P18026: Infant Incubator

Customer Handoff & Final Project Documentation

Table of Contents

Team Vision for Final Demo and Handoff

During this last phase of the project, the team was determined to complete a working prototype to be presented at Imagine RIT. In order to complete the working prototype, the team knew there was a large portion of the electrical system to complete as well as integrating the system into the incubator base. The team also wanted more validation and verification by completing more testing in order to be more confident in the prototype's abilities.

The team accomplished many of the phase goals before Imagine RIT. The major accomplishment was completing the electrical system and integrating it with the rest of the incubator components. This accomplished our goal of having a working incubator prototype as the system properly turned on and all components worked after integration. Since the team was behind in most aspects of the phase, testing was put on hold and may not be completed before Imagine RIT, but instead before the end of the semester.

Test Results Summary

The test plans can be accessed throughout the EDGE website in a live document and will be updated throughout the semester. All test plans are in the excel template except for the sanitation and ergonomics. The ergonomics testing has been completed, but due to the variety of requirements testing within the ergonomics test, the plans were not put into the excel format.

Detailed documentation of test plans were created in order to fully understand the procedure without needing to follow the flow charts in the excel document.

Risk and Problem Tracking

Rick Assessment

The Failure Mode Effects Analysis (FMEA) allows for an in depth evaluation of any potential risks during the use of the product. When evaluating risks, a cause and effect are assigned in order to determine the root of the issue and define countermeasures to lower the potential occurrence.
Updated Assessment Overview
The document owner is Victoria Tripp.
Risk Assessment per FMEA Standards Part 1

Risk Assessment per FMEA Standards Part 1

Risk Assessment per FMEA Standards Part 2

Risk Assessment per FMEA Standards Part 2

Risk Assessment per FMEA Standards Part 3

Risk Assessment per FMEA Standards Part 3

The updated risk assessment document can be found here.

Problem Tracking

Thus far, no risks have manifested as problems, but if needed the template of the problem tracker can be found here.

Final Project Documentation

The incubator prototype is a first generation model. With this being said, the following documentation was created in order to assist in further design and prototyping. Below is a list of links to download the described file.

Electrical Schematic

Electrical Schematic

CAD Models and Drawing Package

The final CAD model was simplified due to time and budget constraints. The CAD model includes the base and top of the incubator along with the inner dehumidifier box and adjustable infant bed. A zip folder of the CAD models and final assembly can be found here, as well as the final drawing package here. A pdf of the CAD drawing package can be previewed below, with the document here. A complete zip file of all CAD models and drawings can be found here.
CAD Drawing Package Preview

CAD Drawing Package Preview

CAD Drawing Package Preview 2

CAD Drawing Package Preview 2

Technical Paper and Final Poster

The team prepared a technical paper in which a concise summary of information of the EDGE website can be found. The paper gives an overview of the project background and design as well as feasibility and testing results found using the prototype. The technical paper can be found here.

As the team prepares for Imagine RIT, a poster was designed in order to give an overview of the project as patrons visit the exhibit. The poster can be seen below.

Final Poster

Final Poster

Functional Demo Materials

For the remainder of the course, all review material will be presented through the team EDGE website along with any physically built components and testing results. No extra materials were needed for this phase review.

Plans for Wrap-up and Next Generation Prototyping

As a team, we are proud to have accomplished a functional prototype which integrated the key elements of an incubator. While the final prototype is fully functioning, further testing and prototyping is needed in order for the incubator to be used for premature infants.

As Imagine RIT approaches, the team still needs to complete sanitation testing and documentation in order to accomplish the objectives of the team and client. Since the testing is not complete, it was also not fully included in the technical paper.

Next Generation Improvements

The team has many suggestions for the next generation prototype that should improve safety for the infant.

Beginning with the overall design and aesthetic, the incubator base and top were heat molded due to size constraints of the vacuum former in the RIT construct. The team is aware that vacuum forming was the best option for the manufacturing of the top and base and learned the issues of using foam as a mold when heat forming. The mechanical engineers would suggest using a heat resistant material for the mold if either vacuum sealed or heat molded in the future in order to prevent the mold from deforming and causing issues with the finished product. Vacuum forming will give better results if properly done, potentially by an outside company. Budget would be important if using an outside vendor. Injection molding would also work better than the heat forming used in creating our prototype, and even better than vacuum forming. The cost for creating a mold for the injection molding would be of concern. A low cost alternative to consider would be 3D printing the exterior and leaving space within the walls in order to hide the electrical wiring and components. By using any of these other techniques, it may even be beneficial to create different section and puzzle the incubator together.

The electrical system in the current prototype includes all necessities recommended by the doctors and nurses at Hospital Escuala. With this being said, many improvements should be made in order for proper environmental control for the premature infant. First, the heating element used for the incubator are heating pads that use a coil system to heat a body by contact. While this is great for some applications, it could be problematic without proper testing on infants. The team would suggest looking at other low cost, safe, heating alternatives. Secondly, the system is currently monitored through an ambient temperature and humidity sensor which is not typically used for an infant incubator. A typical incubator uses a sensor which is placed on the infant's body and monitor's the infant's body temperature which is what needs to be regulated, not the ambient temperature. The team found issues during research where companies did not give information as to how their sensors read the infant's heat and therefore was not feasible for the team to move forward with. Integrating an infrared sensor was the team's stretch goal, but was not able to be completed due to time constraints. Proper testing would also need to occur if the ambien temperature sensor were used long term, and using a heat exchange would provide more accurate results to the feasibility. The circuit board used in the functional prototype was also very large and could be reduced to about 1/10 of the size if a PCB (printed circuit board) was used instead.

Lastly, humidity needs to be properly maintained in an incubator to allow the infant the best survival. The humidifier met the calculated specifications, but issues occurred when searching for a low cost, reasonably sized dehumidifier that would actually meet the specifications for dehumidifying the environment. Testing both the dehumidifier and humidifier were also an issue as the proper environment could not be found on campus. Better simulating the humid and warm environment would conclude to more accurate results.

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