Frequently Asked Questions: Rigid Endoscope Service - Page 3
Service Turn-Around Time and Equipment Protection
Disassembly and Repair Process
Disassembly Process
Describe the disassembly process - including work environment, tools, methods and procedures.
Rigid endoscopes are disassembled in a humidity-controlled environment. Tools specifically designed for rigid endoscopes are utilized and disassemblies are performed to documented procedures.
Hot / cold water tests are performed to detect the presence of fluid prior to opening the scope. All fluid is aerated prior to repair.
Glue joints and solder joints are loosened using heat. Weld joints are turned in a lathe and inspected under the microscope to ensure no damage has occurred.
Mechanical components and lenses are observed under a microscope for damage. Cracked or chipped components are replaced during the repair process.
Repair Process
How do you determine if rod lenses and/or fibers are excessively discolored? What tests are conducted to confirm fitness for use of these components?
The proper transmission of color for rod lenses and fibers is evaluated using visual control and photo analysis. Specifically, the customized IMS target contains different circles representing a color spectrum. Technicians visually compare the actual target colors to the colors as seen through the endoscope. If needed, a photograph of the target as seen through the endoscope is made for comparison to the actual target colors. Any unacceptable discoloration is noted via this visual test.
If manufacturer's fiber components are glass based, do you ever replace with plastic fiber components or vice versa?
IMS does not use plastic fibers as a replacement. Plastic fibers are not as reliable and not used for endoscopes.
What process is used for determining if the distal window's anti-reflective (AR) window is compromised?
The image is checked visually using a microscope for the presence of damage to the distal window's anti-reflective window (i.e. scratches).
If the distal window is cracked or compromised, what process is used to demount the window?
If there is significant damage to the distal window (i.e. broken or chipped), the rest of the window is chipped out. Less severely damaged, glued, or soldered windows are removed using heat, and pressure fitted windows are removed by removing the nut, replacing the window, and reinstalling.
If the distal window is replaced, explain the replacement process, including mounting surface preparation, brazing or epoxy attachment of the window, type of epoxy and cure method.
Replacement processes are the same as the OEM (i.e. epoxy if the OEM uses epoxy or brazing if the OEM does the same). IMS has precision soldering capabilities (including infrared soldering) to replace sapphire-based distal windows. Surfaces are cleaned with ionized air and epoxy is cured in humidity-controlled ovens.
Describe the process of reshafting a badly bent endoscope tube.
- The scope is disassembled.
- The tubing is removed by using heat if the OEM has used glue or solder.
- For laser-welded joints, the device is turned on a lathe to separate the shaft from the body. An inspection is conducted under a microscope for damage following this separation.
- New tubing and fibers are installed.
- Internal parts are inspected and cleaned.
- Scope is reassembled.
When reshafting, is the replacement shaft brazed, soldered, welded or epoxied?
The process used during reshafting is dependent on the scope type. IMS uses brazing, soldering, welding or epoxy depending on how the shaft was originally manufactured by the OEM. IMS can laser weld autoclavable scope shafts if the OEM originally welded the shafts.
What tests are conducted to ensure that the reshafted tube is properly aligned to the central mounting block, both with respect to perpendicularity and rotationally? How is this measured?
Tubing alignment is tested using a meter and a calibrator. A series of measurements are taken of the tubing to ensure that tubing alignment is correct.
Does your process involve modification of the central mounting block, either through pinning, drilling holes, epoxy staking or other methods?
Our process does not involve the alteration or modification of the central mounting block.
When replacing rod lenses, what steps are taken to ensure that rod lenses have the same index of refraction, glass/material type, radius of curvature, proper length and that coatings adequately transmit light in the 400-700 nM wavelength band? Do you confirm this? If so, describe the method.
Pristine rod lenses are subjected to the IMS Advanced Component Engineering™ ("ACE") protocol and a specifications sheet is developed with measured tolerance rates for all relevant optical parameters. This ensures that all inventoried rod lenses have correct optical characteristics.
With such equipment as the EndoBench™ (Lighthouse Imaging Corporation), Autocollimator (TriOptix Corporation), and precision measuring microscopes, IMS engineers measure parameters of illumination, imaging, and material properties for original, properly functioning endoscopes and their various component parts. This helps to guarantee that parts evaluated through the IMS ACE program conform to the original performance standards as intended by the device manufacturer.
What steps are taken to ensure that glare from internal reflections are kept to a minimum?
IMS uses the same spacers as the OEM, which are dark in color to reduce glare and in some cases channeled to provide additional glare reduction.
When replacing proximal (ocular) optics, what techniques and methods are taken to ensure that the field of view is centered, the fine focus is maximized, and the depth of field matches the original equipment manufacturer's (OEM's) specifications?
Centering is performed (if possible) by adjustment of the set screws compared to the center of the eyepiece and the depth field is checked using a Diopter telescope and the Air Force Resolution Targets or customized IMS targets.
Are internal optic positions changed in order to compensate for shortening of the shaft due to shaft tip refurbishment?
IMS adheres to the manufacturer's original optical and mechanical design for the endoscope. The shaft is never shortened to a point where the shaft length falls below the tolerance for the manufacturer's original design - even for shaft tip refurbishment. Therefore, no changes are required for the endoscope's internal optic positions.
What method do you employ to ensure that scopes with critical length requirements remain within original equipment manufacturer's (OEM) tolerance?
Critical length requirements are measured with a digital caliper and the measured length is compared to the OEM working length tolerances for a new device.
Describe your methodology for refurbishing the distal scope tips when damage from shears or lasers has occurred?
In cases where the distal tip has sustained damage from shears or lasers, we recommend shaft replacement.
Describe what methods you use to straighten or reform the scope shaft after damage.
The shaft is manually straightened and alignment is verified taking a series of measurements of the shaft from the mounting block to the distal end taking 90-degree turns of the shaft. The location of the bend damage along the shaft dictates whether or not the endoscope optics must be removed prior to straightening.
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