Rashid B.

Kolaghassi

Professor Thomas G. Bifano

EK – 210

December 4th, 2020

Assignment 6: Final design

Executive Summary:

This report covers the research, design, production and evaluation of a blood oximeter prototype

that is used to alert patients of suspected COVID infections recovering at home of early signs of lung

damage. The development of this prototype was approached in a pragmatic method consisting of several

parts including: developing ambitious objectives and stringent metrics, considering numerous design

alternatives, developing models, producing physical porotypes and iterating on designs. The final

prototype includes an accurate oximeter sensor connected to a microcontroller that relays the results to an

LCD. All the components are enclosed in a highly functional, ergonomic and aesthetically pleasing

packaging that is able to be sanitized using common cleaners. This device has the potential of alerting

millions of COVID infected people about their need to seek medical attention, saving many lives in the

process.
 Table of Contents

Introduction: .................................................................................................................................... 3

I. Motivation: ........................................................................................................................................ 3

II. Problem statement: ............................................................................................................................ 3

III. Objectives & Metrics: ........................................................................................................................ 3

Design Alternatives Considered: ..................................................................................................... 4

I. Function-means chart: ....................................................................................................................... 4

Rationale Behind Design Decisions: ............................................................................................... 5

I. Power modelling: ............................................................................................................................... 5

II. CAD and physical 3D modelling: ..................................................................................................... 5

III. Glass Box Analysis ............................................................................................................................ 5

Evaluation of results: ...................................................................................................................... 6

Final Thoughts: .......................................................................................................................................... 7

Bibliography: ................................................................................................................................... 8

Appendices: ..................................................................................................................................... 8

I. Appendix 1: Model of Power Consumption:..................................................................................... 8

II. Appendix 2:CAD Engineering drawings: …………………………………………………………10

Introduction:

I. Motivation:
The SARS-CoV-2 virus is responsible for the coronavirus disease and can cause lung injury through
inflammation and pneumonia. This can harm the heart’s ability to effectively pump oxygen to the body.
Patients recovering at home might not recognize damage occurring to their lungs and fail to seek medical
attention (McCallum, Katie).

Given the virus’s highly contagious nature, hospitals around the US and the world are running out of bed
capacities for ill people. Consequently, the client needs a device that can measure oxygen saturation
levels for suspected COVID infections that can act as an early warning sign for patients sick at home. The
client needs the device to be accurate as it must be a tool to inform ill individuals

II. Problem statement:

Design a device that can be used to measure oxygen saturation levels to alert patients of suspected
COVID infections recovering at home of early signs of lung damage

III. Objectives & Metrics:

The stated objectives & metrics in table 1 have been carefully created with input from health
professionals. The first metric for measuring the blood level saturation level is that the product must be
able to measure a range of SpO2 of 70 -100 %. The specified range of 70-100% was chosen because
blood oxygen levels between 94-100 % are normal, while for levels below 90%, patients should consult
with medical professionals. For levels below 85%, patients should be concerned and seek medical
attention immediately. The second metric is to provide an accuracy of +/- 2% from 90 to 100%; +/-3%
from 70-89%; Unspecified from <70%. The reason being is that for levels in the range of 90-94%, the
product should be relatively accurate in order to alert the user. As the level drops below 90%, the
accuracy becomes less important as the user should already be seeking medical attention (McCallum,
Katie). We have also paid careful consideration to the cost of the product. Seeing that coronavirus is
disproportionately affecting marginalized and low-income communities, we are aiming to produce a
product that costs less than 15$ at volumes of production that exceed 20,000 units.

Objectives Metrics
Measure blood oxygen saturation level Measuring range from 70 - 100% SpO2
Provide accurate measurements +/- 2% from 85 to 100%; +/-3% from 70-85%; Unspecified from <70%.
Affordable Cost <$15 at volumes greater than 20,000
Reliable Able to perform 1000 measurements before failure
Durable Be able to withstand drops from 2 meters.
Able to be sterilized Resistant to standard medical solvents and ultraviolet light disinfection (UVC).
Fast in completing readings Provide readings in less than 15 seconds
Easy to use Ergonomic fit
Able to operate in range of climates Able to operate in between 5°C- 40°C and from 35% - 75% humidity
Table 1: Objectives and metrics for device that measures oxygen saturation levels
Design Alternatives Considered:

We have explored many design and engineering possibilities to best optimize this design to its stated
purpose. A comprehensive list of chosen means can be found in table 2: functions mean chart.

I. Function-means chart:
Function Mean 1 Mean2 Mean 3
Contact physically with Bracelet (Wrist placed) Touch (Finger placed) Strip (Forehead placed)
body for measurement

Accept user input to initiate Mechanical button trigger Touch button trigger Motion sensor trigger
measurement

Relay relays to user LCD indicators LCD display Speaker

Provide onboard power for
electrical components
Protect components from
cleaning solvents and
liquid damage
AA battery Lithium Ion battery Primary: 9V battery
Secondary: external power
source
Epoxy over exposed circuity Silicone sealed case Rubberized shell

Able to withstand drops Rubberized edges Foam inserts under circuit Laminated screen
from 10 ft or less board

Provide comfortable Lightweight ABS casing No pressure touch interface Polished outer surface
measurements for user with recording area

Preventing other light Account for external light Red light filter around testing receiver with small
sources from interfering interference using external device surface area
with measurement light sensor

Convert absorbed red light Photoresistor to convert MAXREFDES117 integrated

and infrared data to levels of absorption to heart rate and blood oximeter
processable output signal voltage signal sensor

Filter signals to reduce Reject signals that lie out of Calculate average value of
noise specified bounds multiple measurements

Process measured signal to Compare values to known Use machine learning

determine SpO2 and pulse thresholds

Table 2: Function means Chart. Highlighted means for given functions are those used for final product
Rationale Behind Design Decisions:

I. Power modelling:
One of the most significant design choices that had to be determined was the estimated power
consumption of the device. Determining the power would influence the choice of sensors that were to be
used, the on-board power supply device, and the overall dimensions of the casing. The total power has
been estimated using the calculations in appendix 1.

The power model informed us that a 9-volt battery will be a suitable means to supply the Arduino for
about 2 hours of continuous use. Several other power sources were considered including lithium ion
batteries, aa batteries and external power sources. Given that we needed to keep costs low, the 9 volts
battery was the more affordable option, despite lithium ion batteries providing longer battery life. The 9-
voly battery is capable of making an estimated 240 readings if each measurement is assumed to take 30
seconds.

Furthermore, we are able to optimize energy consumption as advised by the findings of the model. The
integrated pulse ox and heart rate MAXREFDES117 sensor would consume only 11.5% of the power
consumed by the separated IR, red LEDS and photo resistor. However, this significant difference in
power consumption does not translate significantly to overall power efficiency, saving about 3.1%
percent of the total estimated power consumption.

We have also considered a dual mean of powering the device if the battery runs out. This is especially
important for the device’s purpose, as potentially COVID infected people should not leave their homes to
purchase batteries if the device runs out of power. A hole cut out was made into the casing of the
packaging to allow a USB connection to connect to and power the device.

II. CAD and physical 3D modelling:

During the design of the physical casing, careful attention was paid to the product’s ability to be
sanitized, and its resistance to drops and damage to meet the stated objectives. See appendix II: CAD
model for the product’s engineering drawings. All circuitry was designed to be enclosed and sealed in an
ABS box. The sensor, which is protruding has its circuit board protected by a layer of epoxy sanded flush
with top surface of the case.

Modelling the design using CAD software and 3D printing prototypes allowed for feedback from users
and identified areas that could be improved on and informed us of initial design flaws. Our preliminary
design for the back case that encloses the product did not aid user experience. For a user to change the
battery of the product, he would need to unscrew 4 screws connecting the back plate to the body. As a
result, we have redesigned the back plate to have a magnetic hinge that can allow the user to easily swap
out the battery without any tools. We have also removed the screw inserts that can attach to the LCD to
improve the aesthetics of the product. Furthermore, we added a USB port to the packaging to enable users
to power the device through alternate means as advised by the power model.

III. Glass Box Analysis

After consulting with users after preliminary designs and identifying areas of improvement, our finalized
product’s functions and means is described in figure 1 below. The device is turned on through a
mechanical button trip (switch), were a 9-volt battery or an external power source connected to the device
through USB power it on. The SpO2 and blood pulse measurements are taken by the MAXREFDES117
sensor. The results are then converted to a processable output signal by the Arduino Uno processor. The
results are then displayed on the LCD display.

Figure 1: Glass box analysis of final product

Evaluation of results:
We were able to meet most of the stated objectives by successfully modifying the product after
several design iterations. The product has not failed a single objective. The most critical objectives of
measuring blood oxygen saturation levels and providing accurate measurements were met. We believe we
can meet all the remaining stated objectives with enough time and resources to test the final metrics. We
are only concerned about the final cost of the product, as the prototype significantly exceeded the
production cost of $15. Yet we believe with large production volume and economies of scale, the cost of
production per unit will not exceed $15. The results and reasoning for each metric is summarized in table
2: evaluation of product

Metric Reasoning
Objectives Metrics
Pass/Fail/TBD
Measure blood Pass
Measuring range from 70 - 100% MAXREFEDES17 sensor is able to
oxygen saturation
SpO2 measure SpO2 for stated range
level
+/- 2% from 85 to 100%; +/-3% Pass
Provide accurate MAXREFEDES17 sensor provides
from 70-85%; Unspecified from
measurements measurement to +/- 1 % from 70 to 100%
<70%.
Cost <$15 at volumes greater than TBD Finalized component list for mass produced
Affordable
20,000 product not yet determined
Able to perform 1000 TBD Need more testing time to complete 1000
Reliable
measurements before failure measurements. Expected to pass
 Be able to withstand drops from 2 Pass Casing dropped up to 5 meters with no
Durable
meters. significant damage
Resistant to standard medical Pass Sensor, LCD and casing wiped frequently
Able to be
solvents and ultraviolet light with alcohol wipes with no signs of
sterilized
disinfection (UVC). damage.
Fast in completing Provide readings in less than 15 Pass
Able to provide reading in 11 seconds
readings seconds
Pass No pressure touch reading interface is
Easy to use Ergonomic fit
ergonomic for user
TBD Product functions in room temperature and
Able to operate in Able to operate in between 5°C-
70% humidity. Needs to be tested in other
range of climates 40°C and from 35% - 75% humidity
environments.

Table 2: Evaluation of product

Final Thoughts:

The final prototype is able to cater and exceed its stated purpose as a device that can be used to
measure oxygen saturation levels to alert patients at home for early signs of lung damage. All this is
delivered in an aesthetically pleasing and functional packaging, that is both easy and comfortable for
users to use.
Bibliography:

McCallum, Katie. Can an Oximeter Help Detect COVID-19 at Home? Houston Methodist
On Health, www.houstonmethodist.org/blog/articles/2020/aug/can-an-oximeter-help-detect-covid-19-at-
home/.

Appendices:

I. Appendix 1: Model of Power Consumption:

The goal of this model is to estimate the total power consumption of the complete circuit to find a suitable
power supply.
Listed specifications for components:
- Arduino: 7-12 V (input voltage) and current consumption ranging between 45mA – 80mA
- MAXREFDES117#: 5.5mW
- IR and red light in series with resistance: R Ohms at 5V
- OPT 101 Light sensors: 2.7 to 36 V with Low Quiescent Current of 120 μA
- 16 X 2 LCD display: 5V and supply current of 120 mA

By looking at the stated specifications for our circuit components, we realize that the power drawn by the
OPT light sensor is negligible. I also assume that the power drawn by the LCD is more or less constant as
given by the above values of 5V and 120mA. Furthermore, there is no significant variability in the power
needed by the Arduino as shown below. At 7 volts, the current drawn will likely be on the higher end of
the stated range.
P (7 volts) = 7V * 80mA = 560 mW
If we were to use a high input voltage of 12 Volts, the current drawn will likely be on the lower end.
P (12 Volts) = 12 V * 45mA = 540 mW
The average power consumed by the Arduino is at 550mW
Therefore, the only variable that can cause a noticeable change in our power consumption is the resistor
used for the LEDs. If we assume the LEDs will be connected in series with a combined resistance R, we
arrive at the following relation.
Total Power consumed = 550mW +
!"
600mW+ # ∗ 10' mW

As can be seen in figure 3, the plot of the

total power consumed vs varying combined
resistances for the LEDs, we see a significant
drop in power up until 600 ohms, were after
that the change in power becomes fairly
negligible. As such, I will be using a
combined resistance of a 600-ohms.

Our Final expected power consumption if we

were to use the independent LEDs:
 Figure3: graph of power cinsumption vs resistance P= 1192mW
The final expected power consumption for if we were to
use the integrated MAXREFF sensor:
P = 1155 mW

If the supply voltage was at 9 volts, the discharge current is 130 mA. Using constant current performance
charts for generic 9-volt battery, the battery will be able to power the Arduino for about 2 hours of
continuous use.
 4 3 2 1
REVISION HISTORY

REV ECN DESCRIPTION DATE

NOTES:
All all thickness at 0.14 inch
1.35
1.22
D .75 D
Mechanical switch housed
2.14 here to turn device on/off
USB port for secondary
source of power

2.92 .52

1.65

.42
.10

C SEE DETAIL A C
.30
.49 .49
.48
4.93 .14
DETAIL A
SCALE 2.000

ABS constuctred housing.

Integrated MAXREFDES117 Durable and resistant to
SEE DETAIL C 1.65 .50 sensor to measure SpO2 houshehold cleaning solvents
and heart rate

.54
B B

3.70 .88
DETAIL C
SCALE 2.000

Expoy layer
covers exposed
circuity of sensor

COURSE SECTION

REFERENCE DOCUMENTS EK 210 A8

DATE
DIMENSIONING &
TOLERANCING
ASME Y14.5-2018 Nov-28-20
4.84
NAME
THIRD ANGLE
PROJECTION Rashid B. Kolaghassi
A GENERAL TOLERANCES
EMAIL

rbrk@bu.edu
A
TITLE REVISION
UNLESS OTHERWISE SPECIFIED
ALL TOLERANCE VALUES ARE

.X .030
Case Assmebly B1
NUMBER MATERIAL

.XX .015 1 ABS

CAD MODEL CAD DRAWING

.XXX .005 FINALASSM (ASSEM) FINALCASE

SIZE UNITS SCALE WEIGHT WEIGHT SOURCE FINISH

ANGLE 1 B INCHES 1.000 SHEET 1 OF 2

CREO Parametric
4 3 2 1
 4 3 2 1

SEE DETAIL B

2.80

D D

.82

16 X 2 LCD to
display results
DETAIL B
SCALE 2.000

C C
R.09
3.75

Removable and magnetically

attatched back plate allows easy
1.21 to battery compartment
9 Volt battery housed
inside

1.70

B B

Arduino Uno computer chip

housed inside to convert red
light and infrared data
to processable output signal
A A

NUMBER REVISION

SIZE

C
UNITS

INCHES
SCALE

1.000 SHEET 2 OF 2
B1
CREO Parametric
4 3 2 1