Critical Design ReviewCritical Design Review 05/12/200605/12/2006

Team Members: Andrew Shabashevich, Greg Team Members: Andrew Shabashevich, Greg Penoyer, Jessica Pierce, Tony Kukla, Bill Dugan, Penoyer, Jessica Pierce, Tony Kukla, Bill Dugan,

Gaurav Sanghi, Piyush AggarwalaGaurav Sanghi, Piyush Aggarwala

Team Mentor: Dr. Edward HenselTeam Mentor: Dr. Edward HenselKate Gleason College of Engineering

Rochester Institute of Technology

Automated Bubble Elimination System#P06219

Design and build a stand-alone system to Design and build a stand-alone system to reduce the number of bubbles on a contact reduce the number of bubbles on a contact lens and in the water celllens and in the water cell 75% Bubble Reduction75% Bubble Reduction

Design the system with potential to be Design the system with potential to be integrated into the automated production integrated into the automated production line (freedial) machine at a later dateline (freedial) machine at a later date Keep the same dimensional constraintsKeep the same dimensional constraints Keep the same power/operating sourcesKeep the same power/operating sources Operate within current cycle timeOperate within current cycle time Comply with Wet Vision Inspection requirementsComply with Wet Vision Inspection requirements

Mission StatementMission Statement

Conducted background researchConducted background research Brainstormed for conceptsBrainstormed for concepts 10 initial concepts tested qualitatively10 initial concepts tested qualitatively Chose 3 for quantitative tests in SD IIChose 3 for quantitative tests in SD II

Ultrasound, Rotary Motion, Recirculation Ultrasound, Rotary Motion, Recirculation Test with and without degassed waterTest with and without degassed water

Designed Test fixtureDesigned Test fixture

Senior Design I Senior Design I MilestonesMilestones

Assemble/Install Test FixtureAssemble/Install Test Fixture Assess the 3 concepts in more detail:Assess the 3 concepts in more detail:

• DOEDOE• Settling time/Time studySettling time/Time study• Cost Benefit AnalysisCost Benefit Analysis

Quantitatively prove concept Quantitatively prove concept feasibilityfeasibility

Propose final solution to B&LPropose final solution to B&L

Objectives for Senior Objectives for Senior Design IIDesign II

Test Fixture Set-upTest Fixture Set-up

Sliding Stage

Water Cell

Test fixture used with Test fixture used with Bausch & Lomb one-Bausch & Lomb one-up vision inspection up vision inspection system standsystem stand

Fixture is modular to Fixture is modular to quantitatively test all quantitatively test all final conceptsfinal concepts

Fixture is easy to Fixture is easy to adjust and modify adjust and modify during testingduring testing

Design Test FixtureDesign Test Fixture

Create bubbles on a contact lensCreate bubbles on a contact lens Take a before picture of the lensTake a before picture of the lens Apply TestApply Test Take an after picture of the lensTake an after picture of the lens Run the images through wet vision Run the images through wet vision

inspection algorithminspection algorithm Record bubble count and bubble areaRecord bubble count and bubble area

Testing ProcedureTesting Procedure

Rotary Motion ModuleRotary Motion Module

Parameters VariedParameters VariedRun

Motor Speed (Volts/RPM)

Cycle Time (sec)

1 8/1570 12 10/1970 0.53 8/1570 0.54 8/1570 15 10/1970 16 10/1970 0.57 8/1570 0.58 10/1970 1

Teflon Head

Water Cell

Rotary Motion Testing Rotary Motion Testing ResultsResults

Non degassed, De-ionized Water

Avg Bubble Count

Total Bubble Count Reduction

Total Bubble Area Reduction

Minimum: 1.79 92.6% 95.1%Maximum: 6.7 97.8% 98.4%Average: 3.69 95.4% 96.9%

Degassed, De-ionized Water

Avg Bubble Count

Total Bubble Count Reduction

Total Bubble Area Reduction

Minimum: 0.48 97.9% 98.1%Maximum: 2.21 99.3% 99.8%Average: 1.40 98.4% 98.8%

Before

After

Ultrasonic ModuleUltrasonic Module

Parameters VariedParameters Varied

Trial # Depth Cycle Time1 5/8" 1 sec2 5/8" 2 sec3 5/8" 1 sec4 1/2" 1 sec5 11/16" 2 sec6 1/2" 1 sec7 1/2" 2 sec8 5/8" 2 sec9 11/16" 1 sec

10 11/16" 2 sec11 1/2" 2 sec12 5/8" 1 sec13 11/16" 1 sec14 5/8" 2 sec

Ultrasonic Tip

Water Cell

Ultrasound Testing Ultrasound Testing ResultsResults

Non degassed, De-ionized water

Degassed, De-ionized water

Avg Bubble Count

Total Bubble Count Reduction

Total Bubble Area Reduction

Minimum: 3.69 91.9% 89.2%Maximum: 9.63 97.3% 97.9%Average: 5.82 95.9% 94.1%

Avg Bubble Count

Total Bubble Count Reduction

Total Bubble Area Reduction

Minimum: 0.04 97.6% 97.4%Maximum: 1.52 99.96% 99.91%Average: 0.39 99.3% 99.6%

Run Number

Images Processed

Total Bubble Count

Total Bubble Area

Avg Bubble Count

1 299 11 466 0.042 298 63 3923 0.223 150 25 2467 0.184 200 14 805 0.08

Live Run with Degassed, De-ionized water

Before

After

Recirculation ModuleRecirculation Module

Parameters VariedParameters VariedRecirculation

VolumeImmersion

DepthCycle Time

1 14 ml 11/16" 6 sec2 7 ml 11/16" 2.5 sec3 7 ml 9/16" 2.5 sec4 9.6 ml 11/16" 3 sec5 14 ml 9/16" 6 sec

Run Number

Inlet/Outlet Tubes

Water Cell

Recirculation Testing Recirculation Testing ResultsResults

Degassed, De-ionized water

Avg Bubble Count

Total Bubble Count Reduction

Total Bubble Area Reduction

Minimum: 12.14 16.0% 5.3%Maximum: 76.93 78.3% 66.6%Average: 39.81 39.6% 41.4%

Before

After

Results – Percent Bubble Results – Percent Bubble ReductionReduction

91%

92%

93%

94%

95%

96%

97%

98%

99%

100%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Run Number

Percen

t B

ub

ble

Red

ucti

on

Ultrasound with Regular DI Water

Ultrasound with Degassed DI Water

Rotary Motion with Regular DI Water

Rotary Motion with Degassed DI Water

Results – Bubbles Remaining Results – Bubbles Remaining on Lenson Lens

0

1

2

3

4

5

6

7

8

9

10

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Run Number

Av

g.

nu

mb

er o

f b

ub

ble

s

Ultrasound with Degassed DI Water

Rotary Motion with Degassed DI Water

Ultrasound with Regular DI Water

Rotary Motion with Regular DI Water

Cost Benefit Analysis

UltrasoundUltrasound

CostCostCost of the Cost of the fixture=$1380fixture=$1380Ultrasound Ultrasound wand =$2,500wand =$2,500Total= $3880

BenefitBenefitCycle Time=2 Cycle Time=2 SecSecSettling time of Settling time of the lens=< 1 secthe lens=< 1 secTotal bubble count reduction % = 99.3

Rotary MotionRotary Motion

CostCostCost of the Cost of the fixture=$1380fixture=$1380Motor and Motor and Teflon head= Teflon head= $50$50Total= $1430

BenefitBenefitCycle Time= 4 Cycle Time= 4 SecSecAverage settling time of the lens= 12.3 secTotal bubble Total bubble count reduction count reduction % = 98% = 98

CostCostCost of the Cost of the fixture=$1380fixture=$1380Pump and Pump and tubes= $1120tubes= $1120Total= Total= $2500$2500

BenefitBenefitCycle Time= 4-Cycle Time= 4-12 Sec12 SecAverage Average settling time of settling time of the lens= 4-10 the lens= 4-10 secsecTotal bubble count reduction % = 41

RecirculationRecirculation

UltrasoundUltrasound Consistent bubble reduction: Consistent bubble reduction:

< 1 average bubbles per lens< 1 average bubbles per lens Settling time < 1 secSettling time < 1 sec Less moving partsLess moving parts

Operating Conditions Frequency – 20 kHzFrequency – 20 kHz Max. Power – 15 WMax. Power – 15 W Tip Diameter – 14 mmTip Diameter – 14 mm Concentric to the water cellConcentric to the water cell 0.25” below water line0.25” below water line

RecommendationRecommendation

Time (s)

Power (W)

15

1 1.5 2

Method for eliminating over 99% of Method for eliminating over 99% of bubbles on a contact lensbubbles on a contact lens

Technical packageTechnical package Background ResearchBackground Research Vender ResearchVender Research

CD packageCD package Complete test dataComplete test data Test fixture design packageTest fixture design package Detailed feasibility test reportsDetailed feasibility test reports

DeliverablesDeliverables

Questions?Questions?

Acknowledgements: Matt Place – Bausch & Lomb SponsorKevin Beebe – Bausch & Lomb Sr. Process Engineer Travis Fisher – Bausch & Lomb Mechanical EngineerTom Natalie – Bausch & Lomb Advanced Engineering ManagerProf. Edward Hensel – MentorProf. Satish Kandlikar – RIT Professor