Accelerate Your Medical Device into a Manufactured Product
ROBOTICS, AUTOMATION & MOTION CONTROL
From Surgical Robots to
Automated Micro-Positioning
PROJECT
3-Axis Micro-Positioning System for Semi-Automated Ophthalmic Instrument
CHALLENGE
A compact joy-stick controlled heavy payload motorized system was required to align components to sub-mm accuracy with 100mm range.
ACCELERATE
A three-stage 4 motor system was designed to mount on a structural column. An anti-backlash design was required to achieve the final positioning accuracy. Alignment times were reduced by applying a quadratic amplification of joystick position to quickly make large movements and accurately make micro movements.
RESULT
The design was completed on schedule. Deliverables included a complete CAD model, Bill Of Materials, and assembly notes. All parts were procured and assembled.
PROJECT
Articulation Refinement of 3-Axis Robot Arm
CHALLENGE
A prototype robotic arm was actuated by three rotational axes, but had excessive backlash and stiction preventing it from effectively aligning its payload.
ACCELERATE
A tolerance analysis revealed the backlash of a gear driven actuator was not practical. Multiple architectures were team brainstormed, evaluated, and scored for down selection. A screw-driven system was found to have the best mechanical leverage and backlash. A design was completed, and prototypes built.
RESULT
The prototype outperformed the gear system it was replacing. It was built on an expedited schedule to reduce impact to the program.
PROJECT
Thermal Analysis and Redesign of Mechatronic Architecture to Manage FPGA Heat Away from Sensitive Components
CHALLENGE
Sensors at the end of a robotic arm were at risk of malfunctioning if the heat from the FPGA-PCB were not mitigated.
ACCELERATE
Thermal flow analysis was first done to validate the claim. Visualizing the problem led the team to feel basic mitigation and cooling was problematic. The FPGA-PCB was then redesigned to fit into another arm of the robot. Power and communication solutions allowed for distancing from the sensors.
RESULT
When the prototype was built the thermal cooling built into the new arm exceeded expectations and the sensors performed perfectly without being affected by the FPGA heat.
PROJECT
Surgical Robot Manufacturing for Engineering Qualifications
CHALLENGE
Concurrently complete the design of a complex re-sterilizable articulation and visualization assembly while generating the test and assembly fixtures.
ACCELERATE
Created 9 independent assembly stations, established in-process test parameters, created Work Instructions and trained staff.
RESULT
Successfully built units for evaluation and trials under ISO13485 certifications.
PROJECT
Surgical Robot Test & Assembly Stations
CHALLENGE
Develop a disposable surgical robot manufacturing line for transfer to a Contract Manufacturer.
ACCELERATE
Developed multiple assembly & test stations after determining the optimal process flow. Procedures, training, qualifications and calibrations.
RESULT
Kicked-off a successful manufacturing line that produced units for clinical trials.
In my 40 plus years of medical device development and manufacturing, Jay stands out at one of the best. Being able to contribute to almost any engineering discipline I always know he can work through the hardest of technical and business challenges. We’ve assessed many programs together and have worked through difficulties that always arise. I know that when I recommend him for a job, you will get the best possible product.