Design of a mechatronic measurement system for surface fatigue of dental composites

Abstract

This thesis focuses on the design and development of a rolling-ball mechatronic system for on-line testing and measurement of surface contact fatigue of dental composites, and is based on a technique initially developed at the Newcastle Dental School. The mechatronic system synergistically combines the mechanical/electronic hardware with a low-cost embedded digital signal controller (DSC microcontroller) hardware and software to monitor and measure in real-time surface wear due to contact fatigue. ISO/TS 14569-2.2001 standard specification for testing of dental materials was used for selecting appropriate test variables. The mechatronic system attempts to simulate the human oral environment with temperature and moisture being controlled. A closed-loop PI control algorithm combining both optical encoder pulse timing and counting methods is used to drive a dc brushless motor at speeds of 240 and 2040 rpm. A small (2mm diameter) ruby ball is mounted in a V-grooved mandrel which over time creates a circular orbital wear path in the dental composite material. One algorithm has been designed to acquire and process the on-line measurement of wear using a linear voltage differential transformer (LVDT), with another monitoring the fatigue cycling process. A graphical user interface (GUI) has also been designed and implemented on a laptop which is connected to the rig embedded controller. A kinematic model of the rolling ball constrained in a V-groove has been developed along with a finite element analysis of the surface deformation. This has been augmented by a comprehensive test programme, in dry, moisturized and elevated temperature (i.e. 37°C), using Synergy D6 specimens. Using ANOVA test, 70% reproducibility of fatigue track measurements was attained. A comparison of LVDT transducer and profilometer measurements indicated 5% consistence with each other. The insight gained from the testing programme sets a basis for an extensive programme to qualify and validate the measurement system basing on ISO/TS 14569-2.2001 specifications.