To:

Brian Hnatkovich,
QBC Diagnostics
(814) 692-7661
bjh@qbcdiag.com

From:

Dane Bralich, drb5301@psu.edu

Thomas Boyer, tub139@psu.edu
Rhian Kogan, rck5086@psu.edu
Ryan Patrick, rmp5191@psu.edu
Jared Yarnall-Schane, jfy5009@psu.edu

Subject:

Date:

March 27th, 2014

Statement of Work

Capstone Senior Design Project

E SC 497
The Pennsylvania State University
Spring 2014

Detailed Specification Report

Executive Summary
In developing countries, disease runs rampant and often undiagnosed due to insufficient medical
equipment and training. QBC Diagnostics has developed a product called the ParaLens Advance, which
provides a low-cost opportunity for doctors in developing countries to use fluorescent microscopy as a
means to diagnose malaria and tuberculosis specifically. The design team has been called upon to help
QBC Diagnostic improve the ParaLens Advance. Specifically, the company would like for the team to
develop a way for the ParaLens Advance to utilize LEDs of a higher intensity than is currently used so
that they can bring a product to market that will increase positive medical outcomes and set themselves
apart from competitors.

In order to solve this design problem, the team must figure out how to manage the increased heat that
comes with utilizing LEDs that emit UV, higher-intensity blue, green and amber light. The current
equipment melts when anything other than the low-intensity blue LED is used, and presents a significant
challenge to QBC Diagnostics desire to expand its product offerings.

The team has developed several concepts, but will be pursuing a fiber optic system to take the heat source
out of the aluminum body and into a separate device that can be more efficiently cooled using both
passive and active cooling methods. With this design, the hope is that there will be a product created that
is low in cost, is easy to use and manufacture, and is efficient in its heat management.

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Statement of Work

Table of Contents
EXECUTIVE SUMMARY ......................................................................................................................... 2
1.0 INTRODUCTION ................................................................................................................................. 5
1.1 INITIAL PROBLEM STATEMENT ............................................................................................................ 5
1.2 OBJECTIVES ............................................................................................................................................ 5
2.0 CUSTOMER NEEDS ASSESSMENT ................................................................................................ 5
2.1 GATHERING CUSTOMER INPUT............................................................................................................. 5
2.2 WEIGHTING OF CUSTOMER NEEDS ...................................................................................................... 7
3.0 EXTERNAL SEARCH ......................................................................................................................... 8
3.1 PATENTS.................................................................................................................................................. 8
3.2 EXISTING PRODUCTS ............................................................................................................................. 9
4.0 ENGINEERING SPECIFICATIONS ............................................................................................... 10
4.1 ESTABLISHING TARGET SPECIFICATIONS .......................................................................................... 10
4.2 RELATING SPECIFICATIONS TO CUSTOMER NEEDS .......................................................................... 10
5.0 CONCEPT GENERATION ............................................................................................................... 11
5.1 PROBLEM CLARIFICATION .................................................................................................................. 11
5.2 CONCEPT GENERATION ....................................................................................................................... 11
5.3 CONCEPT SELECTION .......................................................................................................................... 15
6.0 SYSTEM LEVEL DESIGN................................................................................................................ 16
6.1 TWO CHAMBER ACTIVE COOLING ..................................................................................................... 16
6.2 FIBER OPTIC BOX ................................................................................................................................ 18
7.0 SPECIAL TOPICS .............................................................................................................................. 19
7.1 BUDGET AND VENDOR PURCHASE INFORMATION............................................................................. 19
7.2 PROJECT MANAGEMENT ..................................................................................................................... 20
7.3 RISK PLAN AND SAFETY ...................................................................................................................... 21
7.4 COMMUNICATION AND COORDINATION WITH SPONSOR .................................................................. 21
8.0 DETAILED DESIGN .......................................................................................................................... 21
8.1 MANUFACTURING PROCESS PLAN ...................................................................................................... 21
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8.2 ANALYSIS .............................................................................................................................................. 22

8.3 MATERIAL AND MATERIAL SELECTION PROCESS ............................................................................ 23
8.4 COMPONENT AND COMPONENT SELECTION PROCESS ..................................................................... 24
8.5 CAD DRAWINGS ................................................................................................................................... 26
8.6 TEST PROCEDURE ................................................................................................................................ 26
APPENDIX .................................................................................................................................................. 0
APPENDIX A: PARALENS ADVANCE PROVISIONAL PATENT .................................................................... 1
APPENDIX B: ORIGINAL FIBER OPTIC BOX PATENT .............................................................................. 17
APPENDIX C: DRAWINGS FROM PATENTS................................................................................................ 28
APPENDIX D: MULTIPLE WAVELENGTH LED ARRAY ILLUMINATOR PATENT .................................... 36
APPENDIX E: LW LUMIN SPECIFICATION SHEET ................................................................................... 37
APPENDIX F: HEAT TEST RESULTS .......................................................................................................... 38
APPENDIX G: INITIAL MEETING AGENDA ............................................................................................... 42
APPENDIX H: RESUMES ............................................................................................................................. 43
APPENDIX I: GANTT CHART...................................................................................................................... 49
APPENDIX J: PROTOTYPE HOUSING SCHEMATIC ................................................................................... 52
APPENDIX K: ELECTRICAL ASSEMBLY SCHEMATIC .............................................................................. 53
APPENDIX L: ALUMINUM COMPARISON SHEET ...................................................................................... 54
APPENDIX M: CAD DRAWINGS ................................................................................................................ 56

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Statement of Work

1.0 Introduction
1.1 Initial Problem Statement
The goal of the project is to create a new version of the ParaLens Advance, a device sold by QBC
Diagnostics, a company located in Port Matilda that focuses on diagnosing disease using hematology and
fluorescent microscopy. While designing to fit the constraints of the developing markets that purchase
the product, the goal is to develop upon the existing ParaLens Advance model to create a device that will:
1) Operate using additional wavelengths (green, amber and UV) to diagnose different diseases
2) Be able to withstand the heat associated with the LEDs that emit the above wavelengths of light
3) Improve upon the current blue LED light wavelength model
At the conclusion, the product should at the very least have solved the issue of heat management.
However, there are also secondary objectives related to optimizing the design for use with different filters
and light sources that could lead to the increased applications in the marketplace. To meet this secondary
objective, we are tasked with providing QBC with design and manufacturing plans for our new product.

1.2 Objectives
The design that we develop to solve the problem statement put forth by QBC Diagnostics will not deviate
substantially from the general idea of the ParaLens Advance, since the customer does not want to deviate
too far from its established manufacturing processes and operational methods, of which its customers are
familiar. It will also stay within a reasonable price range, because in order to compete in the developing
nation market QBC Diagnostics must keep its products low-priced. Our design will incorporate some sort
of heat management system in order to expand the current ParaLens Advances capabilities, while also
remaining lightweight, compact and easy to use. Overall, our design will be an improvement upon the
existing model and will build off of several already-established facets.

2.0 Customer Needs Assessment

2.1 Gathering Customer Input
It is important to note that we are creating a product to supplement an existing product line, ParaLens
Advance. Because of the fact ParaLens is currently being sold on the market, we are tasked to create a
product that is similar in form and function for the end consumer. According to QBC, there are three
pressing needs that the ParaLens Advance II must address.

1) The ParaLens Advance II must be low cost, as the majority of their sales are to doctors, hospitals,
and clinics in developing countries.
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Statement of Work

2) To reduce cost, we are to try to keep the design and manufacturing process as similar to ParaLens
Advance as possible.
3) The ParaLens Advance II must be able to be operated on a variety of electrical sources such as
wall outlets, car outlets, and solar packs. It must draw a relatively small power supply so as to
ensure it can work in unfavorable conditions.
4) The ParaLens Advance II must be able to operate on any standard optical microscope.

On top of these three identified needs, the ParaLens Advance II must be user friendly, with ease of
assembly/disassembly. Many customers will not understand English, so actions must be intuitive. We also
must consider safety by designing around preventing burns and possibly blindness due to the LED light.

*Since this product is being sold in developing countries, we are not able to perform direct customer
research. The assessment is a combination of knowledge from QBC and personal experience.

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Statement of Work

2.2 Weighting of Customer Needs

Utilizing the framework for weighting customer needs provided by the Learning Factory, we accurately
portrayed the customers needs so that our end product fit expectations. Beyond this overall goal to
please the customer, utilizing the AHP Pairwise Comparison Chart was important to the success of our
project because it focuses the team on which areas need to be attended to in order to achieve our
objective, while at the same time pointing out which other areas are expendable attributes.
The AHP Pairwise Comparison Chart, which can be seen in Table 1 below, best fit our needs for
weighing the main objective categories of our project. After weighing each category we found that our
main focuses should be on Ease of Manufacturing, Cost, Safety, and Adaptability. Ease of manufacturing
and cost seemed to almost go hand in hand since the main consequence of an increase in manufacturing
would be an increase in cost. The adaptability was also a crucial part of this project in two regards. First,
the whole selling point of the ParaLens Advance is its ability to attach to a normal light microscope and if
you take away that ability you take away the purpose of the project. Second, it needs to be able to be
plugged into different power sources since it will be used in different countries.
Table 1. AHP Pairwise Comparison Chart to Determine Weighting for Main Objective Categories

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Statement of Work

For the hierarchical customer needs list, we first developed sub categories for each category. We then
used conditional weighting to find a weight for each sub category within its respective category and
within the full scope of the entire project. The results of this can be seen below is Table 2.
Table 2. Weighted Hierarchal Customer Needs List

Safety (0.14)
1) Burns (0.67, 0.094)
2) Eye Damage (0.33, 0.046)
Ease of Use (0.12)
1) Intuitive Design (0.75, 0.09)
2) Easy to Assemble (0.25, 0.03)
Ease of Manufacturing (0.16)
1) Use of Existing Manufacturers (0.40, 0.064)
2) Minimize Parts (0.20, 0.032)
3) Mass Production (0.40, 0.064)
Cost (0.15)
1) Material Selection (0.75, 0.1125)
2) Material Reduction (0.25, 0.0375)
Efficiency (0.06)
1) Able to be Used on a Small Battery Pack (1.00, 0.06)
Durability (0.07)
1) Transportability (0.50, 0.035)
2) Field Use (0.50, 0.035)
Portability (0.11)
1) Transportability (0.25, 0.028)
2) Low Weight (0.75, 0.083)
Adaptability (0.14)
1) Use on Any Microscope (0.75, 0.105)
2) Able to Use Any Power Supply (0.25, 0.035)
Aesthetics (0.04)
1) Professional Use (1.00, 0.04)

3.0 External Search

3.1 Patents
Currently, QBC Diagnostics hold a provisional patent for the ParaLens Advance (Appendix A). While
they are still working their way through the process of a full patent, the provisional patent gives protection
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in the marketplace. Originally, the design was protected under another patent (Appendix B), which has
since expired, paving the way for competition to enter the marketplace. When searching through patents,
it can be gathered that QBC has a strong grip on the intellectual property for this ParaLens product. More
specific details related to the actual design of the patent can be found in Appendix C at the end of this
report.
After selecting the fiber optic box design, we again revisited the patent search. In doing so we found a
patent entitled Multiple Wavelength LED Array Illuminator for Fluorescence Microscopy. After
studying the patent, we believe that the Fiber Optic box will be sufficiently different from the claims as to
warrant a new or different patent. However, follow up with a patent attorney is highly suggested as to
ensure we are not encroaching on any of the 22 claims. The full patent can be found in Appendix D.

3.2 Existing Products

QBC Diagnostics ParaLens Advance competes with several products in the marketplace, all of which are
summarized below.
1.) LW Scientific Lumin
LW Scientific, located in the USA, was originally the contract manufacturer for the ParaLens Advance.
At the time, a patent did not protect the product so the design was copied. There are two specific
products, the Lumin Illuminator and the Lumin 60x Objective, and both can be seen below in Figure 1.
The specification sheets for these products are also attached to this report in Appendix D:

2.) FluoroTek

Figure 1. LW Scientific Lumin Products

There is no information about this company or its product online, but based on the conversations with
Brian we know that they are a direct competitor in Asia. Their product is a nearly exact counterfeit of
QBC Diagnostics, and to complicate things further FluoroTek actually markets their product as a QBC
Diagnostics ParaLens Advance.
3.) Godrej/RFCL

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Much like FluoroTek, there is no information about this company that can be found online or by using
any other resource. Brian provided us with his knowledge on Godreg/RFCL and informed us that they
are an Indian conglomerate that, much like FluoroTek, and have a product that they market as the QBC
Diagnostics ParaLens Advance.
4.) Partec
While Partec does not have the same product offering as QBC Diagnostics, it does have a product that
diagnoses malaria specifically and is in the same markets at the ParaLens Advance. The product is made
up of a completely different setup and costs more than the ParaLens, but is nonetheless a competing entity
in the marketplace.
5.) Other FM Microscopes
Companies like Nikon and Olympus produce high-end microscopes that are used specifically for
fluorescent microscopy. These are not necessarily in the same market as the QBC Diagnostics ParaLens
because they are much more expensive, but they serve the same general purpose albeit to a different
audience.

4.0 Engineering Specifications

4.1 Establishing Target Specifications
The team, as well as QBC Diagnostics, determined the following target specifications to help guide the
design process throughout the course of this project. Most importantly, this project is focused on the heat
that is given off by the LED that is housed within the ParaLens Advance. The target specifications are
based on heat tests, the results of which can be found in Appendix F, along with information about the
LED lights we will be using. (*Note that we have several hundred pages of documents, we attached the
most relevant.) Our goal is to develop a system that keeps temperature low, so these specifications are
very helpful in providing a range that we would like to remain within. Furthermore, the outside housing
of the equipment should be kept to a temperature lower than 40 Celsius so that the user will not be burnt
or injured in any way from touching it. Regarding the LEDs, we hope to achieve the largest possible
amount of intensity from them, while at the same time ensuring that the buildup of heat does not
ultimately melt the entire device.

4.2 Relating Specifications to Customer Needs

The customer, QBC Diagnostics, first and foremost wants for us to devise a plan to handle all of the heat
that is dissipated by the LED in the ParaLens Advance. Specific to the LEDs, QBC Diagnostics is
looking to implement the use of UV, Blue, Green and Amber light in that order of priority. The list of
needs for this project is fairly straightforward, and all parties are on the same page with what the final
deliverables should entail.

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Statement of Work

5.0 Concept Generation

5.1 Problem Clarification
For the black box model of the overall product, please refer to the Figure 2 below. The improved version
of the ParaLens Advance that the team is focused on creating will utilize the same basic functions as the
current model. The ParaLens Advances primary function is to deliver images of cells affected by
malaria and tuberculosis to the user through a microscope. The mechanisms by which this occurs are
fairly simple, and consist of an electrical input that powers an LED light. The LED light in turn allows
for fluorescent microscopy to occur, with heat as the main byproduct.
Figure 2. Overall Black Box Model for ParaLens Advance Phase II

LED Light
Electrical Input

LED Light

Input

Deliver Image of
Affected Cells

Fluorescent Microscopy
Heat

LED sends
light towards
lens

Light travels
through filter

Specific light
hits cell
sample

Light returns
to users eye
for viewing

FM

LED turns on
and emits
light

LED
increases
intensity to a
constant
point

Fins and heat

sinks allow
for some heat
exit

Buildup of
heat from
constant light

Heat

5.2 Concept Generation

The following concepts in this section were all generated utilizing the current model of the ParaLens
Advance as a foundation, and brainstorming different ways that it could be improved so that the heat
dissipated by the higher-powered LEDs could be managed.
In Figure 3 below, the first concept can be seen. In order to explore the possibility of active cooling along
the outside of the current body of the ParaLens Advance, we developed this concept. The idea is based
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Statement of Work

on a separate outer housing, centered on the current housing of the ParaLens Advance, that would be used
to facilitate cooling airflow across the outside of the inner core body, in which the LED as well as the rest
of the system would be creating heat and radiating outward towards the body. The create the airflow, a
single fan blade would be attached to the back of the device and pushed out through a chimney off to the
side of the device and away from the work area of the microscope.

Figure 3. Product Concept #1

After developing the first concept for the product based on active cooling of the ParaLens outer body, we
decided as a group to try and explore different and novel approaches to the overarching issue of heat
management.
For the second product concept, found in Figure 4, we focused on the issue of the power source being so
close in proximity to the actual light source, the LED. We developed a concept that would be modeled
very closely after the common computer charger. By removing the DC power supply from the back of
the actual ParaLens Advance itself and housing it in its own box, it could mean that the LED and lens
could be moved further back within the ParaLens Advance housing itself. The hope would be that by
place it farther back, a the housing itself could be perforated with small holes that would better allow for
passive cooling, while still allowing for it to be lightweight, functional and adaptable to the many
environments and stresses that this product is used under.
After our initial analysis of the current ParaLens Advance product, it was seen that fins are currently used
as an effective passive cooling instrument. It was also discovered that the current fin design is not robust
enough to handle the increased heat load from the other LEDs that QBC Diagnostics desires to use in its
next generation of the ParaLens Advance. By enlarging the fins and reorienting them so that they face the
opposite direction as the current design, there would be an increase in surface area. The idea behind this

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Statement of Work

increase in surface area is that it would lead to a greater heat transfer across the aluminum body and keep
the internal temperature at a manageable level. The drawing of this concept can be found in Figure 4.

Figure 4. Product Concepts #2 and #3 Sketches

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Statement of Work

The last and final concept that was developed by the team is actually modeled after the first version of the
ParaLens Advance and can be seen in Figure 5. While the current version of the ParaLens Advance has
all of its components housed in one body, the predecessor to the current design had a separate light and
power source that connected to the filter, which is placed inside of the customized microscope objective.
With this design, there are several benefits. The first of which is the fact that the actual LEDs and
subsequent heat source could be housed in a separate device, allowing for more flexibility when it comes
to active and passive cooling methods. There is also potential with this design for scalability. We have a
vision that we could essentially use this housing to offer different models of LEDs, all housed on a
rotating base that would be set in front of the fiber optic lens depending on the customers preference.
The fiber optic cable could then carry the light through to the filter that would be placed inside of the
customized microscope objective. Overall, this was our strongest option and the choice that at this point
we felt most comfortable with moving forward with.

Figure 5. Product Concept #4 Sketch

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Statement of Work

5.3 Concept Selection

Below, the concept selection matrix for the 4 concepts that we developed, as well as the current model,
can be seen in Table 3. From this, it can be clearly seen that the most promising design for us to pursue
would be that which utilizes fiber optics as a way to transfer the light from the source to the filter.
Table 3. AHP Selection Matrix

From this

Aesthetics

Each concept in the matrix has its own pros and cons, which are detailed below:
2-Cylinder Active Cooling System
Pros: safe
Cons: difficult to manufacture
Fiber Optics System
Pros: safe, easy to use and easy to manufacture
Cons: cost
Liquid Cooling System
Pros: safe
Cons: durability, cost, ease of use and ease of manufacturing
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Statement of Work

Larger Heat Fins

Pros: none
Cons: aesthetics and ease of manufacturing
In summary, it was shown that the best concept for us to pursue would be that of the fiber optic system. It
fits nicely under all of the constraints and specifications that have been laid out thus far in the project, and
will be the design that we move forward with for the duration of this project.

6.0 System Level Design

6.1 Two Chamber Active Cooling
The two chamber active cooling concept, as seen below, is a more simple design inspired from the current
ParaLens. Keeping the housing close to the original design, we built an outer housing to go over the
initial product. This serves two purposes. First, it can protect the users hand from the heat that would be
generated on the inside housing in the original design. Second, with the use of a computer fan and an
outlet at the front we can create active cooling using the outer housing as a tunnel. The inside piece is
virtually the same with the fins being rotated to move along the inside housing, we are also considering
moving the buckpuck DC power supply from directly behind the LED to outside of the entire device,
making it part of the power chord (similar to a laptop charger).

Figure 6. Total System Level Design

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Statement of Work

Figure 7. Inner Housing Design

Figure 8. Outer Housing Design

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6.2 Fiber Optic Box

The fiber optics concept was inspired by a previous ParaLens model, with the idea that it would be easier
to cool as well as allow for extra functionality. The housing is a simple box with slot openings one side
for ventilation and a fan on the other side to blow out the hot air. Active heat transfer is again the primary
use of cooling, and a micro fan is placed against one of the openings. An LED wheel is placed on the
inside for easy transition between LED lights (a bonus for QBC). Also inside would be the buckpuck DC
power supply. We have considered placing heat sinks on the individual LEDs, and possibly using an
epoxy or other methods to cool the inside of the housing. On the outside you can see two chords, one
being the power supply chord, while the other is the fiber optics cable. Below the fiber optics cable are
two knobs to adjust the intensity and also to change the LED lights.

Figure 9. Fiber Optic Box

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Statement of Work

7.0 Special Topics

7.1 Budget and Vendor Purchase Information
Based on the customer needs that we determined, our focus is on safety, ease of manufacturing, cost and
adaptability. From this breakdown, we will be guided on how to best utilize our money over the course of
this project. When it comes to materials, we have been lucky enough to benefit from the use of QBC
Diagnostics facilities and materials, which will greatly reduce our costs related to materials and
machining. However, if we feel as though our design should deviate from the materials available to us,
we will need to use the money provided in our budget to cover those expenses. Travel expenses are also
expected to be minimal, considering that QBC Diagnostics headquarters are located 20 minutes away in
Port Matilda, PA. There really should be no need for us to utilize the budget for anything related to
travel, lodging or meals.
The costs related to the presentation of our final product will also be present. While this is not something
that has been actively discussed thus far, it will require a significant part of the budget and will be kept in
mind throughout the entire course of the project. The majority of the budget will be used for the design
parts. This is the section that we assume will prove the most costly. From our concept design meeting we
created concepts that require little change to the current model and some that will require more deviation
from the current model. For the design of parts that are not currently part of the manufacturing process,
we will assume that testing will cause us to use more material to create our prototypes. We can also
assume that we will have to have multiple tests for our new parts, which will increase our cost in design
materials. We will need to factor in costs of active cooling fans, cooling epoxy and heat dissipation parts
that will be used in concept testing. The table below outlines the initial budget plan as best as can be done
at this point.

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Statement of Work

Table 4. Quantitative Breakdown of Current Budget Status

Budgeted Item

Estimated Cost

Actual Cost

Supplier

Machining

$0

$0

LEDs

$0

$103.03

Mouser

Electronics

$100

$56.73

Luxeon Star, Mouser

Miscellaneous Parts

$100

$15.40

Mouser

Heat Dissipation

$200

$32.04

Micro Center, Newegg

Organization

$50

Trips

$100

Other

$150

Final Project Poster

$50

Table Cloth

$15

Presentation

$100

Total

$865

$207.20

7.2 Project Management

The Gantt chart seen in Appendix I manages the project and serves as a guiding light for progress
throughout the course of the semester. The team is made up of people that have very diverse backgrounds
and interests, but each brings something unique and valuable to the entire group as a whole. The resumes
for each member are included in Appendix H. Three of the five members have strong management and
writing skills, and will be instrumental in ensuring that the group stays on track and communicates
effectively with all of the necessary parties involved. On the technical side of things, two group members
bring a strong understand of electricity and how to best construct an efficient power system. Collectively,
the group also possesses strong technical knowledge in terms of solutions for cooling and methods for
which to produce the different designs that may be conceived.
With the time that is left before the final deliverables are due, there is still much to do. Besides
solidifying plans for a specific concept and design procedure, the team must prepare and familiarize itself
with the capabilities of QBC Diagnostics manufacturing facilities. Furthermore, there must be a plan for
producing a prototype in conjunction with QBC Diagnostics and finally a plan to present the new product
at the final showcase.

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Statement of Work

7.3 Risk Plan and Safety

The main risks associated with this project are safety risks associated with our design. These risks are
outlined below:
LED
- Class 1 Product: safe under almost all operating conditions
- On spec sheet: LZ4-00A108 LED Engin
- 125 degrees Celsius maximum at the diode junction
- Use caution when operating LED in electrostatic intensive area (spec sheet)
- Filters should be installed in the fiber optic device to eliminate harmful infrared radiation (invisible) in
microscopy applications (Fiber Optic Association)
Power supply
- Low voltage/current rating little to no risk involved
- Same minor risks as household electronics
- Power supply should be designed to handle load specifications
- High currents through the body can be fatal. Power supply should be designed to isolate such currents
from possible human contact
-Power supply should be designed to limit heat. Not only can it cause device failure, but also poses a
danger for burns upon contact

7.4 Communication and Coordination with Sponsor

The communication between the team and sponsors consists of an email to update each other on progress
at least once a week. The team also travels to the Port Matilda, PA headquarters bi-weekly to have a faceto-face meeting in which we go over any and all questions that either side may have.

8.0 Detailed Design

8.1 Manufacturing Process Plan
Prototype
The following steps provide a detailed manufacturing process plan for the QBC Diagnostics ParaLens
Advance II prototype.
*Note that this is the manufacturing plan for the prototype, and a mass production manufacturing plan
will be included in the final report.

Housing Assembly Raw stock 24 x 20 x 1/16 sheet of 5052 aluminum

o Use a water jet to cut the sections as shown in Appendix J

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o Drill and debur twenty 1/8 rivet holes

o Use the sheet metal brake to form 90 angles as shown in Appendix J
o Rivet together the bottom and sides of the housing using 1/8 rivets and a rivet gun
Fan Assembly 80 mm computer fan
o Align the fan to ensure that airflow blows through the housing assembly
o Align rubber washers with the housing assembly and fan to reduce vibrations and noise
o Attach the fan to the housing assembly using four 0.165 fasteners
LED Assembly LEDengin Blue LED (model for all LEDs)
o Solder wires onto the LED leads
o Mount the LED to the aluminum heat sink using a thermal conductive adhesive
o Mount the LED and heat sink assembly to a PVC seat within the housing, as outlined in
Appendix J
o Position the lens within the LED assembly and PVC seat
Electrical Assembly All connections made to a breadboard
o Follow the schematics presented in Appendix K to solder the connections together
o Place the potentiometers within the specified holes on the housing assembly
o Mount the electrical components within the housing assembly

Mass Production
The following steps provide a detailed manufacturing process plan for the QBC Diagnostics ParaLens
Advance II.

8.2 Analysis
First and foremost, an analysis was needed to determine just how much needed to be managed. When
calculating, we looked for the cubic feet per minute that would need to be removed in order to ensure that
the internal components would not be affected.
Assuming a maximum temperature of 150F and a room temperature of 100F, the following equation
was used to calculate the volumetric flow rate in order to properly manage the excess heat.
=

3.16

The power of each LED was gathered from the specifications found on the LED Engin website, as well as
the original Luxeon Star LED that is currently used in the ParaLens Advance. Below are the final values,
in cubic feet per minute, that represented how much heat needs to be removed for proper management.
Luxeon Star Blue LED: .214
LED Engin Blue LED: 1.032
LED Engin Green LED: 1.062
LED Engin Amber LED: 0.6636
LED Engin UV LED: 1.15
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Analysis for Resistor Values:

In order to achieve the desired LED voltage range, a resistor was needed in series with the potentiometer.
This value was calculated using the 16.65 V to 12.8 V drop (3.85 V).
= 12.8 = 16.65

!!
!!!!"#$

= 10 ,

(Potentiometer resistance is at minimum)

12.8
1
=
16.65 1 + 10

R1 1 0.769 = 7.69
Solving for R1: = (in series with the potentiometer)
Using the fans power rating, we can calculate the load resistance of the fan:
= ! /
= 1.08 =

12

; =

12 !
; =
1.08

8.3 Material and Material Selection Process

As we identified from section 2.2, the main areas of focus determined from weighting of customer needs
are ease of manufacturing, cost, safety, and adaptability. To account for adaptability we are selecting
small and robust components to ensure that our product remains portable and effective to use anywhere in
the world. Since our product utilizes a fiber optic cable instead of connecting directly to the microscope,
we did not have to worry about strict size constraints.
To ensure the product has a low cost and is easy to assemble we considered several materials for the
housing. The first material we considered was 3-D printed plastic. After consulting with QBC we decided
that 3-D printing is a long process, with many opportunities for failure and cost. At this point we are not
considering plastic injection molding, as the cost to buy the required mold would be around $75,000.
Having crossed plastic off the list, we began to look at different types of metals. Since this is to be used
for health related purposes we want to select something that will not rust or contaminate specimens. At
the same time we are looking for a material that is relatively light, strong, and easily machined. Because
of these requirements, we focused on aluminum products, specifically comparing 5052 and 6061
aluminum. The comparison sheet as seen in Appendix L provides an excellent breakdown of the potential
applications of both metals. Our application includes machining and bending, making 5052 aluminum the
ideal material for our product. The price of a 5052 aluminum sheet with a size of 24 x 24 x 1/16 is
$17.22, compared to the price of a 6061 aluminum sheet of the same size with a price of $25.15. (source
from www.onlinemetals.com )

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8.4 Component and Component Selection Process

The electrical component details, as well as the reasons why they were selected, are as follows:
Breadboard:

Model: Jameco Value Pro Breadboard Segment

Dimensions: 6.65 x 2.125
840 Connection points
Was chosen for its compact dimensions and its flexibility for our prototype

Power Supply:

The same power supply as in the previous ParaLens model will be used.
ParaLume DC Power Supply, 9V, W / 4 Interchangeable Plugs
Short Circuit protection/Over Voltage Protection
9 V Output Voltage
0 A - 1.4 A Load Current
1% Ripple and Noise Margin
2% Voltage Accuracy
1% Line Regulation
2% Load Regulation
This power supply is cost effective, reliable, durable, and can be supported by power outlets in
multiple countries.

DC-DC Module Step-Up and Down Voltage Converter:

The LEDs require a minimum of 12.8 V for operation. Therefore, a step-up voltage regulator is
required to achieve this voltage from a circuit input voltage of 9 V.
Model: LM2596S+LM2577S
Operating Temperature Range: 0-125o C
Input Voltage: 3.5-28 V
Our operating input voltage: 9 V
Desired input voltage: 16.65 V
Maximum Input Current: 3 A (we are in the safe range, at less than 1 A).
Maximum Output Current: 3 A (we are in the safe range, at less than 1 A).
Our operating output current: 700 mA
Internally Limited Power Dissipation
The variable voltage regulator allows us to achieve a very specific voltage value (16.65 V) for the
LED. Although not the cheapest, this was the only device that allowed us to achieve this voltage.

Potentiometer:

Model: Bourns 10K 10% SQAURE SEALED Audio Logarithmic Potentiometer

Through-Hole mounting style
Price was reasonable

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Operating temperature: 1-125o C

Power Rating: 500 mW
Resistance is not linearly related to the angular position of the knob.
Contact Resistance Variation: 2%
Power Rating at 70o C: 0.5 W
Was chosen to allow for a perceivable LED intensity change

BuckPuck:

Model: Luxeon Star 700 mA, Externally Dimmable BuckPuck DC Driver With Leads
Cost effective
Output Current: 700 mA
Input Voltage Range: 5 V 32 V (DC)
Control Pin Voltage: 10 V (DC)
Output tolerance: 5%
Efficiency: 95%
Was chosen to feed a constant current of 700 mA to the LED

Resistors:

Free of cost (from the Penn State Electrical Engineering Stockroom)

The resistor is a linear circuit component, governed by ohms law (V=IR)
Resistance Values (quantity): 33k (1), 51.5 (1)
Calculated to achieve required parameters

The fiber optic cable we are using is from the predecessor to the ParaLens and can be seen in Figure 10
below.

Figure 10. Prototype Fiber Optic Cable

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There are a few problems with the original cable, but we will be using it for our prototype. The cable can
easily break when bent several times, and is geared towards visible light. Our prototype will be using only
blue light from an LED, so this is not a problem. The original fiber optic model used a white halogen
light. We will be using a lens to focus the light into the fiber optic cable. The cable will then fit into the
microscope. The piece that mounts the original ParaLens behind the objective of the microscope will also
fit this fiber optic cable.
When we add the other LED's, we will have to worry about ultraviolet light. We will need to have a
second fiber optic cable that can deal with the wavelength and intensity of UV light.
When the other LED's are added we have decided to have several spots to insert the fiber optic cable into
sockets on the housing (A socket for each LED). We are currently thinking about ways to have the device
detect which socket/port the cable is plugged into. We are looking into using a magnetic system. Having a
different size cable just for the UV LED will prevent the visible light fiber optic cable being used for UV
light.
When choosing which LEDs to use for our product, we utilized the expertise that was available to us in
the form of QBC Diagnostics. Building off of their work and our own research, it was determined that
the best option for the blue, green, amber and UV LEDs was a LED Engin, as opposed to the Luxeon Star
LEDs that are used in the current version of the PareLens. The sole reason for this is because the LEDs
offered by LED Engin offer levels of luminescence that are leagues beyond those offered by Luxeon Star.
In terms of cost, they were more expensive but our sponsor made it very clear that this increase in cost
was to be expected if they were to have brighter LEDs. They are of a superior quality and while they do
not offer any improvement in terms of heat management, their increased brightness solves one of our
projects biggest deliverables.

8.5 CAD Drawings

For all CAD Drawings of the prototype and expected final design, please reference Appendix M.

8.6 Test Procedure

In order to ensure that the product will not overheat (temperatures above 130 F) we will use a
thermocouple probe to test the heat of the system at a variety of locations, including but not limited to:

LED
Heat Sink LED connection
Buck puck
Inside of housing
Outside of housing

In addition, we will leave the system on for an extended period of time (>4 hours) and repeat the tests, to
ensure that the product is robust and can withstand misuse.
Most importantly, we need to ensure that the product achieves its primary function of enabling
fluorescence microscopy to take place. In order to test this function, the following steps must take place:
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Take blood sample and apply the appropriate malaria/tuberculosis test dye
Place the blood sample on a slide and place on a microscope tray
Place the LED box next to the microscope on a flat surface
Decide which LED (blue, green, amber, UV) you would like to use to run the test
Place the appropriate fiber optic cable into the correct aperture
Attach the cable to the correct objective filter, and place into the microscope objective
Turn on the appropriate switch for what LED light you are using
Observe the blood sample for evidence of malaria/tuberculosis

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Appendix
Appendix A: ParaLens Advance Provisional Patent

Appendix B: Rathbone Patent

17

Appendix C: Patent Illustration

28

Appendix D: Multiple Wavelength LED Array Illuminator

36

Appendix E: LW Scientific Lumin Specification Sheet

37

Appendix F: Heat Test Results

38

Appendix G: First Team Meeting Agenda

42

Appendix H: Team Resumes

43

Appendix I: Gantt Chart

49

Appendix J: Prototype Housing Schematic

52

Appendix K: Electrical Assembly Schematic

53

Appendix L: Aluminum Comparison Sheet

54

Appendix M: CAD Drawings

56

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Appendix A: ParaLens Advance Provisional Patent

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Appendix B: Original Fiber Optic Box Patent

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Appendix C: Drawings from Patents

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35
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Appendix D: Multiple Wavelength LED Array Illuminator Patent

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Appendix E: LW Lumin Specification Sheet

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Appendix F: Heat Test Results

LEDEngin Blue - Test 1
Relative Intensity
1.00

70.00

0.90

60.00

0.80
50.00

0.70

Temperature (C)

Relative Intensity

0.60

40.00

0.50

30.00

0.40
0.30

20.00

0.20
10.00

0.10
0.00
0.00

10.00

20.00

30.00
Time (min)
Intensity

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40.00

50.00

0.00
60.00

16.00

70.00

LEDEngin Blue - Test 1

14.00

60.00

12.00

50.00

10.00
40.00
Intensity (K Lux)

Temperature (C)

8.00
30.00

6.00

20.00

4.00

10.00

2.00
0.00
0.00

10.00

20.00

30.00

Time (min)
Intensity

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40.00

50.00

0.00
60.00

Heat Sink Temperature Data

LEDEngin Blue - Test 1
70.00
60.00

Temperature (C)

50.00
40.00
30.00
20.00
10.00
0.00
0.00

10.00

20.00
LED Base

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30.00
Time (min)

40.00
Heat Sink Tip

50.00

60.00

41
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Appendix G: Initial Meeting Agenda

Penn State Senior Design Project

ParaLens Advance Phase II
Team Meeting

AGENDA

28 January 2014

12:30 12:35

Review of Agenda

12:35 12:45

Team Introductions

12:45 1:15

Project Review B. Hnatkovich

12:30 2:00 PM
Auditorium

o
o
o
o

Scope/Goals of Project
Background
System Introduction
Handout PLA Design
Packet

1:15 1:45

Project Discussion, Questions &

Project Planning

1:50 2:00

Review & Action Items

Deliverables:
o Action item list with responsibility and due date.
o Preliminary project plan

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Appendix H: Resumes

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45
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48
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Appendix I: Gantt Chart

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50
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Appendix J: Prototype Housing Schematic

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Appendix K: Electrical Assembly Schematic

Description of Schematic:

The 9 V power supply (the same one used for the previous ParaLens model) supplies 9 V of DC power to
the circuit. The voltage is then stepped up to 16.65 V using a voltage regulator, so that the LED can be
within its operating voltage range. This voltage will be used to power the fan, as well as the LED. On the
fans circuit branch, the 16.65 V will be divided among the fan load, and a chosen resistor. The voltage
across the fan will be 12 V as a result.

Since the LED requires 700 mA of current, a buckpuck is placed after voltage regulator, and does not
interfere with the fan branch of the circuit. In order to keep the LED in its operating voltage range (12.8 V
-16.65 V), a potentiometer and resistor in series are used. The resistor was chosen so that the minimum
voltage of 12.8 V can be maintained when the potentiometer is set at its lowest resistance. Both the LED
and the fan are connected to ground at their lower voltage polarities.

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Appendix L: Aluminum Comparison Sheet

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>> 5052 and 6061 Aluminum Sheet

Properties
Alloy Temper

Ultimate
Tensile Strength
MPa
KSI

Tensile
Yield Strength
MPa
KSI

Elongation

Thermal Conductivity

5052-0

193

28

89.6

13

%4D

BTU in/hr-ftF

25%

5052-H32

228

33

193

28

12%

960
960

6061-T4

255

37

152

22

23%

1070

6061-T6

345

50

290

42

13%

1160

Availability
Alloy

Tempers

Gauges

Widths

Finishes

Typical Uses

Anodizeable

5052

0, H32

0.014-0.190
0.34-5mm

Up to 60
1500mm

M, P, SB, LB, C

Laptops, Mobile
devices

YES

6061

T4, T6

0.026-0.125
0.635-3.2mm

Up to 60
Up to 1524mm

Mobile devices

YES

For requirements outside of standard dimensions, please contact your Alcoa sales representative.
Available Finishes
M) Mill Finish

SB) Short Brush pattern

P) Preferred Mill Finish

LB) Long Brush pattern

BR) One side Bright

C) Coated

The Alcoa Advantage

OEMs are discovering that Alcoa can help them realize increasingly thinner, lighter and more durable products in a
wide variety of looks and finishes. And aluminum is preferred by designers because it is contemporary, stronger and
has an authentic, natural feel. Whether your company is designing the next hot cell phone, notebook computer, or flat
panel display, we can help:
>> Provide industry leading quality materials
>> Select alloys optimized to your application
>> Achieve greater levels of component integration
>> Improve manufacturing practices and cycle times
>> Increase overall product and system performance
>> Create a sustainable, recyclable product
A successful consumer electronics product made with aluminum requires material and design expertise and solid
technology. Most important, it also requires the right partnera metals expert who can bring together all the tools
and brains you needwith a global technology organization and production facilities and expertise worldwide.
Contact us today to learn how we can help your products stand out in the crowd.
Measured at a minimum thickness of .41mm
Measured at 77 F

www.alcoaconsumerelectronics.com
Revision 2010.12 2010 Alcoa, all rights reserved

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Appendix M: CAD Drawings

Side View

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Isometric View

Top View
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