Mechanical Engineering Senior Project Researchir.lib.ksu.edu.tw/bitstream/987654321/16885/2/å°ˆé¡Œè£½ä½œ.pdf · Department of Mechanical Engineering Tainan, Taiwan, R.O.C

Department of Mechanical Engineering

Tainan, Taiwan, R.O.C.

Kun Shan University

May ��

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Mechanical Engineering

Senior Project Research

Chapter I: Pipeline Flow Meter Test Bench Assembly

Chapter II: Peak Flow Meter

Student: Jose Daniel Sandoval Ordoñez

Advisor: Song-Hao Wang

I

II

Contents

Table of Figures ............................................................................................................................ IV

Acknowledgments.......................................................................................................................... V

Chapter I: Pipeline Flow Meter Test Bench Assembly

Abstract I ......................................................................................................................................... 6

1. Introduction ................................................................................................................................. 7

1.1.Background .......................................................................................................................... 7

1.1.1.For oil or natural gas. .................................................................................................. 8

1.1.2.For ammonia. ............................................................................................................... 9

1.1.3.For biofuels (ethanol and biobutanol) ......................................................................... 9

1.1.4.For coal and ore ........................................................................................................... 9

1.1.5.For hydrogen ............................................................................................................. 10

1.1.6.For water .................................................................................................................... 10

1.2.Pipeline Grid Operation ...................................................................................................... 11

1.3.Flow Meter Types .............................................................................................................. 12

2.Materials .................................................................................................................................... 12

3.Assembly.................................................................................................................................... 13

4.Standard Flow Meter.................................................................................................................. 14

4.1.Features .............................................................................................................................. 15

4.2.Short Specifications ............................................................................................................ 15

5.Results ........................................................................................................................................ 16

6.Conclusions ................................................................................................................................ 17

7.References .................................................................................................................................. 18


Abstract II ..................................................................................................................................... 19

1.Introduction ................................................................................................................................ 20

1.1.Asthma ................................................................................................................................ 20

1.2.History ................................................................................................................................ 21

1.3.What is a Peak Flow Meter? ............................................................................................... 22

1.4.Forced Expiratory Volume ................................................................................................. 24

1.5.Lung Volumes .................................................................................................................... 25

III

1.6.Definitions .......................................................................................................................... 26

2.Technologies Used ..................................................................................................................... 27

2.1.Rapid Prototyping ............................................................................................................... 27

2.1.1.The RP (Rapid Prototyping) process ......................................................................... 28

2.1.2.Benefits of rapid prototyping .................................................................................... 29

2.2.3D Drawing or CAD .......................................................................................................... 31

2.2.1.Design Process .......................................................................................................... 32

3.Equipment .................................................................................................................................. 33

3.1.Hardware ............................................................................................................................ 33

3.1.1.FDM machine ............................................................................................................ 34

3.2.Software .............................................................................................................................. 35

3.2.1.Solid Works ............................................................................................................... 35

4.Peak Flow Meter Design ............................................................................................................ 37

4.1.Peak Flow Meter conceptualization ................................................................................... 37

4.2.Peak Flow Meter Prototype01 ............................................................................................ 38

4.3.Peak Flow Meter Prototype02 ............................................................................................ 39

4.4.Peak Flow Meter Prototype03 Design ................................................................................ 40

4.4.1.Peak Flow Meter Prototype 03 Version 2 ................................................................. 43

4.4.2.Design of tester for the coil of the Peak Flow Meter Prototype03 ............................ 44

4.4.3.Tests and Results ....................................................................................................... 46

4.4.4.Peak Flow Meter Prototype 03 Version 3 ................................................................. 47

5.Future Enhancements ................................................................................................................. 49

6.Conclusions ................................................................................................................................ 49

7.References .................................................................................................................................. 50

IV

Table of Figures

Figure 1: Pipeline Grid Operation................................................................................................. 11

Figure 2: Test Bench Assembly .................................................................................................... 13

Figure 3: Flow Rate – Tokyo Keiso Commercial flow meter vs. our flow meter ........................ 16

Figure 4: Asthma Pathology Illustration ....................................................................................... 20

Figure 5: Peak Flow Meter ........................................................................................................... 23

Figure 6: Normal Values of PEF .................................................................................................. 24

Figure 7: Fused Deposition Modeling Process ............................................................................. 31

Figure 8: Iterative Design Process ................................................................................................ 33

Figure 9: Dimension BST Printer ................................................................................................. 34

Figure 10: Peak Flow Meter Concept design ................................................................................ 38

Figure 11: Peak Flow Meter Prototype 01 .................................................................................... 39



Figure 14: PFM Prototype 03 views ............................................................................................. 42

Figure 15: PFM Prototype 03 V2 ................................................................................................. 43

Figure 16: Tester exploded view................................................................................................... 45

Figure 17: Peak Flow Meter P03 V3 ............................................................................................ 48

Figure 18: Peak Flow Meter P03 V3 Dimensions ........................................................................ 48

V

Acknowledgment

First of all I would like to thank God for giving me the knowledge and strength to pursue this

research and an education abroad; without Him I wouldn’t be where I am now neither would

have I been able to accomplish my goals and objectives.

As equally important I would like to express my sincere and deepest thanks to The Republic of

China and its people for giving me the incredibly important opportunity of letting me in their

home and receiving me with their arms open to study and learn so much about their culture and

knowledge.

Secondly I would like to acknowledge ICDF for financing my studies in Taiwan and allowing

me to pursue my dream of obtaining a professional degree in a country so developed and

advanced, for giving me the opportunity of embracing another culture and of learning everything

that now makes me a better person and a better professional.

During the length of the four years that I have been able to live in this beautiful place Kun Shan

University has been my loving home and family, without its caring people it would have been

impossible to me to learn the vast amount of knowledge that I have now; I want to thank

especially the Department Of Mechanical Engineering and all the department teachers and staff

for sharing their huge wisdom and affection with me; the International Office for guiding me

during these four years and showing me the path to follow making my stay easier; and finally the

Military Office for giving me a house and a place to live in the school dorms and managing the

order and discipline, which I am sure is not an easy task.

Special thanks are deeply granted to Dr. Song-Hao Wang, my senior project advisor, for his

guidance, patience and the precious time he bestowed upon me as his student and friend; to

professor Shao-Shu Chu, my class advisor; and to my loved family for their unconditional

support, love, and counsels, for the sacrifice they made of letting me go at such a young age, and

for the patience they have had during this whole time.

And last but not least to my dear friends and classmates for their support, their unconditional

friendship and their selfless love towards me.

Chapter I: Pipeline Flow meter Test Bench Assembly

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Abstract I

The following pages describe the creation of a

test bench system with each material and

parameters used; trying to illustrate how this

project was born as an idea and the purpose

behind it in the clearest way possible is one of

the objectives of this thesis.

As we all know there lies an intrinsic and

obvious importance in testing new products

and their working principles, this helps

designers to review their work and improve

some of the mistakes done during the

construction process.

These tests are not only required to see if the

product does work or not, but most importantly

these investigations are performed to calibrate

and give a high measurement capacity and

accuracy to the new-born devise.

This is where the most profound target and

goal of this work rests, to make this calibration

task easier and more practical in a simple

manner with low costs and every-day easy-to-

obtain materials.


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1. Introduction

Designing a new product is not one of the easiest and simplest procedures a person can intend it

involves a lot of thinking, designing, researching, and above all testing; testing your product is

one of the most critical and important things you have to do to achieve a production level of this

new design; and since testing involves calibrating sometimes we need to come up with new test

bench designs of our own, specially made for the product we intend to create.

The purpose of this test bench is exactly that, to test and calibrate the new flow meter design that

we have come up with and to make it easier for the tester to fine-tune the new equipment, this

assembly is pretty simple and does not require too much time to achieve therefore saving time in

the whole product finishing.

1.1. Background

First we need to understand the different outlines of pipelines and how the flow meters are

implemented in them, the different types of flow meters and how they work.

Pipeline transport is the transportation of goods through a pipe. Most commonly, liquids and

gases are sent, but pneumatic tubes that transport solid capsules using compressed air are also

used.


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As for gases and liquids, any chemically stable substance can be sent through a pipeline.

Therefore sewage, slurry, water, or even beer pipelines exist; but arguably the most valuable are

those transporting fuels: oil (oleoduct), natural gas (gas grid), and biofuels.

Dmitri Mendeleev first suggested using a pipe for transporting petroleum in 1863. [1]

These pipelines are classified depending on the fluid they transport:

1. For oil or natural gas

2. For ammonia

3. For biofuels (ethanol and biobutanol)

4. For coal and ore

5. For hydrogen

6. For water

7. For beverages

7.1. For beer

8. For other uses

We will focus on the pipeline used for water transport, since our flow meter is designed to use

with water, although we will need to know the basic concept and importance of the other types of

pipes thus we will see a little about the rest of their uses.

1.1.1. For oil or natural gas.

Oil pipelines are made from steel or plastic tubes with inner diameter typically from 4 to 48

inches (100 to 1,200 mm). Most pipelines are typically buried at a depth of about 3 to 6 feet

(0.91 to 1.8 m). The oil is kept in motion by pump stations along the pipeline, and usually flows

at speed of about 1 to 6 metres per second (3.3 to 20 ft/s).


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1.1.2. For ammonia.

Highly-toxic ammonia is theoretically the most dangerous substance to be transported through

long-distance pipelines. However, practically incidents on ammonia-transporting lines are

uncommon - unlike on industrial ammonia-processing equipment.

1.1.3. For biofuels (ethanol and biobutanol)

Pipelines have been used for transportation of ethanol in Brazil, and there are several ethanol

pipeline projects in Brazil and the United States. Main problems related to the shipment of

ethanol by pipeline are its high oxygen content, which makes it corrosive, and absorption of

water and impurities in pipelines, which is not a problem with oil and natural gas. [2][3].

1.1.4. For coal and ore

Slurry pipelines are sometimes used to transport coal or ore from mines. The material to be

transported is closely mixed with water before being introduced to the pipeline; at the far end,

the material must be dried.


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1.1.5. For hydrogen

Hydrogen pipeline transport is a transportation of hydrogen through a pipe as part of the

hydrogen infrastructure. Hydrogen pipeline transport is used to connect the point of hydrogen

production or delivery of hydrogen with the point of demand, with transport costs similar to

CNG,[4] the technology is proven. [5]

1.1.6. For water

Two millennia ago the ancient Romans made use of large aqueducts to transport water from

higher elevations by building the aqueducts in graduated segments that allowed gravity to push

the water along until it reached its destination. Hundreds of these were built throughout Europe

and elsewhere, and along with flour mills were considered the lifeline of the Roman Empire. The

ancient Chinese also made use of channels and pipe systems for public works. The famous Han

Dynasty court eunuch Zhang Rang (d. 189 AD) once ordered the engineer Bi Lan to construct a

series of square-pallet chain pumps outside the capital city of Luoyang. [6]

Pipelines are useful for transporting water for drinking or irrigation over long distances when it

needs to move over hills, or where canals or channels are poor choices due to considerations of

evaporation, pollution, or environmental impact.


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1.2. Pipeline Grid Operation

The aqueduct has to be monitored and measured to control its pressure, flow temperature, etc.

these instrumentations besides being used for data gathering are also used as communication

devices, that is when our flow gage is used. How is this going to work? Basically what the flow

meter does is that measures the amounts of liters per second at which the water is running, then

this data is sent to a remote receiver. The field Instrumentation includes flow, pressure and

temperature gauges/transmitters, and other devices to measure the relevant data required. These

instruments are installed along the pipeline on some specific locations, such as injection or

delivery stations, pump stations (liquid pipelines) or compressor stations (gas pipelines), and

block valve stations.

The information measured by these field instruments is then gathered in local Remote Terminal

Units (RTU) that transfer the field data to a central location in real time using communication

systems, such as satellite channels, microwave links, or cellular phone connections.

Figure 1: Pipeline Grid Operation


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1.3. Flow Meter Types

There are five main classifications of flow meters based on the principle governing their

functionality, these are: differential pressure, positive displacement, velocity, mass, open-channel.

These categories have their own sub categories with each flow meter functioning in a slightly

different way than its predecessor:

Differential

pressure

Positive

displacement

Velocity Mass Open-channel

Orifice plate

Venturi tube

Flow tube

Flow nozzle

Pitot tube

Elbow tap

Target

Reciprocating piston

Oval gear

Nutating disk

Rotary vane

Turbine

Vortex shedding

Swirl

Electromagnetic

Ultrasonic, Doppler

Ultrasonic, Transit-

time

Coriolis

Thermal

Weir

Flume

2. Materials

• Bolts

• L-brackets

• L shape aluminum Profiles

• I shape aluminum Profiles

• Nuts

• 1/2” PVC pipe

• 1/2” PVC tap or valves

• 1/2” PVC elbows

• Working flow meter

• Submersible Pump


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3. Assembly

First we need to connect all the PVC tubes in a trident way, two taps on the left and right set of

tubes and on the center set of tubes we need to connect the working and already calibrated flow

meter, this flow meter is going to help us fine-tune the other two meters that are connected at the

end of the right and left set of tubes, the faucets are mounted on the right and left tube to control

the amount of water that flows through each meter, and the pump is going to be connected at the

beginning of the whole pipeline which is at the center tube before the working flow meter.

This whole assembly is going to be mounted in our previously built stand, constructed from the I

shape aluminum profiles and the L shape profiles.

In this picture we have a complete illustration of

the trident form of our test bench assembly the

main pipe as you can see is in the center coming

out of the submersible pump installed on the

beginning of the circuit, after this we can find (in

the center pipe) the control flow meter which is the

one we are going to use to calibrate the other two

flow meters; the red valves regulating the flow of

water can also be appreciated from this picture.

(1) Flow Meters, (2) Valves, (3) Control Flow

Meter, (4) Submersible pump.

2 2

3

1

4

1

Figure 2: Test Bench Assembly


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The water in the system is pumped from the bottom of the tank with the submersible pump after

that it reaches control flow meter in which we read the real flow rate in liters per minute after the

recording of this value is made then the water flows through both of the flow meters attached at

the end of the circuit; the calibration system is then connected to this two flow meters. This is the

basic working principle of the test bench.

The accuracy is a defining factor for the correct calibration of the flow meter, “Calibration is a

comparison between measurements – one of known magnitude or correctness made or set with

one device and another measurement made in as similar a way as possible with a second device.

The device with the known or assigned correctness is called the standard. The second device is

the unit under test, test instrument, or any of several other names for the device being calibrated.”

[7]

This is the main reason why the control flow meter or the standard flow meter accuracy has to be

high, in this work the flow meter accuracy was expressed in percent or actual flow rate as:

% of Rate Accuracy = +- (Flow uncertainty / Instantaneous Flow Rate) x 100

At a maximum flow rate this percentage of accuracy was estimated to be +-2.5% since,

• Flow Uncertainty was equal to 1.15 L

• Instantaneous Flow Rate was equal to 45.5 L/min

In general, the lower the loads a flow meter has, the more accurate it is. In this experiment it was

observed that a constant low load was enough to obtain a constant and accurate flow rate within

a minimum of five liters per minute.

4. Standard Flow Meter

The control Flow Meter used for this project was a Tokyo Keiso Flow Meter, Model W-116 it’s

a Mini-Wheel Flowmeter that measures flow rate of water and water equivalent viscosity liquids

by counting the number of the built-in wheel's rotation.


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• Possible to monitor the flow directly

• Easy reassembling and cleaning

• Excellent linearity of voltage output

• Compact in shape due to precision casting

• CE marking

4.2. Short Specifications

Measuring fluid Cooling water and various liquids

(viscosity: less than 2mPa·s Equivalent to

water, and liquid not corroding wetted parts

materials)

Flow Range Maximum 10 to 100 L/min

Minimum 0.6 to 3 L/min

Fluid Temperature 0 to 50° C (without freezing)

Material Body: SCS 14

Wheel: Nylon 12

Shaft: HC-276

O-ring: NBR

Process Connection Rc ¼, Rc 3/8, Rc ¾ thread

Accuracy ±5% F.S.

Output TW-11□: NPN Open collector pulse

( Unscaled pulse )

TW-12□: DC0 to 5V

Power Supply TW-11□: DC12 to 24V

TW-12□: DC12V±10%


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5. Results

We were able to success with the calibration not only by obtaining a good accuracy in the peak

flow meter but also by maintaining this accuracy throughout the different ranges of flow lectures,

the accuracy is kept constant at a flow rate from 5 to 20 L/min and from 37 to 45.5 L/min.

The following figure shows the comparison of accuracies between the Toyo Keiso commercial

flow meter and our flow meter.

Figure 3: Flow Rate – Tokyo Keiso Commercial flow meter vs. our flow meter

The folowing table presents the relationship between flow rate and power generated for

efficiency assessment.

Flow Rate L/min DC Power Vol DC Power mA DC Power W

5.00 2.50 7.00 0.02

10.00 5.30 25.00 0.13

20.00 10.00 44.00 0.44

30.00 16.00 68.00 1.09

40.00 20.00 100.00 2.00

45.00 20.80 115.00 2.39


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6. Conclusions

Since the beginning of the project our goal was to facilitate and help to the total calibration of the

new flow meters, this could not be made by only one individual so the task to build a frame for

the test bench came to us; with a lot of dedication we tried to make the test bench the most

accurate and practical that we could.

The calibration of all the flow meters that were tested in our test bench were conducted

successfully and satisfactorily thus confirming the correct performance of the system.

As always everything can be perfected and this project is not the exception, further modifications

can include a better control flow meter (standard flow meter)with more precision to achieve an

even higher degree of accuracy and the modification required on the flow meters that are

required to be calibrated to make them even more exact.


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7. References

[1] “Pipeline Transport” article http://en.wikipedia.org/wiki/Pipeline_transport

[2] James MacPherson (2007-11-18). "Ethanol makers consider coast-to-coast pipeline"

[3] USA Today. Retrieved 2008-08-23.; John Whims (August 2002) (PDF). Pipeline

Considerations for Ethanol. Kansas State University. Retrieved 2008-08-23.

[4] Compressorless Hydrogen Transmission Pipelines

http://www.leightyfoundation.org/files/WHEC16-Lyon/WHEC16-Ref022.pdf

[5] DOE Hydrogen Pipeline Working Group Workshop

http://www1.eere.energy.gov/hydrogenandfuelcells/pdfs/hpwgw_airprod_remp.pdf.

[6] Needham, Joseph (1986). Science and Civilization in China: Volume 4, Part 2. Taipei: Caves

Books Ltd. Page 33.

[7] “Calibration” article http://en.wikipedia.org/wiki/Calibrati


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Abstract II

As we know Asthma has been a serious

problematic and mortal disease since ancient

times; it is known that asthma existed in

ancient Egyptian times, and there is some

evidence that asthma has been around even

before that.

A lot of people suffer from this disease; in

1995 statistics show that 71 out of 10,000

people were emergency hospitalized and

treated; even more alarming is the mortality

rate, this being 2 persons out of 100,000

although it sounds a little low it is still a

number that can be reduced with proper control.

This is the main purpose of the development of

a reliable yet inexpensive Peak Flow Meter,

since asthma does not discriminate between

social classes our goal is to provide an

inexpensive control tool, dependable, and

accurate whit which households and doctors

can save more lives.

The following pages describe the design,

construction, working principle, specifications

and overall development and changes that have

been and will be implemented in this prototype

for further study and a possible introduction on

the market.


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1. Introduction

1.1. Asthma

Asthma is an inflammatory disorder of the airways, which causes attacks of wheezing, shortness

of breath, chest tightness, and coughing.

Asthma is caused by inflammation in the airways. When an asthma attack occurs, the muscles

surrounding the airways become tight and the lining of the air passages swell. This reduces the

amount of air that can pass by, and can lead to wheezing sound. Asthma may also be classified as

atopic (extrinsic) or non-atopic (intrinsic). [1]

Figure 4: Asthma Pathology Illustration


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Most people with asthma have attacks separated by symptom-free periods. Some people have

long-term shortness of breath with episodes of increased shortness of breath. Either wheezing or

a cough may be the main symptom. Asthma attacks can last for minutes to days, and can become

dangerous if the airflow is severely restricted.

It is thought to be caused by a combination of genetic and environmental factors. [2] Treatment

of acute symptoms is usually with an inhaled short-acting beta-2 agonist (such as salbutamol). [3]

If the patient takes control of his/her asthma, he/she can keep living the life they want. If not,

they may miss many activities they enjoy. The symptoms can become more dangerous and

require visit to hospital emergency rooms. Left uncontrolled, asthma may cause permanent

damage.

The first step in taking control of asthma is having a plan. The plan should cover how you will

do the day-to-day activities that keep your asthma under control:

• Check: Learn to use a simple device called Peak Flow Meter in order to measure the

breathing regularly.

• Take your medications

• Avoid triggers such as allergens and irritants, animals hair, dust, etc.

• Exercise

1.2. History

The measurement of peak expiratory flow was pioneered by Dr. Martin Wright, Who produced

the first meter specifically designed to measure this index of lung function.


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Since the original design of instrument was introduced in the late 1950s, and the subsequent

development of a more portable, lower cost version (the ‘Mini-Wright’ peak flow meter), other

design and copies have become available across the world. [4]

1.3. What is a Peak Flow Meter?

A peak flow meter is a small, hand-held device used to monitor a person's ability to breathe out

air. It measures the airflow through the bronchi and thus the degree of obstruction in the airways.

[5]

A peak flow meter measures the patient’ Peak Expiratory Flow Rate (PEFR or PEF) this means

the maximum speed of exhalation. When the patient is well the peak flow meter readings are

high, on the other hand they appear low when the airways are constricted.

The basic structure of a Peak Flow Meter consists of a tube with a sliding indicator that moves

along a scale marked in liters per minute. Generally the numbers marked on the tube range from

50 to 800 (Peak Flow Meters with a smaller scale range are used for pediatrics). To use a peak

flow meter you simply take a deep breath, put the peak flow meter in your mouth, and blow as

hard and as fast as you can. It is not necessary to exhale completely since this can cause

coughing and a bad reading.


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Figure 5: Peak Flow Meter

The measurement values will be based on a person’s gender, age and height. The best of three

readings is used as the recorded value of the Peak Expiratory Flow Rate. It may be plotted out on

graph paper charts together with a record of symptoms or using peak flow-charting software.

Peak flow readings are often classified into 3 zones of measurement according to the American

Lung Association: green, yellow and red.

Zone Reading Description

Green zone

80 to 100 percent of the usual or normal peak flow readings are clear.

Indicates that the asthma is under good control.

Yellow zone

50 to 79 percent. Indicates caution. It may mean respiratory airways are narrowing.

Red zone Less than 50 percent. Indicates a medical emergency. Severe airway narrowing may be occurring and immediate action needs to be taken.


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Figure 6: Normal Values of PEF

1.4. Forced Expiratory Volume

The Force Expiratory Volume (FEVT) is the volume of gas expired during a given interval (t)

from the beginning of the FVC maneuver. The Forced Expiratory Volume is normally stated in

liters (FEVT), and T is expressed in seconds. Of the various FEVT measurements the FEV1 is

the most widely used.


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Significance:

Decreased FEVT values are common in both obstructive and restrictive patterns. Distinction

between obstructive and restrictive causes of reduced FEVT is made by relating the FEVT to the

VC as the FEVT/FVC ratio , and to other flow measurements. In obstructive patterns the FVC

may be normal and the FEVT reduced; in restrictive patterns the FVC and the FEVT are

proportionally decreased.

The FEV1 and the FEV1/FVC ratio are the most widely used and best standardized indices of

obstructive disease and is used for assessment of response to bronchodilators, inhalation

challenge studies and for detection of exercise-induced bronchospasm.

1.5. Lung Volumes

Lung volumes and lung capacities refer to the volume of air associated with different phases of

the respiratory cycle. Lung volumes are directly measured. Lung capacities are inferred from

lung volumes.

The average total lung capacity of an adult human male is about 6 litres of air, but only a small

amount of this capacity is used during normal breathing.

Since lung volumes are variable from one person to another there are some factors that affect

lung volumes; some can be controlled and some cannot. Lung volumes vary with different

people as follows:

Larger volumes Smaller volumes

Taller people Smaller people

Non-smokers Smokers

People who live at high altitudes People who live at low altitudes


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The amount of air that you move in and out of your lungs while breathing normally is called

Tidal Volume (VT). This amount of air provides enough oxygen for a person who is resting, and

the maximum amount of air moved in and out of the lungs is called Vital Capacity.

1.6. Definitions

To better comprehend the importance and how the Peak Flow Meter operates, we must state

some significant definitions that are given in the field of spirometry, these are:

Forced Vital Capacity (FVC) Forced vital capacity (FVC) is the volume of air that can forcibly

be blown out after full inspiration, measured in liters. FVC is the most basic maneuver in

spirometry tests.

Forced Expiratory Volume in 1 second (FEV1) is the volume of air that can forcibly be blown

out in one second, after full inspiration. Average values for FEV1 in healthy people depend

mainly on sex and age, values of between 80% and 120% of the average value are considered

normal. [6]

FEV1/FVC ratio (FEV1%) is the ratio of FEV1 to FVC. In healthy adults this should be

approximately 75–80%. Usually decreased in obstructive airways and is independent of the

relative values of FVC and FEV1.

Peak Expiratory Flow (PEF) usually decreased in obstructive airways and is independent of the

relative values of FVC and FEV1.

Tidal volume (TV) is the volume of air inspired or expired in a single breath at rest.

Total Lung Capacity (TLC) is the maximum volume of air present in the lungs.


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Besides the factors related to human nature, we also have diseases we must take into

consideration that affect the overall lung volumes. We can group them into Obstructive lung

disease and Restrictive lung disease.

Obstructive lung disease is a category of respiratory diseases characterized by airway

obstruction. As an example we have the following: asthma, emphysema, bronchitis, chronic

obstructing pulmonary disease.

Restrictive lung disease the restrictive lung diseases are a category of extra pulmonary, pleural,

or parenchymal respiratory diseases that restrict lung expansion, resulting in a decreased lung

volume, an increased work of breathing, and inadequate ventilation and/or oxygenation.

Pulmonary function test demonstrates a decrease in the forced vital capacity.

As seen, the FEV1/FVC ratio is considerably decreased when the patient suffers from obstructive

or restrictive lung disease, so the FEV1 is by far the most frequently used index for assessing

airway obstruction, bronchoconstriction or bronchodilatation. [7]

2. Technologies Used

• Rapid Prototyping

• 3D drawing or CAD

2.1. Rapid Prototyping

Rapid prototyping can be defined as a group of techniques used to quickly fabricate a scale

model of a physical part or assembly using three-dimensional computer aided design (CAD) data.

[8]


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Construction of the part or assembly is usually mostly done using 3D printing technology. The

first techniques for rapid prototyping became available in the late 1980s and were used to

produce models and prototype parts. Today, they are used for a much wider range of applications

and are even used to manufacture production-quality parts in relatively small numbers. Some

sculptors use the technology to produce exhibitions. [9]

Rapid Prototyping has also been referred to as solid free-form manufacturing; computer

automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for

visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put

into a wind tunnel. RP models can be used to create male models for tooling, such as silicone

rubber molds and investment casts. In some cases, the RP part can be the final part, but typically

the RP material is not strong or accurate enough.

2.1.1. The RP (Rapid Prototyping) process

The basic methodology for all current rapid prototyping techniques can be summarized as

follows:

• To begin the rapid prototyping process, a virtual design is created with CAD, computer

aided design, or with another animation modeling software, then this design is converted

to STL format; the resolution can be set to minimize stair stepping.

• This virtual design will be the starting point to create the model or prototype.

• The image will be the basis for the final protocol that is developed.

• The RP machine processes the .STL file by creating sliced layers of the model.

• The first layer of the physical model is created. The model is then lowered by the

thickness of the next layer, and the process is repeated until completion of the model.

In other words rapid prototyping takes the image and begins applying very thin layers of powder,

liquid, or sheet material until the final product has been created. The model takes shape as cross


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sections of the materials begin to take form into the intended design. The cross sections are

fused together once they are complete. The completed physical model and the virtual model

should be nearly identical at the end of the process. At the end of this whole process the

completed piece is removed the bases cut off and the surfaces cleaned and polished.

2.1.2. Benefits of rapid prototyping

• It allows the user to create the finished product very quickly. If these prototypes had to

be created manually it would take anywhere from several hours to possibly several days.

• When rapid prototyping is used a project can be completed in just a few hours. The exact

time it takes varies depending on the specific type of machine that is used and how big

the prototype will be in its final form.

• When a solid freeform fabrication technique is used, two different materials will be used.

One material is used to create the actual prototype of model and the other is used as

support so that the piece can be configured accurately. This technique makes the removal

of the support material easier, allowing the piece to be finished even faster.

• While it is less expensive to create the models using injection molding if you are creating

a large amount of the same items, when the goal is to complete only a few parts then the

additive fabrication can provide a significant cost saving.

The research and development throughout the course of these years since the introduction of the

RP technology and the use of additive manufacturing technology on the 1980s has allowed the

industry and developers of new products to implement new schemes and concepts in the field of

Rapid Prototyping, these concepts have evolved to the point of reaching the production line

which has allowed in its own terms the use of new and more advanced technologies and forms of

RP; each and one of these forms uses different materials, different components, and also each of


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them is used for different purposes than its predecessor or competitors; this huge diversity of

machines opens field to a variety of manufacturing and construction times some of this times

lasting from a few minutes to a couple of days (depending on the complexity of the model being

created by these machines), usually this times range around a common average of a few hours.

A wide division of these technologies can be made taking into account different parameters but

for reasons of efficiency we are going to focus in the most common areas of these technologies;

the following table illustrates the different types of rapid prototyping and the materials each one

uses:

Prototyping Technologies Base Material

Stereolithography (SLA) Photopolymer

Selective Laser Sintering (SLS) Thermoplastic, metal powders

Fused Deposition Modeling (FDM) Thermoplastic, Eutectic metals

Laminated Object Manufacturing (LOM) Paper

3D Printing (3DP) Various materials

Electron Beam Melting (EBM) Titanium alloys

The technology used to create the models for the prototype developed in this project is FDM or

Fused Deposition Modeling, is a solid-based rapid prototyping method that extrudes material,

layer-by-layer, to build a model. The system consists of a build platform, extrusion nozzle, and

control system.

The build material, a production quality thermoplastic, is melted and then extruded through a

specially designed head onto a platform to create a two-dimensional cross section of the model.

The cross section quickly solidifies, and the platform descends where the next layer is extruded

upon the previous layer. This continues until the model is complete, where it is then removed

from the build chamber and cleaned for study or shipping.

The layer thickness and vertical dimensional accuracy of the machine is determined by the

extruder die diameter, which ranges from 0.013 to 0.005 inches. In the X-Y plane, 0.001 inch


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resolution is achievable. A range of materials are available including ABS, polyamide,

polycarbonate, polyethylene, polypropylene, and investment casting wax.

Figure 7: Fused Deposition Modeling Process

2.2. 3D Drawing or CAD

Computer Aided Design is the use of computer systems to assist in the creation, modification,

analysis, or optimization of a design [10]. Beginning in the 1980s computer-aided design

programs reduced the need of draftsmen significantly, especially in small to mid-sized

companies. Since these first steps the CAD techniques have widely evolved and with this

evolution a diversity of software products were born; some of these platforms are, Pro/E, CATIA,

Solid Works, Solid Edge and Inventor; just to mention some.


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The designs or models that these technologies help us analyze are also known as parametric

models or Parametric Sketching. However parametric sketching and drawing are not the same; A

sketch is a collection of geometry (lines, points, and arcs) coupled with relationships (parameters,

equations, dimensions, sketch constraints, and construction geometry) laid out in a 2D format.

A sketch has to be more defined understandable and have a degree of completion from which a

manufacturer can produce an accurate reproduction of the object that is being targeted with the

design, all the geometric elements contained in the drawing have to be related to each other to

reflect the sketch intent. These drafts are used to define 3D geometry, which is then projected to

2D for final prints.

2.2.1. Design Process

Design is the act of devising an original solution to a problem by a combination of principles,

resources and products in design. Design process is the pattern of activities that is followed by

the designer in arriving at the solution of a technological problem.

The design process is an iterative procedure. A preliminary design is made based on the available

information and is improved upon as more and more information is generated. There have been

several attempts to provide a formal description of the stages or elements of the design process.

The design progresses in a step-by-step manner from some statement of need through

identification of the problem, a research for solution and development of the chosen solution to

trial production and use. These descriptions of design are known as models of the design process,

the following picture shows how a basic design process takes place, as it was said above it is an

iterative process in which continuous revision and constant changes are made as new information

on the prototype becomes available.


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Figure 8: Iterative Design Process

3. Equipment

3.1. Hardware

• Rapid Prototyping FDM Machine


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3.1.1. FDM machine

The machine used to construct and print the models for the assemble of our product was a

Dimension BST machine.

Figure 9: Dimension BST Printer

The current specifications for this machine are:

• Starting price: $24,900


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• Model Material: ABSplus in ivory, white, black, red, olive green, nectarine, fluorescent

yellow, blue or gray.

• Support Material: Breakaway Support Technology (BST)

• Build Size: 254 x 254 x 305 mm

• Layer Thickness: .254 mm (.010 in.) or .33 mm. (.013 in.) of precisely deposited

ABSplus model and support material.

• Workstation Compatibility: Windows® XP / Windows Vista® / Windows® 7

• Network connectivity: Ethernet TCP/IP 10/100Base-T

• Size and Weight: 838 x 737 x 1143 mm (33 x 29 x 45 in.) 148 kg (326 lbs.)

• Power Requirements: 110-120 VAC, 60 Hz, minimum15A dedicated circuit; or 220-240

VAC, 50/60 Hz, minimum 7A dedicated circuit.

3.2. Software

• Solid Works 2010

3.2.1. Solid Works

SolidWorks is a 3D mechanical CAD (computer-aided design) program that runs on Microsoft

Windows and is being developed by Dassault Systèmes SolidWorks Corp., a subsidiary of

Dassault Systèmes, S. A. (Vélizy, France). SolidWorks is currently used by over 1.3 million

engineers and designers at more than 130,000 companies worldwide [11]. SolidWorks

Corporation was founded in December 1993 by Jon Hirschtick with headquarters in Waltham,

Massachusetts, USA, [12][13] who recruited a team of engineers to build a company that

developed 3D CAD software that was easy-to-use, affordable and available on the Windows

desktop, with its headquarters at Concord, Massachusetts, and released its first product,


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SolidWorks 95, in 1995, later in 1997 SolidWorks Corporation was acquired by the company

known as Dassault Systèmes, best known for its CATIA CAD software.

Since then Solid Works corporation has launched several new versions of its leading software

improving in each new release the whole software making it more user friendly, more reliable,

adding new features as simulation and libraries with tons of standardized mechanical parts; just

to name a few of the more notorious advancements on this complete solution. But Solid Works

isn’t the company’s only product; they have produced a collaboration tool called eDrawing and

software focusing entirely in a 2D sketching and modeling named DraftSight.

As I mentioned before the version of the software used in this project is Solid Works 2010, the

top enhancements for this version provide improvements to existing products and innovative new

functionality, some of the new features present in this version are:

• User Interface

o Mouse Gesture Support

• Fundamentals

o Reference Planes

• Assemblies

o Assembly visualization

o Mirror components

o Virtual components

• Configurations

o Configuration Publisher

o Modify Configurations

• Drawing and Detail

o Rapid Dimension

o Dimension Palette

o Drawing views of multibody parts

• Enterprise PDM

o Enterprise PDM and toolbox integration


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• Motion Studies

o Event Based Motion Study

• Parts and Features

o Move face Features

• Routing

o Manufacture-style flattening

4. Peak Flow Meter Design

The Design of the Casing for the Peak Flow Meter was based on its utility, components,

ergonomics and size. The process started with several sketches aiming to an appealing and

serious shape, due to its future use in the health sector. There were three prototypes developed

for the further progress and testing of the Peak Flow Meter, these two prototypes were printed

using Rapid Prototyping (RP).

4.1. Peak Flow Meter conceptualization

In the early conceptualization of the PFM, the main components where established, such as; the

LCD Screen, Electronic components PCB, Battery and Generator for a better approach and

layout of the main components. Respecting the layout of the CAD model, which was modeled

using Solidworks, it consisted of a Main body for the PCB and LCD, an Appendix body for the

generator, which was broken down into the generator (stator) casing, the fan (rotor) casing and

the nozzle (mouth piece). Many concept CAD models were made testing shape, function, color

and layout; figure 10 shows the render of the selected concept model for further development

and testing.


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Figure 10: Peak Flow Meter Concept design

4.2. Peak Flow Meter Prototype01

The conceptualizations evolved into Prototype 01(P01), due to space restriction between

components and the size of the rotor and PCB. The P01 consist of a Main body structure, which

holds the LCD, PCB, Battery and the Stator and it’s a partial casing of the rotor, the Rotor lid to

encase the rotor and support the mouth piece, and the Mouth piece. During this stage, the P01

was 3D modeled, and a Reverse Engineering process was applied to the existing components

such as; generator, LCD, Electronic components, PCB, and battery. These were carefully

measured with a caliper, and 3D modeled in Solidworks one by one, resulting in different

assemblies which were used to check the space limitations, clearance, connectivity, final size,

mounting and housing of these components.


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Figure 11: Peak Flow Meter Prototype 01

4.3. Peak Flow Meter Prototype02

The aiming for this design was due to different factors, like; LCD power consumption, Generator

power, Battery recharge-ability, Size, USB port. This Prototype design can be broken down into

five components that are; the Main body, the Rotor Lid to hold the mouth piece, the Mouth piece,

the USB Cap, and the Battery Lid.

The main problem with these previous prototypes were the large volume, size and bulkiness ; the

weight and the generator efficiency and capacity, several studies were made to improve the flaws

on the previous concepts, one of these studies led to the idea of a new type of generator small

enough and powerful enough to provide with energy the entire circuit and achieve a functionality

above the performance of previous cases, another modification made took place in the overall

design of the PFM the purpose of this change was to make it lighter and smaller.


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4.4. Peak Flow Meter Prototype03 Design

The Peak Flow Meter was designed and drawn with Solid Works software. It’s shape follows the

main aspects of “Product Design”:

• Mechanics

• Ergonomics

• Aesthetics

But also taking into account the flaws and disadvantages of previous prototypes to conduct a

research based and directed to the objective of improve these characteristics, the main points


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aimed to develop in this prototype are size, volume, efficiency, generator power output, just to

name some of the desired advancements in this new design.

The idea of the new prototype began with a series of sketches and in analyzing these drawings

we concluded and arrived at a common decision for a main housing; the design of this casing

resembles a whistle, the reasons for this scheme is that a whistle is easy to hold, lightweight and

small giving us an ideal ergonomic factor.

The main components of this prototype can be divided in main lid, covering lid, rotor blades

or fan, generator, mouth piece.

In picture 13 the basic form and basic

components of the new prototype can be

appreciated, mouth piece would be placed

in the air inlet on the downward part of the

sketch and the air outlets allow an

uninterrupted flow of fluid, the main idea

of this design went evolving when more

information became available, for example

one of the principal changes was the

generator since the generator in this first

design was going to be the same generator

as the previous prototype.

The use of this generator would mean a much larger peak flow meter and the ergonomic factor

would have been lost; being this last one really big it would have to have been attached on the

outside of the peak flow meter making it bulkier and adding more volume to the first design, this

generator would have been placed on the main lid (white) of the peak flow meter.



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The flowing picture shows different views of the first sketch of the P03 (prototype 03) in this

picture we can appreciate the mounting surface for the previous generator.

Figure 14: PFM Prototype 03 views

Figure 14 shows the different views of the first design for the peak flow meter prototype 3, the

design has changed completely from its predecessor but the P03 follows the same principle as

P01 and P02 concerning operation, with a few minor differences in layout and results. This

particular shape provides a more ergonomic design, approaching even more to the “hand held

device” statement we aim for.

On the back view the mounting platform for the previous generator can be observed, although is

a powerful source of energy for the recharging of batteries and the power supply to the circuit its

main disadvantage is its size so a further modification to this design took place.


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4.4.1. Peak Flow Meter Prototype 03 Version 2

In this version some huge changes were made, this includes the removal of the outside generator

and the removal of the mounting surface for the generator imbedded on the main lid; following a

new covering lid design (green lid in figure 13) to which some palettes are attached, these

attachments serve as supports for the coil that is going to be winded on the inside of the covering

lid, the magnets are going to be mounted inside as well more precisely on the rotor blades.

The following picture illustrates in a clearer way the inside design of the rotors magnets and lids.

Figure 15: PFM Prototype 03 V2

1

2

3

4

2

5

6


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This is an exploded view, constructed in Solid Works, of the Prototype 03 version 2 to denote

and point at the main components of this step on the design of the peak flow meter and the

fashion in which they are assembled; (1) it’s the main lid the main change in this part of the

prototype is the removal of the mounting surface used in past versions to secure the previous

generator in place, this lid also contains the air inlet and air outlets as well as the holder in which

the shaft is going to be mounted; (2) 3 mm bearing, these bearings are attached to the rotor blade

since the rotor blade is going to be the only moving part of this design; (3) rotor blades; (4)

magnet ring, the first idea for the magnet ring was to build it from twelve different magnets

alternating each one of them from N pole to S pole, in other words one north pole followed by

one south pole until the cylinder is completed; (5) palettes, the copper wire is going to be coiled

around these two sets of palettes, the purpose of the construction of two sets of palettes is two

embrace the magnets ring entirely one set of coils obtaining electromagnetic current from the

outer diameter of the ring and the second set working in conjunction with the inner diameter of

the ring; (6) and finally the covering lid.

4.4.2. Design of tester for the coil of the Peak Flow Meter

Prototype03

The power obtained from the generator was an important issue that needed to be improved. The

previous generator used in P01 was too small, and the power generated was not enough to

partially recharge the battery. And the generator of P02 was too big to be used in our design.

Having this new idea for an inside generator for the P03 a necessity to test this new configuration

arouse; since this type of coil wasn’t implemented in any of the previous prototypes our

information of it was not solid, this was just an idea it was not tested and knowing to work yet;

so we decided to move to the design table again to sketch and study the best way to produce a

test bench for this new set of coils in this configuration; we managed to come up with an


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unconventional design with minimum requirements, easy to operate, lightweight, small and

above all with a small amount of material and new parts used reducing its cost.

The tester is divided in three

main parts; (1) 3 mm bearing; (2)

coil and shaft support, this is

where the copper wire is going to

be coiled and this structure is

going to hold the bearings which

each one of them are going to

hold the shaft in place; and

finally (3) the magnet holder, this

magnet is going to be a

cylindrical magnet wrapped

around the center part of the

holder.

The wire is going to be coiled around the middle part of the tester; when the whole design is

assembled the two coil supports join together at the center and in this center is where the coil is

going to be placed.

Several tests were conducted to study the efficiency of the new generator, the main differences of

each test were the number of times the wire was coiled around the supports or the addition of a

steel clamp on the outside of the supporters to add more resistance to the magnets and generate

more electromagnetic current; the tests were conducted mainly with a configuration of 250

rounds and 400 rounds.

1

2

3

2

1

Figure 16: Tester exploded view


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4.4.3. Tests and Results

First test: Coil Diameter 0.12 mm; Rounds 250.

Peak Voltage: 0.35V

Frequency: 50Hz

Peak Amperage: 6.3mA

Second Test: Coil Diameter 0.12 mm; Rounds 250; addition of steel clamp.

Peak Voltage: 0.36V

Frequency: 58Hz


Third Test: Coil Diameter 0.12 mm; Rounds 400.

Peak Voltage: 0.37V

Frequency: 58Hz



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Fourth Test: Coil Diameter 0.12 mm; Rounds 400; use of steel clamp.

Peak Voltage: 0.41V

Frequency: 80Hz

Peak Amperage 4.85 mA

The voltage in all the tests resulted to be really low, the PFM needed at least 2 volts of energy to

run the circuit in the peak flow meter; the work was not over yet, further studies were conducted

and the information obtained lit up the research, the discovery made let us learn that the main

problem was in the distance from the coil to the magnet, this gap has to be as small as 0.1 mm

for this coil to work, at this distance this coil configuration can grant an energy output of 2 volts

at 200 rpm.

4.4.4. Peak Flow Meter Prototype 03 Version 3

A few more improvements were made to the P03 during the course of the development of the

design, these small modifications were made with the purpose of making easier the task of

closing and securing both lids together, and manage an easier cleaning or fixing of the devise;

the second change was the addition of more support for the center shaft; the multiple magnet idea

was discarded and instead a single magnet ring divided in four poles (two north and two south)

would be used; this led to a further modification of the palettes holding the coil reducing their

number from six to four.

The following picture denotes the final shape and configuration of the peak flow meter prototype

03; this model was also constructed in solid works and the covering lid is made translucent for

the better appreciation of the new palettes, magnet ring and overall internal configuration.


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Figure 17: Peak Flow Meter P03 V3

To better show the size of the PFM P03 V3 the following picture provides some dimensions in

an orderly fashion just to make the reader aware of the actual size of the prototype.

Figure 18: Peak Flow Meter P03 V3 Dimensions


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5. Future Enhancements

Future improvements need to be made to continue with the development of the Peak Flow Meter;

as previously mentioned before a designing of a new product requires a lot of attention and time

it is not a straight forward process, being an iterative set of steps new problems arise and with

these new problems new solutions are developed; the project will continue evolving as new

information becomes available; part of the future evolution process involves the implementation

of the new studied generator with a minimal distance between the coil and the magnet, the

addition of a more efficient rotor blades, and the inclusion of a solar panel to add in the

recharging of the system; these are merely a few ideas for upcoming prototypes.

6. Conclusions

The “Peak Flow Meter” has still a long road ahead of it, it is not a simple task but surely is a

highly rewarding one; from the beginnings of the conceptualization, to the first prototypes, to the

arrival at this final PFM a huge load of countless ideas have risen or fallen, some of these ideas

were taken into account and some of them discarded but the most important attribute of this

project is the dedication and care with which has been build, a merging of ideas results in better,

more reliable, and closer-to-the-objective products; a perceivable amount of improvement can be

seen from the first birth of the idea to the actualized P03.

I believe we accomplished and exceeded several of our objectives; reducing the size and volume,

thus making it more ergonomic and portable; managing a better understanding of the generator

and working our way to achieve the power needed; and overall obtaining a better product.


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7. References

[1] Kumar, Vinay; Abbas, Abul K; Fausto, Nelson; Aster, Jon (2010). Robbins and Cotran

Pathologic Basis of Disease (8th ed.). Saunders. p. 688. ISBN 978-1-4160-3121-5.

[2] Martinez FD (2007). "Genes, environments, development and asthma: a reappraisal". Eur

Respir J 29 (1): 179–84 http://erj.ersjournals.com/content/29/1/179.

[3] NHLBI Guideline 2007, p. 214.

[4] http://en.wikipedia.org/wiki/Peak_flow_meter#History

[5] en.wikipedia.org/wiki/Peak_flow_meter

[6] LUNGFUNKTION — Practice compendium for semester 6. Department of Medical Sciences,

Clinical Physiology, Academic Hospital, Uppsala, Sweden. Retrieved 2010.

[7] http://en.wikipedia.org/wiki/Restrictive_lung_disease

[8] http://www.efunda.com/processes/rapid_prototyping/intro.cfm

[9] http://en.wikipedia.org/wiki/Rapid_prototyping

[10] Narayan, K. Lalit (2008). Computer Aided Design and Manufacturing. New Delhi: Prentice

Hall of India. pp. 3.

[11] “Solid Works” http://en.wikipedia.org/wiki/SolidWorks

[12] “Solid Works Company History” http://www.solidworks.com/sw/656_ENU_HTML.htm

[13] “Solid Works company Information”

http://www.solidworks.com/sw/656_ENU_HTML.htm

Documents

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