Calibration bench for gas flow meters
Calibration bench "CalBench X
Starting situation
IMT Analytics does not compromise when it comes to the precision of measuring instruments in the medical field. IMT Analytics took a big step forward by taking gas flow and pressure measuring instruments to the next level with a specially developed, fully automated calibration stand. Their goal was not only to increase efficiency but also to ensure the highest quality and strict compliance with ISO 17025 standard requirements. The result is an innovative calibration stand that meets their high standards while raising the accuracy of the measuring instruments to a new level.
Project objectives
The project goal was quickly defined, and the project name "Saoseo" symbolized an inspiring and achievable end goal in the picturesque Swiss mountain landscape. The basis for successful calibration services at various locations is an industrial-grade calibration system that will usher in a new era for IMT Analytics' future calibration centers in terms of robustness, reliability, ease of maintenance, ergonomic operation, and intuitive graphical user guidance. The chosen project name fits perfectly with the goal: "Saoseo" a mountain lake that rewards the arduous climb with an unforgettable panoramic view.
Technical implementation
Although a predecessor product already existed, a detailed inventory analysis of current users, processes, facilities, and problems was conducted in an ideation phase. Stakeholder meetings, expert interviews, and shadow video analyses were used for this purpose. Based on the findings, concepts were then developed and outlined. The most important features quickly crystallized: simple, modular, robust, and compact.
With the help of a "fail early - fail often" mentality and design thinking methods, innovation workshops were held. Cardboard models, 3D prints, milled wood models, and interactive GUI mockups were used. In this way, the key challenges in daily use (usability) and the resulting user experience (UX) were quickly identified and improved.
Insights into the innovation workshops
Cardboard model with hose guide
Cardboard model with cable guide
3D prints with interchangeable filters
GUI mockup
After extensive preliminary work, including sketches, cardboard models, wooden models, and 3D printing, the industrial design and the device name "CalBench X" were created. The design combines all the main features and is complemented by other aspects such as flexibility, independence, comprehensibility, and ergonomics:
System architecture
The successful implementation of a complex development project depends significantly on the system architecture. The creative and design process does not end with an appealing industrial design or buzzwords. A convincing system architecture does not emerge overnight but also requires a design process. The system architecture was developed in an interdisciplinary manner.
First, the relevant perspectives (viewpoints) were defined, on the basis of which the necessary diagrams were created. This resulted in the following descriptions, among others: System Context Diagram, System Decomposition, Pneumatic Design, and Electronic Design.
System context:
The pneumatic design, which includes high-precision measurement technology for the flow, pressure, temperature, and humidity of the gas, presented a particular challenge. Through an analytical approach, combining the analysis of the existing pneumatic system with an in-depth understanding of the physical principles, it was possible to identify and subsequently solve various challenges. In this way, we were able to gradually achieve both functional and metrologically relevant improvements to the existing system. As a by-product of this iterative and open-minded approach, the innovative gas humidification system was created.
After just over two months of productive use and around 200 calibrations performed, the investment is proving to be worthwhile in terms of system stability, throughput, and success rate.
Results
The goal was to build three identical systems. Due to the time-critical delivery situation of certain components, procurement of the key components was already initiated during the design process. It was decided to build, verify, validate, and integrate a system into productive operation as quickly as possible. During the various tests, some weaknesses in the system were identified, which were investigated and corrected without significantly delaying the project. After about a year of development, three CalBench X units were handed over to the calibration laboratory (ISO 17025) of IMT Analytics.
