price products.
-the electronic part could be done
very fast by an expert
-This product will improve practical
classes in medical universities.
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8. CONCLUSIONS
SUMLUNG is an innovative paediatric and neonatal lung simulator that fulfils the main
requirements established by the Hospital Sant Joan de Dèu, which were to develop a new
concept of lung simulator, one that imitates the breathing of neonates and children, that can
be remotely controlled and that covers different clinical scenarios, which will be used for
educational purposes in hospitals and universities of medicine.
The most important issue that can be improved thanks to this new concept is the experience
of students during practical classes allowing a more reliable evaluation of their skills this being
translated in the increase of efficiency during the future implementation of their knowledge in
real clinical scenarios.
The fact that the product is quite sophisticated in comparison with current lung simulators and
initial demands from the hospital, is due to a differential factor, which means that the fully
developed simulator could be seen in the future as a new product to introduce in the market
as an educational training device.
Because of the shortness of time and not having a member in the team with an electronic
background, it has not been possible to achieve the level that we would have liked to, in order
to present a completely developed control of all parameters of the simulator. However, thanks
to the collaboration of two professors of the university, Cristobal Raya and José Matas and the
help of some students from electronics, we could successfully control remotely the most
relevant parameter out of the four, the spontaneous breathing.
RECOMMENDATIONS AND FURTHER WORK
To ensure the future development of this conceptual simulator and hopefully the
manufacturing of it we would like to detail some recommendations for further work:
-
To develop a more completed prototype to test all the parameters. Due to a lack of
time, it was not possible to make a complete prototype with all the functions of the
simulator working. In order to ensure the well-functioning of them it is necessary to
develop a final prototype to be tested.
-
To design a bag to carry the simulator. The project was focused on developing a new
simulator with all its elements and developing a prototype to test one of the functions.
Although designing a bag was one of our established requirements, we didn’t achieve
this point; nevertheless it has to be included according to the requirements analysis
that was made.
-
To develop the electronics to control all the elements. In the concept design the
electronic system to control all the parameters has been considered as a black box
that has to be developed.
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-
To develop an interactive interface prototype. In this project it has been developed
the interface that the user is going to use to control the simulator but it is necessary to
develop the prototype to test it with the users.
-
Make usability tests using the whole product in the real scenario. Once having
developed a complete prototype of the simulator and the interface, it is necessary to
test the functioning of all the system with the hospital ventilator in order to redesign
and develop the final product.
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9. BIBLIOGRAPHY
9.1.
WEBSITES
[1] Human Anatomy and Physiology. The Respiratory System’, from website of
University of Nevada, available on the Internet:
http://faculty.unlv.edu/jyoung/BIOL440-respiration.pdf
[2] ‘Overview of Pulmonary Anatomy and Physiology’ from NIOSH Spirometry Training
Guide, available on the Internet:
http://www.cdc.gov/niosh/docs/2004-154c/pdfs/2004-154c.pdf, pages 15-23
[3] ‘Pediatric Airway & Respiratory physiology’ by S. Kache, MD, Stanford School of
Medicine, available on the Internet:
http://peds.stanford.edu/Rotations/picu/pdfs/10_Peds_Airway.pdf
[4] ‘Anatomy of Your Child’s Respiratory System’ from Paediatric Health Library of
University of Minnesota Amplatz Children's Hospital, available on the Internet:
http://www.uofmchildrenshospital.org/healthlibrary/Article/88967
[5] ‘Diseases and conditions’ from website of Monroe Carell Jr. Children's Hospital at
Vanderbilt, available on the Internet:
http://www.childrenshospital.vanderbilt.org/library/article.php?ContentT
[6] ‘Lung Function Tests’ from Lung Disease & Respiratory Health Centre, available on
the Internet: http://www.webmd.com/lung/lung-function-tests
[7] ‘Mannequins’ from HealthPartners Clinical Simulation & Learning Center website,
available on the Internet at: http://www.hpclinsim.com/mannequins.html
[8] “Newborn HAL brochure”, available [online]:
https://store45a09.mybigcommerce.com/product_images/productbrochures/S3010_B
rochure_2011NoPrices.pdf
[9] PediaSIM® description from HELSIM, available [online]:
http://www.hellenic-simulations.com/Pedia_Sim.html
[10] Child Heart and Lung Sound Training Model description from Simulaids, available
[online]:
http://www.anatomystuff.co.uk/product-child-heart-lung-sound-trainer_247256.aspx
[11] Gear Technical Reference ‘The Role Gears are Playing’ from Kohara Gear Industry
Co., LTD. available [online]:
http://www.khkgears.co.jp/en/gear_technology/pdf/gear_guide1.pdf
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[12] Part No’s. 919D7 – 919D14. Timing Pulleys. [online]:
http://lars.mec.ua.pt/public/LAR%20Projects/RescueRobotics/2009_DanielAfonso/fon
tes/catalogos/MFA/gearbox_colour_brochure_12-19.pdf
[13] 3 Position Cylinder by SMC Co. available [online]:
http://www.smc.eu/portal/NEW_EBP/07)Speciality_Cylinder/7.1)Specialty_Cylinder/m
)RZQ/RZQ_EU.pdf
[14] Cylinders, Valves and Tubing by Festo Co. available [online]:
http://www.festo.com/net/startpage/
[15] ‘Mannequins’ from HealthPartners Clinical Simulation & Learning Center website,
available on the Internet at: http://www.hpclinsim.com/mannequins.html
[16] “Newborn HAL brochure”, available [online]:
https://store45a09.mybigcommerce.com/product_images/productbrochures/S3010_B
rochure_2011NoPrices.pdf
[17] PediaSIM® description from HELSIM, available [online]:
http://www.hellenic-simulations.com/Pedia_Sim.html
[18] Child Heart and Lung Sound Training Model description from Simulaids, available
[online]:
http://www.anatomystuff.co.uk/product-child-heart-lung-sound-trainer_247256.aspx
[19] ‘Background of Silicon’ available [online]: http://www.madehow.com/Volume6/Silicon.html
[20] ‘Injection Molding Manufacturing Process’ available [online]:
http://en.wikipedia.org/wiki/Injection_molding
[21] ‘The Difference between HDPE and PVC – A Functional Comparison’ available
[online]: http://www.mcelroy.com/pdf/HDPEvsPVC.pdf
[22] ‘The Advantages, Disadvantages and Applications of HDPE’ by United Plastic
Components (UPC) Co. available [online]:
http://www.upcinc.com/resources/materials/HDPE.html
[23] ‘The Extrusion Manufacturing Process’ available [online]:
https://www.tut.fi/ms/muo/tyreschool/moduulit/moduuli_6/hypertext/3/3_2.html
[24] ‘The Background and Properties of ABS’ available [online]:
http://en.wikipedia.org/wiki/Acrylonitrile_butadiene_styrene
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[25] ‘The Advantages and Disadvantages of ABS’ by RTP Co. available [online]:
http://www.rtpcompany.com/products/product-guide/acrylonitrile-butadienestyrene-abs/
[26] ‘The Injection Moulding of Plastics’ available [online]:
http://www.technologystudent.com/equip1/inject1.htm
[27] ‘The Background and Properties of Polycarbonate (PC)’ available [online]:
http://en.wikipedia.org/wiki/Polycarbonate
[28] ‘Basics of Injection Molding Design’ by 3DSYSTEMS available [online]:
http://www.3dsystems.com/quickparts/learning-center/injection-molding-basics
[29] ‘Electroválvula proporcional compacta’ by SMC Co. available [online]:
http://content2.smcetech.com/pdf/PVQ_ES.pdf
[30] ‘The Definition of Bluetooth’ by Techcopedia Co. available [online]:
http://www.techopedia.com/definition/26198/bluetooth
[31] ‘The Basics of Bluetooth Technology’ by available [online]:
http://www.bluetooth.com/Pages/Basics.aspx
[32] ‘Controlling Arduino Board by Android Phone’ by available [online]:
http://www.instructables.com/id/How-control-arduino-board-using-an-androidphone-a/
9.2.
LITERATURE
[1] C. BAUER Jeffrey, Ph.D: (2006), “The Future of Medical Simulation: New
Foundations for Education and Clinical Practice”. [online].
[2] PALÉS ARGULLÓS, J.L. and GOMAR SANCHO, C: (2010) “El uso de las simulaciones
en educación médica” from Universidad de Salamanca. [online].
[3] VAZQUEZ-MATA, G. and GUILLAMET-LLOVERAS, A: (2009) “El entrenamiento
basado en la simulación como innovación imprescindible en la formación médica” ,
Educ. méd. vol.12, n.3, pp. 149-155. ISSN 1575-1813. [online].
[4] HUNTER, C and K. RAVERT, P: “Nursing Students’ Perceptions of Learning Outcomes
throughout Simulation Experiences” article from Brigham Young University. [online].
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[5] Meduri GU, Johanson WG Jr: International Consensus Conference: “Clinical
investigation of ventilator-associated pneumonia”. Introduction [Editorial]. Chest
102:551S-552S, 1992 (supply)
[6] Berry AJ: “Respiratory support and renal function”. Anaesthesiology 55:655-667,
1981
[7] A.F.M. Verbraak, P.R. Rijnbeek, J.E.W. Beneken, J.M. Bogaard, A. Versprille: “A new
approach to mechanical simulation of lung behaviour -pressure controlled and time
related piston movement.” Medical & Biological Engineering & Computing, 2001, Vol.
39M
[8] Sarah Heili-Frades, German Peces-Barba, Maria Jesus Rodriguez-Nieto: Design of a
Lung Simulator for Teaching Lung Mechanics in Mechanical Ventilation. Arch
Bronconeumol. 2007:43(12):674-9
[9] Stefano Cecchini, Emiliano Schena, Sergio Silvestri: “An open-loop controlled active
lung simulator for preterm infants.” Medical Engineering & Physics (2011) 47-55edical
[10] Robert L. Chatburn: “Computer Control of Mechanical Ventilation”. Respiratory
Care, May 2004 Vol. 49 No. 5
[11] Datasheet of TL2 PRO Test Lung System [online].
[12] “Maquet Critical Care” AB (2007) [online].
[13] John H. Bickford: “Mechanisms for Intermittent Motion; Chapter 9 – Geneva
Mechanisms” pg. 127-138 [online].
9.3.
TABLES AND FIGURES
9.3.1. TABLES
[1] ‘Eco Audit of Lung Simulator’ available on CES EDUPACK 2013.
[2] ‘Weights and Prices of The Components’ available on SOLIDWORKS 2013.
[3] ‘Materials and Manufacturing Process’ available on CES EDUPACK 2013.
9.3.2. FIGURES
[1] ‘The 4P’s of Marketing – Marketing Mix Strategies’ available [online]:
http://business-fundas.com/2011/the-4-ps-of-marketing-the-marketing-mixstrategies/
[2] ‘Arduino Uno Electronic Board’ by Arduino Co. available [online]:
http://arduino.cc/en/Main/arduinoBoardUno
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[3] ‘Stress Simulation Analysis’ available on NX 8.0 and SOLIDWORKS 2013.
[4] ‘Injection Molding Process’ by Anole Injection Tech. available [online]:
http://www.anole-hot-runner.com/injection-molding-process_296.htm
[5] ‘Plastics Extrusion Process’ available [online]:
http://en.wikipedia.org/wiki/Plastics_extrusion
[5] ‘Injection Moulding of Plastics’ available [online]:
http://www.technologystudent.com/equip1/inject1.htm
[6] ‘Bluetooth’ by Electronic Design available [online]:
http://electronicdesign.com/sitefiles/electronicdesign.com/files/uploads/2013/07/1003_DSblu2th_Fig3.gif
[7] ‘BlueTerm Application’ available [online]:
https://lh6.ggpht.com/C_tzFrjoZ4NsbAhe57mgwqK5fCeJG64QkXgR5W0JSAz29YFhfhv32Sw5pM8klJtJfJ7=h310-rw
[8] ‘Arduino Electronic Board’ available [online]:
http://cdn.instructables.com/FI6/B1WK/HD7TZGDS/FI6B1WKHD7TZGDS.MEDIUM.jpg
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10.TABLE OF FIGURES
Figure 1. Example of Human simulation ..................................................................................... 10
Figure 2. Resusci Anne mannequin ............................................................................................. 11
Figure 3. Virtual dental implant training simulator..................................................................... 11
Figure 4. NeuroTouch is the world’s most advanced virtual reality neurosurgical simulator .... 12
Figure 5. Human respiratory system: general view .................................................................... 16
Figure 6. Human respiratory system: lungs ................................................................................ 16
Figure 7. Inhaling and exhaling process ...................................................................................... 17
Figure 8. Human respiratory system: bronchi............................................................................. 18
Figure 9. Parts of respiratory system of a child........................................................................... 20
Figure 10. Alveoli and mucus ...................................................................................................... 20
Figure 11. Collapsed lung in infant .............................................................................................. 24
Figure 12. Air leak treatment ...................................................................................................... 24
Figure 13. Childhood bronchial asthma ...................................................................................... 25
Figure 14. Evolution of the disease ............................................................................................. 26
Figure 15. Pulmonary hypertension ............................................................................................ 29
Figure 16. RSV-Respiratory syncytial virus .................................................................................. 30
Figure 17. Elements of a Lung Simulator system ........................................................................ 33
Figure 18. Schematic diagrams of closed-loop control of a mechanical ventilator .................... 35
Figure 19. Display ........................................................................................................................ 36
Figure 20. Premie HAL S3009 ...................................................................................................... 37
Figure 21. Example of lung compliance graphically .................................................................... 39
Figure 22. Parts of lung simulator ............................................................................................... 40
Figure 23. Ventilator Respironics V200 from Philips ................................................................... 41
Figure 24. Ventilator SERVO-U from Maquet.............................................................................. 41
Figure 25. Ventilator HAMILTON-C3 ........................................................................................... 42
Figure 26. Example of the simulator functioning with a manual ventilator ............................... 43
Figure 27. Babi.plus lung simulator with the optional manometer ............................................ 43
Figure 28. Lung simulator TL2 PRO TEST LUNG........................................................................... 44
Figure 29. Lung simulator DEMO LUNG ...................................................................................... 45
Figure 30. Newborn HAL mannequin .......................................................................................... 46
Figure 31. PediaSIM mannequin ................................................................................................. 47
Figure 32. Child Heart and Lung Sound Training Model ............................................................. 48
Figure 33. Illustration of the purpose of the lung simulator in its context of use ...................... 49
Figure 34. Darwin Simulation Centre of Sant Joan de Déu Hospital ........................................... 51
Figure 35. Hospital’s ventilator monitor ..................................................................................... 52
Figure 36. Current lung simulators of the Hospital ..................................................................... 52
Figure 37. Example of a University Laboratory ........................................................................... 53
Figure 38. Example of a University conference room ................................................................. 53
Figure 39. Scheme of the whole system divide in: current devices and needs .......................... 55
Figure 40. Current hospital simulator: SMART LUNG ................................................................. 56
Figure 41. Ventilator SERVO-I Maquet ........................................................................................ 57
Figure 42. Parts of the lung simulator system that have to be designed ................................... 60
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Figure 43. Storyboard of use ....................................................................................................... 61
Figure 44. Mind Map ................................................................................................................... 63
Figure 45. First sketches of the system with two lungs .............................................................. 64
Figure 46. First sketches of the system with one lung ................................................................ 64
Figure 47. General scheme of the concept ................................................................................. 65
Figure 48. Bag concept: balloon shape ....................................................................................... 67
Figure 49. Bag concept: bellow shape......................................................................................... 68
Figure 50. Final shape of the bag for two lung sizes ................................................................... 68
Figure 51. Sketches of cylinder system for spontaneous breathing ........................................... 71
Figure 52. Final design for spontaneous breathing..................................................................... 72
Figure 53. Structure of the bag ................................................................................................... 72
Figure 54. Results of the simulation: displacement of the structure .......................................... 74
Figure 55. Mechanism to generate the spontaneous breathing: electrovalve + flow regulator 75
Figure 56. Mechanism to generate the spontaneous breathing: proportional control valve .... 75
Figure 57. Chosen system to generate the spontaneous breathing: cylinder ............................ 76
Figure 58. Chosen system to generate the spontaneous breathing: proportional control valve77
Figure 59. Chosen system to generate the spontaneous breathing: fittings + tubing................ 78
Figure 60. Top view of the lung simulator to see the pneumatic elements position and their
connections ................................................................................................................................. 78
Figure 61. Sketches of screw system for controlling compliance ............................................... 79
Figure 62. Sketches of band system for controlling compliance ................................................ 80
Figure 63. Final design of the system for controlling compliance .............................................. 80
Figure 64 and 65. Grooves in the rigid structure ........................................................................ 80
Figure 66. Mechanism to adjust compliance .............................................................................. 82
Figure 67. Sketches of push and pull system for controlling resistance ..................................... 84
Figure 68. Sketches of wheel system for controlling resistance ................................................. 84
Figure 69. Final design of the system to control resistance ........................................................ 85
Figure 70. Curve fit for resistance measurements ...................................................................... 86
Figure 71. Mechanism to control resistance ............................................................................... 87
Figure 72. Mechanism to control resistance: Geneva wheel ...................................................... 87
Figure 73. Mechanism to control resistance: Specification ........................................................ 87
Figure 74. Internal Geneva Wheel: parameters .......................................................................... 89
Figure 75. DC motor for controlling resistance ........................................................................... 90
Figure 76. Sketches of pull and push system for controlling leaks ............................................. 91
Figure 77. Sketches of ring system for controlling leaks ............................................................. 91
Figure 78. Final design of the system for controlling leaks ......................................................... 91
Figure 79. Mechanism for controlling leaks ................................................................................ 92
Figure 80. Mechanism for controlling leaks: gear trains ............................................................. 93
Figure 81. Mechanism for controlling leaks: gear tooth profiles ................................................ 94
Figure 82. Case shape.................................................................................................................. 96
Figure 83. Elements removal....................................................................................................... 97
Figure 84. Simulator components ............................................................................................... 97
Figure 85. Graphical elements of the case .................................................................................. 98
Figure 86. Power icon .................................................................................................................. 98
Figure 87. Battery status icons .................................................................................................... 98
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Figure 88. Spontaneous breathing icon
................................................................................ 99
Figure 89. Leaks and resistance icons
.................................................................................. 99
Figure 90. Interior mechanisms of the case ................................................................................ 99
Figure 91. Placement of the elements inside the case ............................................................. 100
Figure 92. Subjection piece for motors ..................................................................................... 100
Figure 93. Bottom view of the case to show subjection elements
................................. 100
Figure 94. Subjection piece for the cylinder………………………………………………………………………..100
Figure 95. Design of the remote ............................................................................................... 101
Figure 96. Principle of Bluetooth technology............................................................................ 101
Figure 97. Scheme with Bluetooth board
............................................ 102
Figure 98. BlueTerm application
............................................................................. 102
Figure 99. Interface design ........................................................................................................ 103
Figure 100. Iconography of the interface.................................................................................. 103
Figure 101. Interface: compliance ............................................................................................. 104
Figure 102. Interface: spontaneous breathing.......................................................................... 104
Figure 103. Bag .......................................................................................................................... 105
Figure 104. Manufacturing process of the bag ......................................................................... 108
Figure 105. Rigid structure ........................................................................................................ 109
Figure 106. Manufacturing process of rigid structure .............................................................. 110
Figure 107. Simulation analysis of resistance ........................................................................... 111
Figure 108. Cross-sectional area of the structure ..................................................................... 112
Figure 109. Tube........................................................................................................................ 115
Figure 110. Extrusion process ................................................................................................... 116
Figure 111. Element to control leaks ........................................................................................ 117
Figure 112. Element to control resistance ................................................................................ 119
Figure 113. Manufacturing process for the element controlling resistance............................. 120
Figure 114. Band....................................................................................................................... 121
Figure 115. Pulley ...................................................................................................................... 121
Figure 116. Case ........................................................................................................................ 124
Figure 117. Cap.......................................................................................................................... 126
Figure 118. Prototyping: piston................................................................................................. 128
Figure 119. Prototyping: cylinder plate ..................................................................................... 128
Figure 120. Prototyping: Arduino Uno ...................................................................................... 129
Figure 121. Prototyping: electronic board ................................................................................ 129
Figure 122. Prototyping: BlueTerm app .................................................................................... 129
Figure 123. Prototyping: bag ..................................................................................................... 129
Figure 124. Prototyping: Proportional valve ............................................................................. 130
Figure 125. Prototyping: laboratory system ............................................................................. 130
Figure 126. The 4P's description ............................................................................................... 132
Figure 127. Final product .......................................................................................................... 133
Figure 128. Context of use ........................................................................................................ 134
Figure 129. Sale price structure ................................................................................................ 137
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11. TABLE OF TABLES
Table 1. Anatomy differences for adult and child ....................................................................... 20
Table 2.Newborn HAL mannequin selected features ................................................................. 46
Table 3. PediaSIM mannequin selected features........................................................................ 47
Table 4. Child Heart and Lung Sound Training Model selected features .................................... 48
Table 5. Tasks to do using the simulator by the different users ................................................. 50
Table 6. Requirements for the lung simulator according to the environment ........................... 54
Table 7. Main parts of the SMART LUNG .................................................................................... 56
Table 8. Main parameters of the Smart Lung for adult .............................................................. 57
Table 9. Main parameters of the Smart Lung for infant ............................................................. 57
Table 10. Parameters of SERVO-i Infant...................................................................................... 58
Table 11. Standard values for compliance depending on child age ............................................ 79
Table 12. Values of compliance chosen for lung simulator ........................................................ 79
Table 13. Typical values of airway resistance ............................................................................. 83
Table 14. Values of resistance for lung simulator ....................................................................... 83
Table 15. Diameters for existing lung simulator ......................................................................... 86
Table 16. Diameters for proposed lung simulator ...................................................................... 86
Table 17. Motor specification ..................................................................................................... 90
Table 18. Calculations for standard spur gear ............................................................................ 95
Table 19. General properties of silicone rubber ....................................................................... 107
Table 20. Eco properties of silicone rubber .............................................................................. 107
Table 21. General properties of high-density polyethylene .................................................... 109
Table 22. General properties of polyvinyl chloride ................................................................... 115
Table 23. General properties of Acrylonitrile Butadiene Styrene ............................................. 117
Table 24. General properties of Acrylonitrile Butadiene Styrene ............................................. 119
Table 25. Properties of Polyamide ............................................................................................ 121
Table 26. General properties of Poly ether ether ketone ......................................................... 122
Table 27. Properties of polycarbonate ...................................................................................... 124
Table 28. Properties of polycarbonate ...................................................................................... 126
Table 29. 4P & 4C ...................................................................................................................... 133
Table 30. Comparison between lung simulators....................................................................... 139
151
EPS/IDPS 2014
12. APPENDIX
TABLE OF COMPONENTS
COMPONENT
QUANTITY
MATERIAL
REGULATIONS
PRICE
1
PC with 10% glass
fiber
-
3€
1
PC with 30% glass
fiber and 5%
silicone
-
0.82€
1
HDPE
-
0.14€
1
Silicone rubber
-
0.83€
1
Silicone rubber
-
0.28€
1
PVC
-
0.02€
1
HDPE
-
0.0005€
Case
Cap
Rigid structure
Children bag
Neonate bag
Tube
Bracket
152
EPS/IDPS 2014
Cylinder surface
1
ABS
-
0.03€
1
Aluminium
ISO 21287
43€
1
Standard
ISO 15407-1
180€
1
Standard
ISO 14644-1
20€
500 mm
max.
Polyurethane
ISO 5599
7.70€
1
ABS (medium
impact)
-
0.07€
1
ABS (medium
impact)
-
0.02€
2
ABS (medium
impact)
-
1.15€
3
Standard
-
1.37€
3
Standard
-
2€
Cylinder
Proportional valve
Fitting
Tubing
Geneve wheel
Leaks ring
Gear
Motor
Motor subjection
153
EPS/IDPS 2014
Screw
14
Steel
M2 0.4
4€
1
PA type wth 15%
glass fiber
-
0.03€
1
PEEK
-
3.80€
1
Standard
ANSI/UL 8750
0.05€
1
Standard
ISO9001
25€
1
1
Standard
Standard
-
14€
4.50€
1
Standard
-
100€
Band
Pulley
LED
Arduino board
Bluetooth receiver
Battery
Tablet
154
EPS/IDPS 2014
WEIGHT OF LUNG SIMULATOR
This table shows the weight of the product having included all the components. It was done
through the application for calculating the weight of SOLIDWORKS program.
WEIGHT
(g)
case
856,95
cap
233,95
Rigid structure
103,53
neonate bag
43,48
tube
11,21
bracket
0,38
cylinder surface
8,22
geneva wheel
25,97
leaks ring
5,24
gear
15,33
band
3,31
pulley
52,46
arduino uno
28
motor
45
piston
139
screw
3
LED
0,44
Bluetooth receiver
5
TOTAL
COMPONENTS
QUANTITY
TOTAL WEIGHT (g)
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
14
1
1
856,95
233,95
103,53
43,48
11,21
0,38
8,22
25,97
5,24
30,66
3,31
52,46
28
135
139
42
0,44
5
1724,8
155
EPS/IDPS 2014
ECO-AUDIT INTERPRETATION
The CES Edupack software is used for better understanding of environmental issues, create
material charts, perform materials and processes selection and eco audit or life cycle analysis
allowing alternative design choices to meet the engineering requirements and reduce the
environmental burden.
An energy and CO2 eco audits were performed for the lung simulator. The parts are
manufactured closed to Spain and shipped 100 km to Spain, where it is sold and used. It
weighs 1.7 kg of which 1 kg is Polycarbonate representing the case and cap, 105 gr Highdensity Polyethylene and the rest a mixture between PVC, ABS, silicone rubber and aluminum.
The parts that consume the most energy to be processed are the case and the cylinder surface
and the biggest CO2 footprint is the one of the cylinder and Geneva wheel.
From the graphs in page 1, regarding Energy and CO2 footprint, it can be observed that the
main problems are in usage, material and a small proportion, in comparison with the other, in
manufacturing and while the results are approximate, there is a need to retain sufficient
discrimination to differentiate between alternative choices, this is not a tool to calculate the
full life cycle analysis.
After seeing and interpreting the results, the conclusion is that some materials of certain parts
need to be changed so that the impact on the environment and the future generations can be
diminished. By application of renewable and recycled sources the life cycles of building
materials can be closed. Renewable sources will be reproduces by nature during life time of
the material and the recycled materials will enter a second life, without taking resources from
nature.
156
EPS/IDPS 2014
Eco Audit Report
Product Name
Lung Simulator
Product Life (years)
7
ENERGY AND CO2 FOOTPRINT SUMMARY:
157
EPS/IDPS 2014
Energy (MJ)
Energy (%)
CO2 (kg)
CO2 (%)
Material
2.07e+05
45.2
1.2e+04
43.5
Manufacture
3.32e+04
7.2
2.47e+03
8.9
77.8
0.0
5.53
0.0
2.18e+05
47.5
1.31e+04
47.5
338
0.1
23.7
0.1
4.59e+05
100
2.76e+04
100
Phase
Transport
Use
Disposal
Total (for first life)
End of life potential
0
0
158
EPS/IDPS 2014
Eco Audit Report
ENERGY ANALYSIS
Energy (MJ)/year
Equivalent annual environmental burden (averaged over 7 year product life):
6.55e+04
DETAILED BREAKDOWN OF INDIVIDUAL LIFE PHASES
Material:
Component
Material
Recycled
content*
(%)
Part
mass
(kg)
Qty.
Total mass
processed**
(kg)
Energy
(MJ)
%
case
PC (10% glass fiber)
Virgin (0%) 8.6e+02
1
8.6e+02
9.1e+04
43.8
cap
PC (30% glass fiber, 2%
silicone)
Virgin (0%) 2.3e+02
1
2.3e+02
2.1e+04
10.2
rigid structure
PE-HD (20-30% long
glass fiber)
Virgin (0%)
1e+02
1
1e+02
7.8e+03
3.7
neonate bag
Silicone (VMQ, heat
cured, low hardness)
Virgin (0%)
43
1
43
6e+03
2.9
PVC (semi-rigid, molding
Virgin (0%)
and extrusion)
11
1
11
6.5e+02
0.3
tube
bracket
cylinder surface
cylinder
geneva wheel
PE-HD (20-30% long
glass fiber)
Virgin (0%)
0.38
1
0.38
29
0.0
ABS (extrusion)
Virgin (0%)
8.2
1
8.2
7.8e+02
0.4
1
1.4e+02
2.7e+04
13.1
1
26
2.5e+03
1.2
Aluminum, 319.0,
Virgin (0%) 1.4e+02
permanent mold cast, T6
ABS (medium-impact,
injection molding)
Virgin (0%)
159
26
EPS/IDPS 2014
ABS (medium-impact,
injection molding)
Virgin (0%)
5.2
1
5.2
5e+02
0.2
gear
ABS (high-impact,
injection molding)
Virgin (0%)
15
2
31
2.9e+03
1.4
motor
Aluminum, 6063,
wrought, O
Virgin (0%)
45
3
1.4e+02
2.8e+04
13.6
screw
Bake hardening steel,
YS260 (cold rolled)
Virgin (0%)
3
14
42
1.1e+03
0.5
band
PA (type 6, 15% glass
fiber)
Virgin (0%)
3.3
1
3.3
3.7e+02
0.2
pulley
PEEK (unfilled)
Virgin (0%)
52
1
52
1.6e+04
7.5
Diodes and LEDs
Virgin (0%)
0.44
1
0.44
2e+03
1.0
32
1.7e+03
2.1e+05
100
leaks ring
LED
Total
*Typical: Includes 'recycle fraction in current supply
'**Where applicable, includes material mass removed by secondary processes
Manufacture:
Process
% Removed
Amount processed
Energy
(MJ)
%
case
Polymer molding
-
8.6e+02 kg
2e+04
60.2
cap
Polymer molding
-
2.3e+02 kg
5.3e+03
16.1
rigid structure
Polymer molding
-
1e+02 kg
2.5e+03
7.5
Component
160
EPS/IDPS 2014
neonate bag
Polymer molding
-
43 kg
6.4e+02
1.9
tube
Polymer extrusion
-
11 kg
67
0.2
tube
Cutting and trimming
-
0 kg
0
0.0
bracket
Polymer extrusion
-
0.38 kg
2.4
0.0
cylinder surface
Polymer extrusion
-
8.2 kg
50
0.2
cylinder surface
Fine machining
-
0 kg
0
0.0
Casting
-
1.4e+02 kg
1.6e+03
4.7
geneva wheel
Polymer molding
-
26 kg
5.4e+02
1.6
geneva wheel
Fine machining
-
0 kg
0
0.0
leaks ring
Polymer molding
-
5.2 kg
1.1e+02
0.3
leaks ring
Fine machining
-
0 kg
0
0.0
gear
Polymer molding
-
31 kg
5.5e+02
1.7
motor
Rough rolling, forging
-
1.4e+02 kg
2e+02
0.6
screw
Extrusion, foil rolling
-
42 kg
2.2e+02
0.7
band
Polymer extrusion
-
3.3 kg
21
0.1
pulley
Polymer molding
-
52 kg
1.4e+03
4.2
paiting casing
Painting
-
0.6 m^2
7.2
0.0
add adhesive
Adhesives, heat curing
-
0.2 m^2
5.4
0.0
3.3e+04
100
cylinder
Total
161
EPS/IDPS 2014
Transport:
Breakdown by transport stage
Stage name
Transport of parts
Total product mass = 1.7e+03 kg
Transport type
Distance (km)
Energy (MJ)
%
32 tonne truck
1e+02
78
100.0
1e+02
78
100
Total
Breakdown by components
Component mass (kg)
Energy (MJ)
%
case
8.6e+02
39
50.7
cap
2.3e+02
11
13.8
rigid structure
1e+02
4.8
6.1
neonate bag
43
2
2.6
tube
11
0.52
0.7
bracket
0.38
0.017
0.0
cylinder surface
8.2
0.38
0.5
1.4e+02
6.4
8.2
geneva wheel
26
1.2
1.5
leaks ring
5.2
0.24
0.3
gear
31
1.4
1.8
motor
1.4e+02
6.2
8.0
screw
42
1.9
2.5
band
3.3
0.15
0.2
pulley
52
2.4
3.1
Component
cylinder
162
EPS/IDPS 2014
LED
0.44
0.02
0.0
Total
1.7e+03
78
100
Use:
Static mode
Energy input and output type
Mobile mode
Electric to
mechanical (electric
motors)
Fuel and mobility type
Use location
Use location
Spain
Spain
Product mass (kg)
Power rating (kW)
10
Usage (hours per day)
3
Usage (days per year)
1e+02
Product life (years)
1e+02
50
7
7
Mode
Energy (MJ)
%
Static
1.6e+05
75.6
Mobile
5.3e+04
24.4
Total
2.2e+05
100
Breakdown of mobile mode by components
Energy (MJ)
%
case
2.7e+04
50.7
cap
7.4e+03
13.8
rigid structure
3.3e+03
6.1
neonate bag
1.4e+03
2.6
163
1.7e+03
Distance (km per day)
Relative contribution of static and mobile modes
Component
Diesel - heavy
goods vehicle
EPS/IDPS 2014
tube
3.5e+02
0.7
12
0.0
cylinder surface
2.6e+02
0.5
cylinder
4.4e+03
8.2
geneva wheel
8.2e+02
1.5
leaks ring
1.7e+02
0.3
gear
9.7e+02
1.8
motor
4.3e+03
8.0
screw
1.3e+03
2.5
band
1e+02
0.2
pulley
1.7e+03
3.1
LED
14
0.0
Total
5.3e+04
100
bracket
Disposal:
End of life
option
% recovered
Energy
(MJ)
%
case
Landfill
100.0
1.7e+02
50.7
cap
Landfill
100.0
47
13.8
rigid structure
Landfill
100.0
21
6.1
neonate bag
Landfill
100.0
8.7
2.6
tube
Landfill
100.0
2.2
0.7
Component
164
EPS/IDPS 2014
bracket
Landfill
100.0
0.076
0.0
cylinder surface
Landfill
100.0
1.6
0.5
cylinder
Landfill
100.0
28
8.2
geneva wheel
Landfill
100.0
5.2
1.5
leaks ring
Landfill
100.0
1
0.3
gear
Landfill
100.0
6.1
1.8
motor
Landfill
100.0
27
8.0
screw
Landfill
100.0
8.4
2.5
band
Landfill
100.0
0.66
0.2
pulley
Landfill
100.0
10
3.1
LED
Landfill
100.0
0.088
0.0
3.4e+02
100
%
Total
EoL potential:
End of life
option
% recovered
Energy
(MJ)
case
Landfill
100.0
0
cap
Landfill
100.0
0
rigid structure
Landfill
100.0
0
neonate bag
Landfill
100.0
0
tube
Landfill
100.0
0
bracket
Landfill
100.0
0
Component
165
EPS/IDPS 2014
cylinder surface
Landfill
100.0
0
cylinder
Landfill
100.0
0
geneva wheel
Landfill
100.0
0
leaks ring
Landfill
100.0
0
gear
Landfill
100.0
0
motor
Landfill
100.0
0
screw
Landfill
100.0
0
band
Landfill
100.0
0
pulley
Landfill
100.0
0
LED
Landfill
100.0
0
0
Total
Notes:
166
100
EPS/IDPS 2014
Eco Audit Report
CO2 FOOTPRINT ANALYSIS
CO2 (kg)/year
Equivalent annual environmental burden (averaged over 7 year product life):
3.95e+03
DETAILED BREAKDOWN OF INDIVIDUAL LIFE PHASES
Material:
Component
case
cap
Qty.
Total mass
processed**
(kg)
CO2
footprint
(kg)
%
Virgin (0%) 8.6e+02
1
8.6e+02
5.1e+03
42.4
PC (30% glass fiber, 2%
Virgin (0%) 2.3e+02
silicone)
1
2.3e+02
1.2e+03
9.8
Material
PC (10% glass fiber)
Recycled
content*
(%)
Part
mass
(kg)
rigid structure
PE-HD (20-30% long
glass fiber)
Virgin (0%)
1e+02
1
1e+02
3e+02
2.5
neonate bag
Silicone (VMQ, heat
cured, low hardness)
Virgin (0%)
43
1
43
3.9e+02
3.2
PVC (semi-rigid, molding
Virgin (0%)
and extrusion)
11
1
11
28
0.2
tube
bracket
cylinder surface
cylinder
PE-HD (20-30% long
glass fiber)
Virgin (0%)
0.38
1
0.38
1.1
0.0
ABS (extrusion)
Virgin (0%)
8.2
1
8.2
31
0.3
1
1.4e+02
1.6e+03
13.5
Aluminum, 319.0,
Virgin (0%) 1.4e+02
permanent mold cast, T6
Geneva wheel
ABS (medium-impact,
injection molding)
Virgin (0%)
26
1
26
99
0.8
leaks ring
ABS (medium-impact,
injection molding)
Virgin (0%)
5.2
1
5.2
20
0.2
167
EPS/IDPS 2014
gear
ABS (high-impact,
injection molding)
Virgin (0%)
15
2
31
1.2e+02
1.0
motor
Aluminum, 6063,
wrought, O
Virgin (0%)
45
3
1.4e+02
1.7e+03
14.3
screw
Bake hardening steel,
YS260 (cold rolled)
Virgin (0%)
3
14
42
77
0.6
band
PA (type 6, 15% glass
fiber)
Virgin (0%)
3.3
1
3.3
24
0.2
pulley
PEEK (unfilled)
Virgin (0%)
52
1
52
1.2e+03
10.1
Diodes and LEDs
Virgin (0%)
0.44
1
0.44
1e+02
0.8
32
1.7e+03
1.2e+04
100
LED
Total
*Typical: Includes 'recycle fraction in current supply'
**Where applicable, includes material mass removed by secondary processes
Manufacture:
Process
% Removed
Amount processed
CO2
footprint
(kg)
%
case
Polymer molding
-
8.6e+02 kg
1.5e+03
60.7
cap
Polymer molding
-
2.3e+02 kg
4e+02
16.2
rigid structure
Polymer molding
-
1e+02 kg
1.9e+02
7.5
neonate bag
Polymer molding
-
43 kg
51
2.1
tube
Polymer extrusion
-
11 kg
5.1
0.2
tube
Cutting and trimming
-
0 kg
0
0.0
Component
168
EPS/IDPS 2014
bracket
Polymer extrusion
-
0.38 kg
0.18
0.0
cylinder surface
Polymer extrusion
-
8.2 kg
3.7
0.2
cylinder surface
Fine machining
-
0 kg
0
0.0
Casting
-
1.4e+02 kg
94
3.8
geneva wheel
Polymer molding
-
26 kg
40
1.6
geneva wheel
Fine machining
-
0 kg
0
0.0
leaks ring
Polymer molding
-
5.2 kg
8.1
0.3
leaks ring
Fine machining
-
0 kg
0
0.0
gear
Polymer molding
-
31 kg
41
1.7
motor
Rough rolling, forging
-
1.4e+02 kg
15
0.6
screw
Extrusion, foil rolling
-
42 kg
16
0.7
band
Polymer extrusion
-
3.3 kg
1.5
0.1
pulley
Polymer molding
-
52 kg
1e+02
4.2
paiting casing
Painting
-
0.6 m^2
0.59
0.0
add adhesive
Adhesives, heat curing
-
0.2 m^2
0.94
0.0
2.5e+03
100
cylinder
Total
169
EPS/IDPS 2014
Transport:
Breakdown by transport stage
Stage name
Transport of parts
Total product mass = 1.7e+03 kg
Transport type
Distance (km)
CO2 footprint
(kg)
%
32 tonne truck
1e+02
5.5
100.0
1e+02
5.5
100
Total
Breakdown by components
Component mass (kg)
CO2 footprint
(kg)
%
case
8.6e+02
2.8
50.7
cap
2.3e+02
0.76
13.8
rigid structure
1e+02
0.34
6.1
neonate bag
43
0.14
2.6
tube
11
0.037
0.7
bracket
0.38
0.0012
0.0
cylinder surface
8.2
0.027
0.5
1.4e+02
0.45
8.2
geneva wheel
26
0.085
1.5
leaks ring
5.2
0.017
0.3
gear
31
0.1
1.8
motor
1.4e+02
0.44
8.0
screw
42
0.14
2.5
band
3.3
0.011
0.2
Component
cylinder
170
EPS/IDPS 2014
pulley
52
0.17
3.1
LED
0.44
0.0014
0.0
Total
1.7e+03
5.5
100
Use:
Static mode
Energy input and output type
Mobile mode
Electric to
mechanical (electric
motors)
Fuel and mobility type
Use location
Use location
Spain
Spain
Product mass (kg)
Power rating (kW)
10
Usage (hours per day)
3
1e+02
Diesel - heavy
goods vehicle
Distance (km per day)
1e+02
50
7
7
Relative contribution of static and mobile modes
Mode
CO2 footprint (kg)
%
Static
9.3e+03
71.2
Mobile
3.8e+03
28.8
Total
1.3e+04
100
Breakdown of mobile mode by components
Component
CO2 (kg)
%
case
1.9e+03
50.7
cap
5.2e+02
13.8
171
1.7e+03
EPS/IDPS 2014
rigid structure
2.3e+02
6.1
neonate bag
97
2.6
tube
25
0.7
0.85
0.0
18
0.5
3.1e+02
8.2
geneva wheel
58
1.5
leaks ring
12
0.3
gear
69
1.8
motor
3e+02
8.0
screw
94
2.5
band
7.4
0.2
pulley
1.2e+02
3.1
LED
0.98
0.0
Total
3.8e+03
100
bracket
cylinder surface
cylinder
Disposal:
End of life
option
% recovered
CO2
footprint
(kg)
%
case
Landfill
100.0
12
50.7
cap
Landfill
100.0
3.3
13.8
Component
172
EPS/IDPS 2014
rigid structure
Landfill
100.0
1.4
6.1
neonate bag
Landfill
100.0
0.61
2.6
tube
Landfill
100.0
0.16
0.7
bracket
Landfill
100.0
0.0053
0.0
cylinder surface
Landfill
100.0
0.12
0.5
cylinder
Landfill
100.0
1.9
8.2
geneva wheel
Landfill
100.0
0.36
1.5
leaks ring
Landfill
100.0
0.073
0.3
gear
Landfill
100.0
0.43
1.8
motor
Landfill
100.0
1.9
8.0
screw
Landfill
100.0
0.59
2.5
band
Landfill
100.0
0.046
0.2
pulley
Landfill
100.0
0.73
3.1
LED
Landfill
100.0
0.0062
0.0
24
100
%
Total
EoL potential:
End of life
option
% recovered
CO2
footprint
(kg)
case
Landfill
100.0
0
cap
Landfill
100.0
0
Component
173
EPS/IDPS 2014
rigid structure
Landfill
100.0
0
neonate bag
Landfill
100.0
0
tube
Landfill
100.0
0
bracket
Landfill
100.0
0
cylinder surface
Landfill
100.0
0
cylinder
Landfill
100.0
0
Geneva wheel
Landfill
100.0
0
leaks ring
Landfill
100.0
0
gear
Landfill
100.0
0
motor
Landfill
100.0
0
screw
Landfill
100.0
0
band
Landfill
100.0
0
pulley
Landfill
100.0
0
LED
Landfill
100.0
0
0
Total
Notes:
174
100
15
16
17
18
19
1
2
14
3
4
5
13
6
12
11
10
9
8
7
20
B
B
20
Fitting
1
19
Bracket
1
18
Motor sujection 2
1
17
Leaks ring
1
16
Tube
1
15
Geneve stop wheel
1
14
Geneve index wheel
1
13
Geneve base
1
12
Motor
3
11
Gear
2
10
Motor sujection 1
2
9
Band
1
8
Pulley
1
7
Electrovalve
1
6
Cap
1
5
Cylinder
1
4
Case
1
3
Cylinder surface
1
2
Children/neonate bag
1
Rigid structure
Signal
Name
DATA
Drawn by
Professor
Id. Ser. No
28/05/2014
1
1
Pieces Regulation Material
Weight
SURNAME, NAME
The team
Boladeras Díaz, Marta
Projection
Scale
1:2
Dimensions
European and Industrial design project semester
EPS/IDPS 2014
LUNG SIMULATOR
Name of the project: Pediatric and neonatal lung simulator
Drawing number:
Material:
118
20
29
21
SECTION B-B
SCALE 1 : 2
99,70
75,48
A
R1
10
R4
3,7
B
25
R9
3
°
118,7
82,4
12,5
93,50
180,2
28
4
R1
R4
B
19,44
2
R6
1,
3
6
A
SECTION A-A
SCALE 1 : 2
27,3°
1
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
1:2
EPS/IDPS 2014
RIGID STRUCTURE
Drawing number:
Material:
1
1,35
R1
2
8,5
12,3
M2x0.4
30,25
33,20
10
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
MOTOR SUJECTION 1
Drawing number: 10
Material:
20
31,3
28
5
4
Teeth number
16
Pressure angle
20
Primitive diametre
28
11
DATA
Drawn by
Professor
Id. Ser. No
28/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
GEAR
Drawing number: 11
Material:
F
1,9
F
26,
3
28,
4
3,8
9
60
3,8
9
13,
8
25,
3,8
7
19
3,8
14,
5
SECTION F-F
13
DATA
Drawn by
Professor
Id. Ser. No
SURNAME, NAME
21/05/2014
The team
Projection
Scale
1:1
EPS/IDPS 2014
GENEVE BASE
Drawing number: 13
Material:
,8
R3
6
R6
A
A
56,2
3,4
4
53,7
,8
3,8
8
2
24,3
SECTION A-A
14
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
1:1
EPS/IDPS 2014
GENEVE INDEX WHEEL
Drawing number:
Material:
14
3,4
3,8
1,9
2,1
9
4
24,
15
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
GENEVE STOP WHEEL
Drawing number: 15
Material:
20
O
82,3
O
16
SECTION O-O
10
16
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
TUBE
Drawing number: 16
Material:
20
31,3
10
20
28
5
4
Teeth number
16
Pressure angle
20
Primitive diametre
28
5
17
DATA
Drawn by
Professor
Id. Ser. No
SURNAME, NAME
28/05/2014
The team
Projection
Scale
2:1
EPS/IDPS 2014
LEAKS RING
Drawing number: 17
Material:
1,35
R1
2
24,60
20,40
M2x0.4
30,25
33,20
18
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
MOTOR SUJECTION 2
Drawing number: 18
Material:
°
,94
92
105
2
93,9
2
19
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
Bracket
Drawing number: 19
Material:
26
18
24
R2
73
25,7
5,5
11
1
20
87,9
124,6
,6°
°
,3
76
R2
1
80
25
8,3
2
40
2
45,5
86,4
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
1:1
EPS/IDPS 2014
CHILDREN BAG
Drawing number: 2
Material:
26
24
9,6
41,1
29,5
1
20
1
3°
,8°
61
,
86
1
27,8
R1
76
,3
°
15
27,5
51,8
R2
2
67
8,30
25
59
62
73,8
2
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
1:1
EPS/IDPS 2014
NEONATE BAG
Drawing number: 2 bis
Material:
40
5
6,50
31°
5
3
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
CYLINDER SURFACE
Drawing number: 3
Material:
15
8
,6
136,9
270
0
R7
5
6
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
1:2
EPS/IDPS 2014
CAP
Drawing number: 6
Material:
15
N
50
N
35
30
20
10
12,5
2
SECTION N-N
6°
26,
15
25
8
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
1:2
EPS/IDPS 2014
PULLEY
Drawing number: 8
Material:
1
180
12
9
DATA
Drawn by
Professor
Id. Ser. No
21/05/2014
SURNAME, NAME
The team
Projection
Scale
2:1
EPS/IDPS 2014
BAND
Drawing number: 9
Material:
Resumen de configuración para Cilindro compacto
ADN-16-30-A-P-A
#536224
Función
Características básicas
Feature
Función
Diámetro del émbolo en mm
Carrera en mm
Rosca del vástago
Amortiguación
Detección de posiciones
Value
ADN Cilindro compacto, de doble efecto, en base a ISO
21287
16 mm
30 mm
A Rosca exterior
P Anillos elásticos / placas de amortiguación en ambos lados
A Para detector de posiciones
Otras opciones de productos
Feature
Value
Seguro antigiro
Tipo de vástago
K2 - Rosca prolongada del vástago
K5 - Rosca especial
Resistencia a temperaturas
Funcionamiento constante
marcha suave
Mayor duración
Protección contra corrosión
Mayor fuerza tranversal
Placa de identificación imperdible
Muy temperatura baja
Rascador
Certificación EU (ATEX)
Sin
Vástago simple
Sin
Rosca estándar en el vástago
Estándar
Sin
Estándar
Sin
Estándar
Sin
Placa de características pegada
Sin
Estándar
Sin
24.05.2014 - Reservado el derecho de modificación - Festo AG & Co. KG
1/1
Proportional directional control valves MPYE
• High dynamics
• Final control element for closed control
loops
• 5/3 –way function
2012/06 – Subject to change
Internet: www.festo.com/catalog/...
1
Key features
General information
• The directly actuated proportional
directional control valve has a
position-controlled spool. This
transforms an analogue input
signal into a corresponding
opening cross-section at the valve
outputs.
• In combination with an external
position controller and
displacement encoder, a precise
pneumatic positioning system can
be created.
• Flow control function for varying
cylinder speed
• 5/3-way function for varying the
direction of movement
Wide choice of variants
• Setpoint value input
– Analogue voltage signal
– Analogue current signal
2
• Flow rates from
100 … 2 000 l/min
Subject to change – 2012/06
Key features and type codes
Short machine cycle times – fast switching of programmed flow rates
A:
Proportional valves allow
different speed levels and speed
ramps to be set.
B:
Speed regulation with directional
control valves is more difficult
and is performed by means of
exhaust air flow control.
Rapid speed
Cylinder speed
• Reduce machine cycle times by
optimising cylinder speeds
– Assembly technology
– Handling technology
– Furniture industry
Medium speed
Creep speed
Cylinder stroke
Flexible cylinder speeds – Achieving variable flow rates
Cylinder speed
• Flexibly adapting cylinder speeds
to the process. Traversing
individual acceleration ramps
(gentle approach with delicate
goods)
– Automobile suppliers
– Production technology
– Conveyor technology
– Test engineering
Cylinder stroke
Proportional directional control valve as final control element – Dynamic and fast changing of flow rates
Cylinder speed
• Fatigue tests
• Pneumatic positioning with
SPC200
• SoftStop with end-position
controller SPC11
Time
Type codes
MPYE
—
5
—
x LF
—
010
—
B
Type
MPYE
Proportional directional control valve
Valve function
5
5/3-way valve
M5
x LF
x HF
¼
y
M5
Gx Low Flow
Gx High Flow
G¼
Gy
Setpoint value input
010
420
Analogue voltage signal
Analogue current signal
Generation
B
B series
3
Peripherals overview
9
3
7
6
5
4
8
2
1
2
1
1
Accessories
1
2
3
4
5
6
7
8
9
4
Brief description
Page/Internet
Push-in fitting
QS
Silencer
For connecting compressed air tubing with standard external diameters
quick star
For fitting in exhaust ports
u
Setpoint module
MPZ
Sensor socket
SIE-WD-TR
Sensor socket
SIE-GD
Connecting cable
KMPYE
Connecting cable
KVIA-MPYE
MPYE
Digital input/output
For generating 6+1 analogue voltage signals
–
Angled, 4-pin, M12x1
8
Straight, 4-pin, M12x1
8
–
8
Connecting cable to the analogue module of valve terminal type 03
8
–
5
For controlling the setpoint module
–
Technical data
Variants
• Setpoint value input as analogue
voltage signal 0 … 10 V
current signal 4 … 20 mA
Function
Voltage
17 … 30 V DC
Flow rate
100 … 2 000 l/min
Pressure
0 … 10 bar
General technical data
Valve function
Constructional design
Sealing principle
Actuation type
Type of reset
Type of pilot control
Direction of flow
Type of mounting
Mounting position1)
Nominal size
Product weight
1)
M5
[mm]
[l/min]
[g]
Gx
Low flow
G¼
Gy
8
1 400
530
10
2 000
740
High flow
5/3-way, normally closed
Piston spool, directly actuated, controlled piston spool position
Hard
Electrical
Mechanical spring
Direct
Non-reversible
Via through-holes
Any
2
4
6
100
350
700
290
330
330
If the proportional directional control valve is in motion during operation, it must be mounted at right angles to the direction of movement.
Current type MPYE-5-…-420-B
q [%]
q [%]
Flow rate q at 6 > 5 bar as a function of the setpoint voltage U
Voltage type MPYE-5-…-010-B
Iw [mA]
Uw [V]
5
Technical data
Electrical data
Power supply
Max. current consumption
Setpoint value
Max. hysteresis1)
Valve mid-position
in mid-position
at full stroke
Voltage type
Current type
Voltage type
Current type
Duty cycle2)
Critical frequency3)
Safety setting
Protection against polarity
reversal
Protection class
Electrical connection
1)
2)
3)
M5
Voltage type
Current type
[V DC]
[mA]
[mA]
[V DC]
[mA]
[%]
[V DC]
[mA]
[%]
[Hz]
Gx
Low flow
G¼
Gy
High flow
17 … 30
100
1 100
0 … 10
4 … 20
0.4
5 (±0.1)
12 (±0.16)
100
125
100
100
90
Active mid-position in the event of setpoint value cable break
For all electrical connections
For setpoint value
IP65
4-pin plug socket, round design, M12x1
65
Referred to the maximum stroke of the piston spool.
The proportional direction control valve automatically switches off if it overheats (goes to mid-position) and switches back on once it cools down.
Corresponds to the 3dB frequency at the maximum movement stroke of the piston spool.
Operating and environmental conditions
Operating pressure
Operating medium
Note on operating/pilot medium
Ambient temperature
Vibration resistance1)
Continuous shock resistance1)
CE symbol
Temperature of medium
[bar]
[°C]
[°C]
0 … 10
Compressed air in accordance with ISO 8573-1:2010 [6:4:4]
Operation with lubricated medium not possible
0 … 50
To DIN/IEC 68 Parts 2 -6, severity level 2
To 89/336/EEC (EMC regulation)
5 … 40, condensation not permitted
*
1)
Materials
Sectional view
1
1
2
3
–
6
2
Housing
Valve spool
Housing for electronics
Seals
3
Anodised aluminium
Tempered aluminium
Galvanised acrylic butadiene styrene
Nitrile rubber
Technical data
Download CAD Data www.festo.com/us/cad
Dimensions
D1
B
B1
D
∅
H
H1
H2
H3
H4
M5
Gx
G¼
Gy
26
26
35
40
–
–
26
26
5.5
5.5
6.5
6.5
129.9
149.3
164.6
176.6
69
88.4
103.7
115.7
56.1
71.3
79.6
98.4
38.1
55.1
68.1
79.4
32.1
45.8
56.6
65.4
D1
M5
Gx
G¼
Gy
H5
H6
H7
H8
L
L1
L2
L3
L4
20.1
26.8
33.6
37.4
38.1
55.3
68.1
82.4
26.1
36.3
45.1
51.4
14.1
17.3
22.1
20.4
45
45
58
67
–
–
45
45
14.8
14.8
14.8
14.8
3.2
3.2
3.2
3.2
32
35
46
54
Terminal allocation
1
2
3
4
Ordering data
Pneumatic
connection
M5
Gx
G¼
Gy
24 V DC, supply voltage
GND
Uw/IW, setpoint input
GND
Voltage type 0 … 10 mV
Current type 4 … 20 mA
Part No.
Type
Part No.
Type
154 200
151 692
151 693
151 694
151 695
MPYE-5-M5-010-B
MPYE-5-xLF-010-B
MPYE-5-xHF-010-B
MPYE-5-¼-010-B
MPYE-5-y-010-B
162 959
161 978
161 979
161 980
161 981
MPYE-5-M5-420-B
MPYE-5-xLF-420-B
MPYE-5-xHF-420-B
MPYE-5-¼-420-B
MPYE-5-y-420-B
7
Accessories
Ordering data
Description
Cable length
[m]
Part No.
Screened
5
151 909
X length1)
151 910
KMPYE-…
5
161 984
KVIA-MPYE-5
10
161 985
KVIA-MPYE-10
0.3
170 239
KMPYE-AIF-1-GS-GD-0,3
2
170 238
KMPYE-AIF-1-GS-GD-2
–
18 494
Technical data Internet: sie-gd
SIE-GD
–
12 956
Technical data Internet: sie-wd
SIE-WD-TR
Generation of 6+1 analogue setpoint values
–
546 224
Technical data Internet: mpz
MPZ-1-24DC-SGH-6-SW5
Connecting cable
Connecting cable to the analogue module of valve terminal
type 03
Connecting cable to the axis interface of the axis controller
SPC200
Sensor socket
Sensor socket
Setpoint module
1)
8
Type
Technical data Internet: kmpye, kvia
KMPYE-5
Max. 10 m
Product Range and Company Overview
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With a comprehensive line of more than 30,000 automation components, Festo is capable of solving the most complex
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Supporting Advanced Automation… As No One Else Can!
Festo is a leading global manufacturer of pneumatic and electromechanical systems, components and controls for industrial automation,
with more than 12,000 employees in 56 national headquarters serving more than 180 countries. For more than 80 years, Festo has
continuously elevated the state of manufacturing with innovations and optimized motion control solutions that deliver higher performing,
more profitable automated manufacturing and processing equipment. Our dedication to the advancement of automation extends beyond
technology to the education and development of current and future automation and robotics designers with simulation tools, teaching
programs, and on-site services.
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Festo Corporation is committed to supply all Festo products and services that will meet or exceed
our customers’ requirements in product quality, delivery, customer service and satisfaction.
To meet this commitment, we strive to ensure a consistent, integrated, and systematic approach
to management that will meet or exceed the requirements of the ISO 9001 standard for Quality
Management and the ISO 14001 standard for Environmental Management.
© Copyright 2008, Festo Corporation. While every effort is made to ensure that all dimensions and specifications are correct, Festo cannot guarantee that
publications are completely free of any error, in particular typing or printing errors. Accordingly, Festo cannot be held responsible for the same. For Liability and
Warranty conditions, refer to our “Terms and Conditions of Sale”, available from your local Festo office. All rights reserved. No part of this publication may be
reproduced, distributed, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of
Festo. All technical data subject to change according to technical update.
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Festo North America
Festo Regional Contact Center
United States
5300 Explorer Drive
Mississauga, Ontario L4W 5G4
Canada
USA Customers:
For ordering assistance,
Call: 1.800.99.FESTO (1.800.993.3786)
Fax: 1.800.96.FESTO (1.800.963.3786)
Email: [email protected]
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Call: 1.866.GO.FESTO (1.866.463.3786)
Fax:
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USA Headquarters, East: Festo Corp., 395 Moreland Road, Hauppauge, NY 11788
Phone: 1.631.435.0800; Fax: 1.631.435.8026;
www.festo.com/us
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Fax:
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Canada
USA Headquarters
Festo Corporation
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P.O. Box 18023
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USA Sales Offices
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Headquarters: Festo Inc., 5300 Explorer Drive, Mississauga, Ontario L4W 5G4
Phone: 1.905.624.9000; Fax: 1.905.624.9001;
www.festo.ca
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4935 Southfront Road, Suite F
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Headquarters: Festo Pneumatic, S.A., Av. Ceylán 3, Col. Tequesquinahuac,
54020 Tlalnepantla, Edo. de México
Phone:011 52 [55] 53 21 66 00; Fax: 011 52 [55] 53 21 66 65;
www.festo.com/mx
Central USA
Western USA
Festo Corporation
1441 East Business
Center Drive
Phone:1.847.759.2600
Fax: 1.847.768.9480
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4935 Southfront Road,
Suite F
Phone: 1.925.371.1099
Fax:
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Resumen de configuración para Cilindro compacto
ADN-16-30-A-P-A
#536224
Función
Características básicas
Feature
Función
Diámetro del émbolo en mm
Carrera en mm
Rosca del vástago
Amortiguación
Detección de posiciones
Value
ADN Cilindro compacto, de doble efecto, en base a ISO
21287
16 mm
30 mm
A Rosca exterior
P Anillos elásticos / placas de amortiguación en ambos lados
A Para detector de posiciones
Otras opciones de productos
Feature
Value
Seguro antigiro
Tipo de vástago
K2 - Rosca prolongada del vástago
K5 - Rosca especial
Resistencia a temperaturas
Funcionamiento constante
marcha suave
Mayor duración
Protección contra corrosión
Mayor fuerza tranversal
Placa de identificación imperdible
Muy temperatura baja
Rascador
Certificación EU (ATEX)
Sin
Vástago simple
Sin
Rosca estándar en el vástago
Estándar
Sin
Estándar
Sin
Estándar
Sin
Placa de características pegada
Sin
Estándar
Sin
24.05.2014 - Reservado el derecho de modificación - Festo AG & Co. KG
1/1
• High dynamics
• Final control element for closed control
loops
• 5/3 –way function
1
Key features
General information
• The directly actuated proportional
directional control valve has a
position-controlled spool. This
transforms an analogue input
signal into a corresponding
opening cross-section at the valve
outputs.
• In combination with an external
position controller and
displacement encoder, a precise
pneumatic positioning system can
be created.
• Flow control function for varying
cylinder speed
• 5/3-way function for varying the
direction of movement
Wide choice of variants
• Setpoint value input
– Analogue voltage signal
– Analogue current signal
2
• Flow rates from
100 … 2 000 l/min
Key features and type codes
Short machine cycle times – fast switching of programmed flow rates
A:
Proportional valves allow
different speed levels and speed
ramps to be set.
B:
Speed regulation with directional
control valves is more difficult
and is performed by means of
exhaust air flow control.
Rapid speed
Cylinder speed
• Reduce machine cycle times by
optimising cylinder speeds
– Assembly technology
– Handling technology
– Furniture industry
Medium speed
Creep speed
Cylinder stroke
Flexible cylinder speeds – Achieving variable flow rates
Cylinder speed
• Flexibly adapting cylinder speeds
to the process. Traversing
individual acceleration ramps
(gentle approach with delicate
goods)
– Automobile suppliers
– Production technology
– Conveyor technology
– Test engineering
Cylinder stroke
Proportional directional control valve as final control element – Dynamic and fast changing of flow rates
Cylinder speed
• Fatigue tests
• Pneumatic positioning with
SPC200
• SoftStop with end-position
controller SPC11
Time
Type codes
MPYE
—
5
—
x LF
—
010
—
B
Type
MPYE
Valve function
5
5/3-way valve
M5
x LF
x HF
¼
y
M5
Gx Low Flow
Gx High Flow
G¼
Gy
Setpoint value input
010
420
Analogue voltage signal
Analogue current signal
Generation
B
B series
3
Peripherals overview
9
3
7
6
5
4
8
2
1
2
1
1
Accessories
1
2
3
4
5
6
7
8
9
4
Brief description
Page/Internet
Push-in fitting
QS
Silencer
For connecting compressed air tubing with standard external diameters
quick star
For fitting in exhaust ports
u
Setpoint module
MPZ
Sensor socket
SIE-WD-TR
Sensor socket
SIE-GD
Connecting cable
KMPYE
Connecting cable
KVIA-MPYE
MPYE
Digital input/output
For generating 6+1 analogue voltage signals
–
8
8
–
8
Connecting cable to the analogue module of valve terminal type 03
8
–
5
For controlling the setpoint module
–
Technical data
Variants
voltage signal 0 … 10 V
current signal 4 … 20 mA
Function
Voltage
17 … 30 V DC
Flow rate
100 … 2 000 l/min
Pressure
0 … 10 bar
General technical data
Valve function
Constructional design
Sealing principle
Actuation type
Type of reset
Type of pilot control
Direction of flow
Type of mounting
Mounting position1)
Nominal size
Product weight
1)
M5
[mm]
[l/min]
[g]
Gx
Low flow
G¼
Gy
8
1 400
530
10
2 000
740
High flow
5/3-way, normally closed
Piston spool, directly actuated, controlled piston spool position
Hard
Electrical
Mechanical spring
Direct
Non-reversible
Via through-holes
Any
2
4
6
100
350
700
290
330
330
Current type MPYE-5-…-420-B
q [%]
q [%]
Flow rate q at 6 > 5 bar as a function of the setpoint voltage U
Voltage type MPYE-5-…-010-B
Iw [mA]
Uw [V]
5
Technical data
Electrical data
Power supply
Max. current consumption
Setpoint value
Max. hysteresis1)
Valve mid-position
in mid-position
at full stroke
Voltage type
Current type
Voltage type
Current type
Duty cycle2)
Critical frequency3)
Safety setting
Protection against polarity
reversal
Protection class
Electrical connection
1)
2)
3)
M5
Voltage type
Current type
[V DC]
[mA]
[mA]
[V DC]
[mA]
[%]
[V DC]
[mA]
[%]
[Hz]
Gx
Low flow
G¼
Gy
High flow
17 … 30
100
1 100
0 … 10
4 … 20
0.4
5 (±0.1)
12 (±0.16)
100
125
100
100
90
Active mid-position in the event of setpoint value cable break
For all electrical connections
For setpoint value
IP65
4-pin plug socket, round design, M12x1
65
Referred to the maximum stroke of the piston spool.
The proportional direction control valve automatically switches off if it overheats (goes to mid-position) and switches back on once it cools down.
Corresponds to the 3dB frequency at the maximum movement stroke of the piston spool.
Operating and environmental conditions
Operating pressure
Operating medium
Note on operating/pilot medium
Ambient temperature
Vibration resistance1)
Continuous shock resistance1)
CE symbol
Temperature of medium
[bar]
[°C]
[°C]
0 … 10
Compressed air in accordance with ISO 8573-1:2010 [6:4:4]
Operation with lubricated medium not possible
0 … 50
To 89/336/EEC (EMC regulation)
5 … 40, condensation not permitted
*
1)
Materials
Sectional view
1
1
2
3
–
6
2
Housing
Valve spool
Housing for electronics
Seals
3
Anodised aluminium
Tempered aluminium
Galvanised acrylic butadiene styrene
Nitrile rubber
Technical data
Download CAD Data www.festo.com/us/cad
Dimensions
D1
B
B1
D
∅
H
H1
H2
H3
H4
M5
Gx
G¼
Gy
26
26
35
40
–
–
26
26
5.5
5.5
6.5
6.5
129.9
149.3
164.6
176.6
69
88.4
103.7
115.7
56.1
71.3
79.6
98.4
38.1
55.1
68.1
79.4
32.1
45.8
56.6
65.4
D1
M5
Gx
G¼
Gy
H5
H6
H7
H8
L
L1
L2
L3
L4
20.1
26.8
33.6
37.4
38.1
55.3
68.1
82.4
26.1
36.3
45.1
51.4
14.1
17.3
22.1
20.4
45
45
58
67
–
–
45
45
14.8
14.8
14.8
14.8
3.2
3.2
3.2
3.2
32
35
46
54
Terminal allocation
1
2
3
4
Ordering data
Pneumatic
connection
M5
Gx
G¼
Gy
24 V DC, supply voltage
GND
Uw/IW, setpoint input
GND
Voltage type 0 … 10 mV
Current type 4 … 20 mA
Part No.
Type
Part No.
Type
154 200
151 692
151 693
151 694
151 695
MPYE-5-M5-010-B
MPYE-5-xLF-010-B
MPYE-5-xHF-010-B
MPYE-5-¼-010-B
MPYE-5-y-010-B
162 959
161 978
161 979
161 980
161 981
MPYE-5-M5-420-B
MPYE-5-xLF-420-B
MPYE-5-xHF-420-B
MPYE-5-¼-420-B
MPYE-5-y-420-B
7
Accessories
Ordering data
Description
Cable length
[m]
Part No.
Screened
5
151 909
X length1)
151 910
KMPYE-…
5
161 984
KVIA-MPYE-5
10
161 985
KVIA-MPYE-10
0.3
170 239
KMPYE-AIF-1-GS-GD-0,3
2
170 238
KMPYE-AIF-1-GS-GD-2
–
18 494
Technical data Internet: sie-gd
SIE-GD
–
12 956
Technical data Internet: sie-wd
SIE-WD-TR
Generation of 6+1 analogue setpoint values
–
546 224
Technical data Internet: mpz
MPZ-1-24DC-SGH-6-SW5
Connecting cable
Connecting cable to the analogue module of valve terminal
type 03
Connecting cable to the axis interface of the axis controller
SPC200
Sensor socket
Sensor socket
Setpoint module
1)
8
Type
Technical data Internet: kmpye, kvia
KMPYE-5
Max. 10 m
Product Range and Company Overview
A Complete Suite of Automation Services
Our experienced engineers provide complete support at every stage of your development process, including: conceptualization,
analysis, engineering, design, assembly, documentation, validation, and production.
Custom Automation Components
Complete custom engineered solutions
Custom Control Cabinets
Comprehensive engineering support
and on-site services
Complete Systems
Shipment, stocking and storage services
The Broadest Range of Automation Components
With a comprehensive line of more than 30,000 automation components, Festo is capable of solving the most complex
automation requirements.
Electromechanical
Electromechanical actuators, motors,
controllers & drives
Pneumatics
Pneumatic linear and rotary actuators,
valves, and air supply
PLCs and I/O Devices
PLC's, operator interfaces, sensors
and I/O devices
Supporting Advanced Automation… As No One Else Can!
Festo is a leading global manufacturer of pneumatic and electromechanical systems, components and controls for industrial automation,
with more than 12,000 employees in 56 national headquarters serving more than 180 countries. For more than 80 years, Festo has
continuously elevated the state of manufacturing with innovations and optimized motion control solutions that deliver higher performing,
more profitable automated manufacturing and processing equipment. Our dedication to the advancement of automation extends beyond
technology to the education and development of current and future automation and robotics designers with simulation tools, teaching
programs, and on-site services.
Quality Assurance, ISO 9001 and ISO 14001 Certifications
Festo Corporation is committed to supply all Festo products and services that will meet or exceed
our customers’ requirements in product quality, delivery, customer service and satisfaction.
To meet this commitment, we strive to ensure a consistent, integrated, and systematic approach
to management that will meet or exceed the requirements of the ISO 9001 standard for Quality
Management and the ISO 14001 standard for Environmental Management.
© Copyright 2008, Festo Corporation. While every effort is made to ensure that all dimensions and specifications are correct, Festo cannot guarantee that
publications are completely free of any error, in particular typing or printing errors. Accordingly, Festo cannot be held responsible for the same. For Liability and
Warranty conditions, refer to our “Terms and Conditions of Sale”, available from your local Festo office. All rights reserved. No part of this publication may be
reproduced, distributed, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of
Festo. All technical data subject to change according to technical update.
Printed on recycled paper at New Horizon Graphic, Inc., FSC certified as an environmentally friendly printing plant.
Festo North America
Festo Regional Contact Center
United States
5300 Explorer Drive
Mississauga, Ontario L4W 5G4
Canada
USA Customers:
For ordering assistance,
Call: 1.800.99.FESTO (1.800.993.3786)
Fax: 1.800.96.FESTO (1.800.963.3786)
For technical support,
Call: 1.866.GO.FESTO (1.866.463.3786)
Fax:
1.800.96.FESTO (1.800.963.3786)
USA Headquarters, East: Festo Corp., 395 Moreland Road, Hauppauge, NY 11788
Phone: 1.631.435.0800; Fax: 1.631.435.8026;
www.festo.com/us
Canadian Customers:
Call: 1.877.GO.FESTO (1.877.463.3786)
Fax:
1.877.FX.FESTO (1.877.393.3786)
Canada
USA Headquarters
Festo Corporation
395 Moreland Road
P.O. Box 18023
www.festo.com/us
USA Sales Offices
Appleton
North 922 Tower View Drive, Suite N
Greenville, WI 54942, USA
Headquarters: Festo Inc., 5300 Explorer Drive, Mississauga, Ontario L4W 5G4
Phone: 1.905.624.9000; Fax: 1.905.624.9001;
www.festo.ca
Boston
120 Presidential Way, Suite 330
Woburn, MA 01801, USA
Mexico
Chicago
1441 East Business Center Drive
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1825 Lakeway Drive, Suite 600
Lewisville, TX 75057, USA
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2601 Cambridge Court, Suite 320
Auburn Hills, MI 48326, USA
New York
395 Moreland Road
Silicon Valley
4935 Southfront Road, Suite F
Headquarters: Festo Pneumatic, S.A., Av. Ceylán 3, Col. Tequesquinahuac,
54020 Tlalnepantla, Edo. de México
Phone:011 52 [55] 53 21 66 00; Fax: 011 52 [55] 53 21 66 65;
www.festo.com/mx
Central USA
Western USA
Festo Corporation
1441 East Business
Center Drive
Phone:1.847.759.2600
Fax: 1.847.768.9480
Festo Corporation
4935 Southfront Road,
Suite F
Phone: 1.925.371.1099
Fax:
1.925.245.1286
Festo Worldwide
Argentina
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www.festo.com
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Racor rápido roscado
QSM-M5-4
Número de artículo: 153304
Programa básico
Rosca exterior con hexágono exterior.
Hoja de datos
Característica
Propiedades
Tamaño
Diámetro nominal
Tipo de junta del eje atornillable
Posición de montaje
Tamaño del depósito
Construcción
Presión de funcionamiento en función de la temperatura
Fluido
Indicación sobre los fluidos de funcionamiento y de mando
Clase de resistencia a la corrosión KBK
Temperatura ambiente
Homologación
Par de apriete máximo
Peso del producto
Conexión neumática
Mini
2,2 mm
Junta anular
indistinto
10
Principio Push-Pull
-0,95 ... 14 bar
Aire comprimido según ISO 8573-1:2010 [7:-:-]
Opción de funcionamiento con lubricación
1
-10 ... 80 °C
Germanischer Lloyd
1,5 Nm
3,2 g
Rosca exterior M5
für Schlauch Außen-Ø 4 mm
azul
Conforme con RoHS
latón
niquelado
POM
NBR
Acero inoxidable de aleación fina
Color del anillo extractor
Indicación sobre el material
Información sobre el material del cuerpo
Información sobre el material del anillo de liberación
Información sobre el material de la junta del tubo flexible
Información sobre el material del segmento de sujeción del tubo flexible
24.05.2014 – Reservado el derecho de modificación – Festo AG & Co. KG
1/1

eps - project - Universitat Politècnica de Catalunya (UPC)

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