Pneumatic system with advanced system diagnostic capabilities

Abstract

The present disclosure relates to diagnosing and locating fluid leaks within a pneumatic system (5) using a minimum number of pressure sensors (55, 75, 89). Typically, each branch (51, 71, 85) of the pneumatic system (5) includes an associated pressure sensor (55, 75, 89), and depending on how the pneumatic components (57, 59, 61, 77, 91, 93, 95) associated with the pneumatic branch (51, 71, 85) are switched and monitored, a minimum number of pressure sensors (55, 75, 89) can be used to detect and locate leaks within the branch (51, 71, 85). More specifically, when the pneumatic components (57, 59, 61, 77, 91, 93, 95) are in a particular configuration, the pressure and pressure decay within the branch (51, 71, 85) can be measured by the sensors (55, 75, 89). Thereafter, the configuration is changed, and the pressure and pressure decay are again measured by the sensors (55, 75, 89). The results of these two measurements can enable the pneumatic system (5) to ascertain the existence and location of a leak.

Description

[0001] Cross-references to related applications

[0002] This application relates to and claims the benefit of Provisional Patent Application No. 62 / 785,850, entitled “Pneumatics System with Advanced System Diagnostics Capabilities,” filed December 28, 2018, with the U.S. Patent and Trademark Office. The entire contents of that provisional patent application are incorporated herein by reference. Background Technology

[0003] Pneumatic system leaks or leak failures have historically been difficult to diagnose and repair in the field. In many cases, field service engineers fail to detect leaks, and while a leak may not cause a problem in the primary subsystem, it can lead to secondary issues in related subsystems, making diagnosis even more challenging. Accurate diagnosis requires a broad skill set and detailed knowledge of pneumatic systems from the field service engineer to pinpoint the leak. Trial-and-error methods, using sub-branch isolation, are time-consuming and do not always yield correct results.

[0004] Therefore, there is a need for a method or system that enables pneumatic systems to self-diagnose and accurately locate leaks within the pneumatic system. Summary of the Invention

[0005] This disclosure relates to a method for diagnosing leakage faults in a pneumatic system. In one exemplary method, multiple components servicing a common branch of the pneumatic system are configured into a first configuration using multiple corresponding valves. Leakage in the multiple components in the first configuration is then measured jointly. The multiple components are then configured into a second configuration using multiple corresponding valves, and leakage in the multiple components in the second configuration is measured jointly. If the leakage measured when the multiple components are in the first configuration is less than a first configuration threshold, and the leakage measured when the multiple components are in the second configuration is less than a second configuration threshold, the method reports a pass result.

[0006] In another example method, a first passageway is pressurized. In this example, the first passageway extends from a manifold through a valve to a first fitting. Thereafter, a first pressure decay within the first passageway is measured, where the first pressure decay is based at least in part on a change in pressure within the first passageway over a first time period. Thereafter, a second passageway is pressurized. In this example, the second passageway extends from the manifold through the valve to a second fitting. Thereafter, a second pressure decay within the second passageway is measured, where the second pressure decay is based at least in part on a change in pressure within the second passageway over a second time period. After measuring both pressure decays, the first pressure decay and the second pressure decay are compared to a limit threshold. In response to determining that the first pressure decay and the second pressure decay are greater than the limit threshold, the method determines that a leak exists between the manifold and the valve. In response to determining that the first pressure decay is greater than the limit threshold and the second pressure decay is less than the limit threshold, the method determines that a leak exists between the valve and the first fitting. In response to determining that the first pressure decay is less than the limit threshold and the second pressure decay is greater than the limit threshold, the method determines that a leak exists between the valve and the second fitting.

[0007] In another example method, a sensor is pneumatically associated with a branch of a pneumatic system. In this example, the branch includes at least two three-way four-port valves pneumatically associated with pneumatic components, and each of the pneumatic components is pneumatically drivable to transition between a first state and a second state. Thereafter, each of the pneumatic components in the branch is pneumatically driven to pressurize a plurality of passageways within the branch. In response to pressurizing a passageway of the plurality of passageways, a pressure within the passageway is measured with the sensor over a time period to determine a pressure decay. Thereafter, a location of a leak within the branch is determined, where the determination is based at least in part on the measured pressure decay. BRIEF DESCRIPTION OF DRAWINGS

[0008] While the specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the application, it is believed the application will be better understood from the following description of certain examples, taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures, and in which:

[0009] Figure 1A schematic diagram depicting an example operating environment of an example laboratory instrument;

[0010] Figure 1B another schematic diagram depicting an example operating environment of an example laboratory instrument;

[0011] Figure 2 schematic diagram depicting an example computer system used in the operating environment of Figure 1A schematic diagram depicting an example computer system used in the operating environment of

[0012] Figure 3 schematic diagram depicting an example computer system used in the operating environment of Figure 1Aschematic diagram of an exemplary pneumatic system of a laboratory instrument;

[0013] Figure 4 depicts an exemplary bidirectional three-port valve used in the pneumatic system of Figure 3

[0014] Figure 5 depicts an exemplary three-way four-port valve used in the pneumatic system of Figure 3

[0015] Figure 6 depicts an exemplary method for checking for leaks in the pneumatic system of Figure 3

[0016] Figure 7 depicts another exemplary method for checking for leaks in the pneumatic system of Figure 3

[0017] Figure 8 depicts an exemplary method for checking for leaks in an exemplary first branch of the pneumatic system of Figure 3

[0018] Figure 9 depicts an exemplary method for checking for leaks in an exemplary second branch of the pneumatic system of Figure 3

[0019] Figure 10A depicts a portion of an exemplary method for checking for leaks in an exemplary third branch of the pneumatic system of Figure 3

[0020] Figure 10B depicts another portion of an exemplary method for checking for leaks in an exemplary third branch of the pneumatic system of Figure 3

[0021] Figure 10C depicts another portion of an exemplary method for checking for leaks in an exemplary third branch of the pneumatic system of Figure 3

[0022] Figure 11 depicts another exemplary method for checking for leaks in the pneumatic system of Figure 3

[0023] Figure 12 depicts another exemplary method for checking for leaks in the pneumatic system of Figure 3

[0024] ​​​​​​​​​​​The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the application can be carried out in various other ways, including those not necessarily depicted in the drawings. The accompanying drawings illustrate several aspects of the application, and together with the description, serve to explain the principles of the application; it being understood, however, that the application is not to be limited to the exact arrangements and methods shown. DETAILED DESCRIPTION

[0025] The following description of certain examples of the application should not be used to limit the scope of the present application. Other examples, features, aspects, embodiments, and advantages of the application will become apparent to those of ordinary skill in the art upon review of the following description, some of which are also described in the claims. As will be realized, the application is capable of other different and obvious aspects, all without departing from the application. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

[0026] It should be appreciated that any one or more of the teachings, expressions, versions, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, versions, examples, etc. described herein. The above-described teachings, expressions, versions, examples, etc. should therefore not be viewed in isolation from each other. Various suitable ways in which the teachings herein can be combined will depend on the disclosure presented herein and the knowledge of one of ordinary skill in the art.

[0027] I. Operating Environment

[0028] Reference is now made to Figure 1A and Figure 1B An operating environment (1) in accordance with some versions of the present application can include a laboratory instrument (3). The laboratory instrument (3) can include an analyzer or any other type of laboratory testing device or instrument for testing biological samples. The laboratory instrument (3) can include a pneumatic system (5) with advanced system diagnostic capabilities for driving or facilitating various elements within the laboratory instrument (3), hereinafter referred to as a pneumatic system (5) with advanced system diagnostic capabilities. The pneumatic system (5) can include various valves, channels, and fittings for facilitating pneumatic driving of various elements within the laboratory instrument (3). Pneumatic leaks, leak faults, or decay can be monitored and reported by various diagnostic and maintenance mechanisms associated with the pneumatic system (5), which will be discussed in greater detail below.

[0029] According to some versions of the application, the operating environment (1) can include a remote management service (7). The remote management service (7) can initiate or facilitate remote diagnostic and maintenance mechanisms within the pneumatic system (5) and can alert a field service engineer (FSE) about issues with the laboratory instrument (3). Certain versions of the remote management service (7) can receive and store information about maintenance or diagnostic tests of the laboratory instrument (3) and apply logic or other data analysis to the data to arrive at fault detection or maintenance information for use by the field service engineer.

[0030] According to some versions of the application, the operating environment (1) can include a computing device (9). The field service engineer or a user can use the computing device (9) to view data or drive components associated with the laboratory instrument (3) and / or the remote management service (7). For example, the computing device (9) can include a handheld tablet for providing the field service engineer with diagnostic data about the laboratory instrument (3) collected by the remote management service (7).

[0031] In some versions of the operating environment (1), the laboratory instrument (3), the remote management service (7), and the computing device (9) can send and receive communications directly between one another. Alternatively, in other versions of the operating environment (1), the laboratory instrument (3), the remote management service (7), and the computing device (9) can communicate with one another through a network (24). The network (24) can include one or more private networks or public networks (e.g., the Internet) that enable the exchange of data.

[0032] Figure 1B An example schematic diagram of the operating environment (1) and diagnostic relationships between the remote management service (7), a user of the laboratory instrument (3), and a field service engineer is depicted. In some versions of the operating environment (1), the user can periodically service the laboratory instrument (3), which can include driving or otherwise running a general pneumatic leak test of the pneumatic system (5) of the laboratory instrument (3). This can be driven by manually pressing an interface or other mechanism on the laboratory instrument (3). In response to such periodic general pneumatic leak tests, data is collected about the overall performance and stability of the pneumatic system (5). Thereafter, the remote management service (7) can be updated with the test data from the general pneumatic leak test.

[0033] If no significant leak is detected by the general pneumatic leak test, the remote management service (7) can reference the particular lab instrument (3) to update historical data stored therein. If a significant enough leak is detected, i.e., a leak that can lead to errors in the lab instrument (3), the user is notified and thereafter the user can initiate a diagnostic pneumatic leak test. In the diagnostic pneumatic leak test, the location of the leak is determined by testing each branch of the pneumatic system (5). Once the location of the leak is identified, the user can attempt to repair the cause of the leak. For example, a tubing element or fitting can be replaced by the user. Thereafter, the general pneumatic leak test is run by the user to determine if the user has repaired the leak. If the user has not repaired the leak, the user can call a hotline or otherwise receive a verbal / video instruction from a field service engineer or technician with instructions on how to repair the leak. Thereafter, the general pneumatic leak test is run by the user to determine if the user has repaired the leak. If the user has not repaired the leak, a field service engineer can be dispatched to repair the cause of the leak by repairing the pneumatic system (5) and re-running the general pneumatic leak test until the leak is repaired.

[0034] In some versions of the operating environment (1), any relevant metrics, data, historical trends, or test results can be notified to a field service engineer by the lab instrument (3), the remote management service (7), and / or the computing device (9). This can be in the form of an alert or email to the field service engineer, or some sort of notation, such that the particular lab instrument (3) can require immediate attention or attention during the next scheduled on-site visit to the lab instrument (3). For example, if a diagnostic test of the pneumatic system (5) shows a small leak in a particular pneumatic branch, an alert or notification can be provided to the field service engineer to inspect the pneumatic branch during the next on-site visit to the particular lab instrument (3).

[0035] Reference will now be made to Figure 2The laboratory instrument (3), remote management service (7), and computing device (9) of the operating environment (1), and network (24) can be consolidated or implemented on one or more computing devices or systems, such as the example computer system (26). The computer system (26) can include a processor (28), a memory (30), a mass storage memory device (32), an input / output (I / O) interface (34), and a user interface (UI) (36), which in some versions of the laboratory instrument (3) can include a graphical user interface. The computer system (26) can also be operatively coupled, while in operation, to one or more external resources (38) via the network (24) or I / O interface (34). The external resources can include, but are not limited to, servers, databases, mass storage devices, peripheral devices, cloud-based network services, or any other suitable computer resources that can be used by the computer system (26).

[0036] The processor (28) can include one or more devices selected from a microprocessor, a microcontroller, a digital signal processor, a microcomputer, a central processing unit, a field programmable gate array, a programmable logic device, a complex programmable logic device, a logic circuit, an analog circuit, a digital circuit, or any other device that manipulates signals (analog or digital) based on instructions stored in the memory (30) or firmware of the device. The memory (30) can include a single memory device or multiple memory devices or any other device capable of storing information. The mass storage device (32) can include a data storage device such as a hard disk drive, an optical disk drive, a magnetic tape drive, a non-volatile solid state device, or any other device capable of storing information.

[0037] The processor (28) can operate under control of an operating system (40) that is resident in the memory (30). The operating system (40) can manage computer resources such that computer program code implemented as one or more computer software applications, such as the application (42) that is resident in the memory (30), can have instructions executed by the processor (28). In alternative implementations, the processor (28) can directly execute the application (42), in which case the operating system (40) can be omitted. One or more data structures (44) can also be resident in the memory (30) and can be used by the processor (28), the operating system (40), or the application (42) to store or manipulate data.

[0038] The I / O interface (34) can provide a machine interface that couples the processor (28) in operation to other devices and systems, such as the network (24) or external resources (38). Thus, the applications (42) can work in conjunction with the network (24) or external resources (38) by communicating via the I / O interface (34) to provide various features, functions, applications, processes, or modules including embodiments of the present application. The applications (42) can also have program code executed by one or more external resources (38) or otherwise rely on functionality or signals provided by other system or network components external to the computer system (26). Indeed, given the almost limitless number of possible hardware and software configurations, those of ordinary skill in the art will appreciate that embodiments of the present application can include applications provided by computing resources (hardware and software) located external to the computer system (26), distributed among multiple computers or other external resources (38), or provided by services conducted over the network (24), such as cloud computing services.

[0039] The UI (36) can be operatively coupled to the processor (28) of the computer system (26) in a known manner to allow a user to interact with the computer system (26) directly. The UI (36) can include a video or alphanumeric display, a touch screen, a speaker, and any other suitable audio and visual indicators capable of providing data to a user. The UI (36) can also include input devices and controls capable of accepting commands or input from a user and transmitting the entered input to the processor (28), such as an alphanumeric keyboard, a pointing device, a keypad, buttons, control knobs, a microphone, etc.

[0040] The database (46) can reside on the mass storage memory device (32) and can be used to collect and organize data used by the various systems and modules described herein. The database (46) can include data as well as supporting data structures to store and organize the data. In particular, the database (46) can be arranged to have any database organization or structure, including but not limited to a relational database, a hierarchical database, a network database, or combinations thereof. A database management system in the form of a computer software application executing on the processor (28) can be used to access information or data stored in records of the database (46) in response to queries, where the queries can be dynamically determined and executed by the operating system (40), other applications (42), or one or more modules.

[0041] II. Pneumatic System

[0042] The exemplary pneumatic system (5) is in Figure 3The diagram depicts and includes three branches or lines extending from a manifold (47) configured to receive pneumatic fluid (e.g., air or liquid) from an accumulator (49). Each line is an example and illustration of a different configuration of a pneumatic branch with multiple sub-branches and pneumatic elements, associated with a single pressure sensor for detecting leaks and identifying the location of a specific sub-branch. The advanced system diagnostic capabilities of the pneumatic system (5) fully utilize the individual sensors in each pneumatic branch, along with other features, to achieve leak detection, isolation, and obtaining information about pressure decay or leakage. Components of the pneumatic system (5) can be switched and monitored to detect leaks in the system, isolate leaks, and determine the overall leak rate or decay, and this data can then be provided to field service engineers, users, or other monitoring systems.

[0043] The first branch of the pneumatic system (5), referred to below as the blue line (51), is associated with a blue line shut-off valve (53) and a blue line sensor (55) configured to determine the pressure within the blue line (51). In some versions of the pneumatic system (5), the blue line (51) is associated with three pneumatic elements implemented by a "pick-up and place" (PnP) actuator. Specifically, in Figure 3 In the example shown, the blue line (51) is associated with the sample PnP actuator (57), the incubation PnP actuator (59), and the analysis PnP actuator (61).

[0044] Located between each PnP actuator (57, 59, 61) and the shut-off valve (53) is a corresponding bidirectional three-port valve, configured to deliver fluid to the associated PnP actuator (57, 59, 61) in a first position and to discharge fluid to the atmosphere in a second position. An example schematic diagram of the bidirectional three-port valve is shown in [the diagram]. Figure 4 Described in the text.

[0045] Specifically, a sample pick-up and place (S-PnP) valve (63) is positioned between the blue line shut-off valve (53) and the sample PnP actuator (57). The S-PnP valve (63) is configured to allow fluid to be passed through it to the sample PnP actuator (57) when the S-PnP valve (63) is in a first position and to prevent fluid from being passed through it to the sample PnP actuator (57) when the S-PnP valve (63) is in a second position. When the S-PnP valve (63) is in the second position, the fluid between the S-PnP valve (63) and the sample PnP actuator (57) is freely discharged to the atmosphere.

[0046] Similarly, disposed between the blue line stop valve (53) and the incubation PnP actuator (59) is an incubation pick and place (I-PnP) valve (65). The I-PnP valve (65) is configured to pass fluid therethrough to the incubation PnP actuator (59) when the I-PnP valve (65) is in a first position, and to prevent fluid from passing therethrough to the incubation PnP actuator (59) when the I-PnP valve (65) is in a second position. When the I-PnP valve (65) is in the second position, fluid between the I-PnP valve (65) and the incubation PnP actuator (59) is freely vented to atmosphere.

[0047] Disposed between the blue line stop valve (53) and the analysis PnP actuator (61) is an analysis pick and place (A-PnP) valve (67). The A-PnP valve (67) is configured to pass fluid therethrough to the analysis PnP actuator (61) when the A-PnP valve (67) is in a first position, and to prevent fluid from passing therethrough to the analysis PnP actuator (61) when the A-PnP valve (67) is in a second position. When the A-PnP valve (67) is in the second position, fluid between the A-PnP valve (67) and the analysis PnP actuator (61) is freely vented to atmosphere.

[0048] Certain versions of the blue line (51) use a different pressure than that provided by the accumulator (49), and thus can provide a blue line regulator (69) to change the pressure before the fluid enters the blue line stop valve (53).

[0049] A second branch of the pneumatic system (5), referred to below as the green line (71), is associated with a green line stop valve (73) and a green line sensor (75) configured to determine the pressure within the green line (71). In some versions of the pneumatic system (5), the green line (71) is associated with a bulk feeder (77) having a cylinder element (79) that can move between a cylinder in position and a cylinder out position.

[0050] Disposed between the bulk feeder (77) and the green line stop valve (73) is a respective three-way four-port valve, referred to below as the bulk feeder valve (81). An example schematic of the green line bulk feeder valve (81) is shown in FIG. 6. Figure 5The bulk feeder valve (81) can be transitioned between an energized state or a de-energized state. In the energized state, the bulk feeder valve (81) is configured to drive the cylinder element (79) of the bulk feeder (77) to the cylinder in position. In the de-energized state, the bulk feeder valve (81) is configured to drive the cylinder element (79) of the bulk feeder (77) to the cylinder out position. Other versions of the green line stop valve (73) can be configured to provide the opposite drive, i.e., to drive the cylinder element (79) to the cylinder out position in the energized state and to drive the cylinder element (79) to the cylinder in position in the de-energized state.

[0051] Some versions of the green line (71) use a different pressure than that provided by the accumulator (49) and, as such, can provide a green line regulator (83) to change the pressure before the fluid enters the green line stop valve (73).

[0052] A third branch of the pneumatic system (5), referred to below as the yellow line (85), is associated with a yellow line stop valve (87) and a yellow line sensor (89) configured to determine the pressure within the yellow line (85). In some versions of the pneumatic system (5), the yellow line (85) is associated with three pneumatic elements, which are generally configured to transition between a first position and a second position.

[0053] In particular, in the example shown in Figure 3 the yellow line (85) is associated with a “reagent storage module” (RSM) gripper (91), a “reagent storage module” (RSM) door (93), and a wash wheel (95), which is shown in some figures as “WW”. The RSM gripper (91) includes a gripper element (97) that can be moved between an open position and a closed position. The RSM door (93) includes a door element (99) that can be moved between an open position and a closed position. The wash wheel (95) includes a wash wheel arm element (101) that can be moved between an up position and a down position.

[0054] Disposed between the RSM gripper (71) and the yellow line stop valve (87) is a respective three-way four-port valve, referred to below as the gripper valve (103). An example schematic of the gripper valve (103) is shown in Figure 5The clamping valve (103) can be transitioned between an energized state or a de-energized state. In the energized state, the clamping valve (103) is configured to drive the clamping element (97) of the RSM clamp (91) to an open position. In the de- energized state, the clamping valve (103) is configured to drive the clamping element (97) of the RSM clamp (91) to a closed position. The clamping valve (103) can be configured to provide the opposite drive, i.e., to drive the clamping element (97) to the closed position in the energized state and to the open position in the de-energized state. Other versions of the clamping valve (103) can include a self-latching valve with one electrical input for opening and one input for closing, neither of which requires continuous energy to maintain position.

[0055] Disposed between the RSM gate (93) and the yellow line shut-off valve (87) is a corresponding three-way, four-port valve, hereinafter referred to as the gate valve (105). An example schematic of the gate valve (105) is depicted in Figure 5 The gate valve (105) can be transitioned between an energized state or a de- energized state. In the energized state, the gate valve (105) is configured to drive the gate element (99) of the RSM gate (93) to an open position. In the de-energized state, the gate valve (105) is configured to drive the gate element (99) of the RSM gate (93) to a closed position. The gate valve (105) can be configured to provide the opposite drive, i.e., to drive the gate element (99) to the closed position in the energized state and to the open position in the de-energized state.

[0056] Disposed between the wash wheel (95) and the yellow line shut-off valve (87) is a corresponding three-way, four-port valve, hereinafter referred to as the wheel valve (107). An example schematic of the wheel valve (107) is depicted in Figure 5 The wheel valve (107) can be transitioned between an energized state or a de- energized state. In the energized state, the wheel valve (107) is configured to drive the wash wheel arm element (101) of the wash wheel (95) to an up position. In the de- energized state, the wheel valve (107) is configured to drive the wash wheel arm element (101) of the wash wheel (95) to a down position. The wheel valve (107) can be configured to provide the opposite drive, i.e., to drive the wash wheel arm element (101) to the down position in the energized state and to the up position in the de-energized state.

[0057] Some versions of the yellow line (85) use a different pressure than that provided by the accumulator (49) and, as such, can provide a yellow line regulator (not shown) to change the pressure before the fluid enters the yellow line shut-off valve (87).

[0058] A manifold sensor (109) may be provided to sense the pressure in the manifold (47). The manifold sensor (109) is located downstream of the accumulator (49) and upstream of the blue-line shut-off valve (53), green-line shut-off valve (73), and yellow-line shut-off valve (87) to provide information about the pressure between the accumulator (49) and these components.

[0059] The cylinder element (79), gripper element (97), door element (99), and washing wheel arm element (101) are shown and described for illustrative purposes only. Any pneumatic component may be used in conjunction with or in place of these pneumatic components.

[0060] Figure 4 A schematic diagram of a two-way three-port valve (111) in the de-energized and closed position and in the energized and open position is depicted. As discussed above, in some versions of the pneumatic system (5), the S-PnP valve (63), I-PnP valve (65), and / or A-PnP valve (67) may resemble or include the valve (111). The two-way three-port valve (111) can be configured to pressurize a fitting (110) located on one of the pneumatic components connected thereto, namely the sample PnP actuator (57), the thermal PnP actuator (59), and / or the analytical PnP actuator (61).

[0061] Figure 5 A schematic diagram of a three-way four-port valve (113) in both a de-energized and energized state is depicted. As discussed above, in some versions of the pneumatic system (5), the bulk feeder valve (81), gripper valve (103), gate valve (105), and / or wheel valve (107) may resemble or include the valve (113). The three-way four-port valve (113) may be configured to pressurize fittings (112) disposed on one of the pneumatic components connected thereto, namely, the bulk feeder (77), the RSM gripper (91), the RSM gate (93), and / or the washing wheel (95). The three-way four-port valve (113) may also be configured to pressurize fittings (114) disposed on one or more of the pneumatic components connected thereto.

[0062] Figure 6 A method (115) for determining the presence of a leak and capturing information about the decay of the leak is described within a pneumatic system (5). The terms “leak,” “leakage,” and “leakage failure” are used interchangeably throughout this disclosure to refer to the unintentional discharge of pneumatic fluid from the pneumatic system (5).

[0063] Method (115) begins with a leak check request step (117). The leak check request step (117) can be initiated by the system of the laboratory instrument (3), manually by the user, or by an external source connected to the laboratory instrument (3). Once initiated, the leak check request step (117) proceeds to step (119). In step (119), one or more valves associated with the specific part of the pneumatic system (5) being tested are configured and / or switched to the desired state of that part of the pneumatic system (5) (i.e., open valve and closed valve, etc.). Thereafter, step (119) proceeds to step (121).

[0064] In step (121), a delay is initiated to allow the valve in the specific part of the pneumatic system (5) being tested to stabilize and normalize. After this delay, step (121) proceeds to step (123). In step (123), the pressure within the specific part of the pneumatic system (5) being tested is sensed, and the pressure data is captured and stored. The initial pressure measurement value is... Figure 6 The value is denoted as "P1". Depending on the specific part of the pneumatic system (5) being tested, sensors such as the blue line sensor (55), green line sensor (75), and yellow line sensor (89) can be used. Once P1 is captured, step (123) proceeds to step (125). In step (125), a delay is initiated to allow for the time difference between pressure readings. After this delay, step (125) proceeds to step (127). In step (127), the pressure within the specific part of the pneumatic system (5) being tested is sensed, and this pressure data is captured and stored. This subsequent pressure measurement is... Figure 6 This is denoted as "P2". If a leak is present, the pressure will decrease during the intermediate time between capturing P1 and P2. After capturing P2, step (127) proceeds to step (129).

[0065] In step (129), the pressure difference within the specific section of the pneumatic system (5) being tested is calculated by subtracting P2 from P1. If there is no difference in pressure readings, or only a nominal difference in pressure readings, method (115) determines that there is no leak. If there is a difference between P1 and P2, method (115) determines that there is a leak. Furthermore, the difference between P1 and P2 plotted over the time delay in step (125) provides information about the decay of the leak. For example, if P1 equals 10 psi, P2 equals 8 psi, and the time delay between the pressure readings is 2 seconds, method (115) determines that there is a leak, and the leak is associated with a pressure decay of approximately 1 psi per second.

[0066] After step (129), method (115) proceeds to step (131), in which the leak check is completed, and any data requested or provided by method (115) can be passed to the initiator of method (115) for further use.

[0067] III. Diagnostic Testing of Pneumatic Systems

[0068] Typically, a field service engineer or technician or the instrument itself can determine the presence of a leak in a pneumatic system, but the specific part of the pneumatic system containing the leak is unknown. Therefore, the entire pneumatic system, such as pneumatic system (5), must be tested to determine the location of the leak. Alternatively, leak checks of pneumatic system (5) can be incorporated into routine system checks that typically monitor the health of laboratory instruments (3), and especially the health of pneumatic system (5).

[0069] Reference Figure 1A and Figure 1B The inspection of the entire pneumatic system (5) can be driven by a remote management service (7) or a computing device (9). For example, a technician can drive the inspection of the entire pneumatic system (5) via a computing device (9) implemented by a tablet computer in the field. Alternatively, the laboratory instrument (3) may include a triggering element that allows a user or technician to manually drive the inspection of the entire pneumatic system (5) by pressing a button or a similar interface feature included in the laboratory instrument (3).

[0070] Figure 7 A method (201) is described for performing diagnostic tests on the entire pneumatic system (5) to determine the presence of any leaks and to isolate leaks to specific subsystems. Compared to conventional pneumatic system diagnostic tests, method (201) uses a reduced and / or minimal number of sensors to perform system-wide diagnostic tests. Conventional systems associate sensors with every branch of the pneumatic system, which increases the cost, complexity, and time required to run diagnostic tests. While method (201) illustrates diagnostic testing of the entire pneumatic system (5), other versions of method (201) allow users to select specific sub-branch of the pneumatic system (5) to run diagnostic tests. For example, a user might want to run a portion of method (201) to determine if a leak exists within the blue line (51).

[0071] Method (201) begins with step (203), thereby initiating diagnostic testing of the pneumatic system (5). Step (203) can be initiated by the system of the laboratory instrument (3), manually by the user, or by an external source connected to the laboratory instrument (3). Once initiated, step (203) typically proceeds simultaneously to the blue line system check step (205), the green line system check step (207), and the yellow line system check step (209) to determine whether a leak exists in any of these three subsystems. Generally and as needed, until a leak is identified and isolated, the blue line system check step (205), the green line system check (207), and the yellow line system check (209) each repeatedly open and close their associated valves, polling the associated sensors, namely the blue line sensor (55), the green line sensor (75), and the yellow line sensor (89), to determine whether a leak exists in that particular configuration of the underlying valve structure using the method (115) described above. Once identified, the location and decay of the leak are transmitted to the requesting entity, such as a technician, the system of the laboratory instrument (3), or an external source connected to the laboratory instrument (3).

[0072] Reference Figure 8 The blue line system inspection step (205) is discussed in more detail. However, in general, the blue line system inspection step (205) begins with step (211). In step (211), the blue line (51) is inspected with all valves open to determine if there is a leak at any location within the blue line (51). In some versions of method (201), this determination is performed using method (115). Step (211) then proceeds to step (213), thereby determining if there is a leak at any location within the blue line (51), and if a leak is found, determining the associated leak rate or decay. If a leak is determined to be below an acceptable leak rate, step (213) proceeds to step (215), thereby terminating the blue line system inspection step (205) without proceeding to the individual sub-branches of the blue line (51) because no leak was detected. Step (215) then optionally proceeds to step (217) to report the results of the relevant leak inspection, and simultaneously concludes the diagnosis in step (219). If step (213) determines that the measured leakage rate within the blue line (51) exceeds an acceptable limit, then step (213) proceeds to step (221). In step (221), a leak isolation protocol is initiated, thereby testing each sub-branch of the blue line (51) to determine the location of the leak. Once the leak is located, step (221) may optionally proceed to step (217) to report the results of the relevant leak inspection, and simultaneously end the diagnostics in step (219).

[0073] Reference Figure 9The green line system inspection step (207) is discussed in more detail. However, generally, the green line system inspection step (207) begins with step (223). In step (223), the cylinder element (79) is moved to the cylinder in position and the green line (71) is checked to determine if there is a leak. In some versions of method (201), this determination is performed using method (115). Thereafter, step (223) proceeds to step (225). In step (225), the cylinder element (79) is moved to the cylinder out position and the green line (71) is checked to determine if there is a leak. In some versions of method (201), this determination is performed using method (115). Thereafter, step (225) may optionally proceed to step (217) to report the results of the relevant leak inspection, and simultaneously conclude the diagnosis in step (219).

[0074] Reference Figures 10A to 10C The yellow line system inspection step (209) is discussed in more detail. However, generally, the yellow line system inspection step (209) begins at step (227), whereby the yellow line (85) is moved to a default configuration, where the clamp valve (103), gate valve (105), and wheel valve (107) are moved to specific positions corresponding to the default positions. The yellow line (85) in the default position is then inspected to determine if any leaks are present. In some versions of method (201), this determination is performed using method (115). Step (227) then proceeds to step (229). In step (229), the yellow line (85) is moved to a non-default configuration, where the clamp valve (103), gate valve (105), and wheel valve (107) are moved to specific positions corresponding to the non-default positions. The yellow line (85) in the non-default positions is then inspected to determine if any leaks are present. In some versions of method (201), this determination is performed using method (115). Subsequently, step (229) proceeds to step (231). In step (231), it is determined whether the leakage rate measured in steps (227) and (229) exceeds an acceptable limit. If so, step (331) proceeds to step (233), whereby the yellow line system check step (209) terminates without proceeding to the individual sub-branches of the yellow line (85) because no leakage was detected. Subsequently, step (233) optionally proceeds to step (217) to report the results of the relevant leak check, and simultaneously ends the diagnosis in step (219). If step (231) determines that the measured leakage rate within the yellow line (85) exceeds an acceptable limit, then step (231) proceeds to step (235). In step (235), a leak isolation protocol is initiated, whereby each sub-branch of the yellow line (85) is tested to determine the location of the leak. Once the leak is located, step (235) may optionally proceed to step (217) to report the results of the relevant leak inspection, and simultaneously end the diagnosis in step (219).

[0075] Once the blue line system check step (205), green line system check (207), and yellow line system check (209) are completed, the leakage decay rate and leakage location are isolated to a specific sub-branch of the blue line (51), green line (71), or yellow line (85), and the leakage decay rate is known. Then, a technician or user / owner of the laboratory instrument (3) can take steps to address the leak. Because the blue line system check step (205), green line system check (207), and yellow line system check (209) can be performed in parallel, method (201) can be completed in a short time, thereby minimizing downtime of the laboratory instrument (3) and the technician's time.

[0076] A. Blue Line System Inspection

[0077] exist Figure 8 The blue line system inspection steps (205) are described in more detail below. Blue line system inspection steps (205) begin with step (235), which requests a leak diagnosis. Step (235) then proceeds to step (237). In step (237), all valves within the blue line (51) are opened, namely the S-PnP valve (63), I-PnP valve (65), and A-PnP valve (67). Step (237) then proceeds to step (239), whereby a leak detection method such as method (115) is performed on the blue line (51) with all valves open, and it is determined whether a leak is detected in this configuration. If no leak is detected, step (239) proceeds to step (241) to indicate that a pneumatic check of the blue line (51) has been passed and no leak has been detected in the blue line (51). Subsequently, step (241) may optionally proceed to step (243) to report the results of the Blue Line System Check step (205), and simultaneously proceed to step (245) to restore the default hardware configuration of Blue Line (51) and end the Blue Line System Check step (205).

[0078] If a leak is detected, step (239) proceeds to step (247). In step (247), all valves within the blue line (51), namely the S-PnP valve (63), I-PnP valve (65), and A-PnP valve (67), are closed. Thereafter, step (247) proceeds to step (249), whereby a leak detection method such as method (115) is performed on the blue line (51) with all valves closed, and it is determined whether a leak is detected in this configuration. If a leak is detected, step (249) proceeds to step (251) to indicate that a leak exists between the manifold (47) and one of the valves on the blue line (51). Due to the topology of the pneumatic system (5), the detected leak cannot be further isolated. Therefore, step (251) may optionally proceed to step (243) to report the results of the Blue Line System Check step (205), and simultaneously proceed to step (245) to restore the default hardware configuration of the Blue Line (51) and end the Blue Line System Check step (205).

[0079] If no leak is detected, step (249) proceeds to step (253) to indicate a leak between the valve in the blue line (51) and the specific actuator associated with that valve. More specifically, step (253) indicates a leak between one or more of the following: the S-PnP valve (63) and the sample PnP actuator (57); the I-PnP valve (65) and the thermal PnP actuator (59); or the A-PnP valve (67) and the analytical PnP actuator (61). Step (253) and those subsequent steps are generally reflected in... Figure 7 In step (221), a leak isolation protocol is executed to isolate the leak and to identify which valves are associated with the leak. Step (253) proceeds to step (255).

[0080] In step (255), the S-PnP valve (63) is opened while the I-PnP valve (65) and A-PnP valve (67) are closed. Step (255) then proceeds to step (257), whereby a leak detection method such as method (115) is performed, and it is determined whether a leak exists between the S-PnP valve (63) and the sample PnP actuator (57). If a leak is detected, step (257) proceeds to step (259) to indicate the presence of a leak between the S-PnP valve (63) and the sample PnP actuator (57). Step (259) then optionally proceeds to step (243) to report the result, and simultaneously proceeds to step (261). Similarly, if no leak is detected, step (257) proceeds to step (261).

[0081] In step (261), the I-PnP valve (65) is opened while the S-PnP valve (63) and A-PnP valve (67) are closed. Step (261) then proceeds to step (263), whereby a leak detection method such as method (115) is performed, and it is determined whether a leak exists between the I-PnP valve (65) and the thermoplastic PnP actuator (59). If a leak is detected, step (263) proceeds to step (265) to indicate the presence of a leak between the I-PnP valve (65) and the thermoplastic PnP actuator (59). Step (265) then optionally proceeds to step (243) to report the result, and simultaneously proceeds to step (267). Similarly, if no leak is detected, step (263) proceeds to step (267).

[0082] In step (267), the A-PnP valve (67) is opened while the S-PnP valve (63) and the I-PnP valve (65) are closed. Step (267) then proceeds to step (269), whereby a leak detection method such as method (115) is performed, and it is determined whether a leak exists between the A-PnP valve (67) and the analytical PnP actuator (61). If a leak is detected, step (269) proceeds to step (271) to indicate the presence of a leak between the A-PnP valve (65) and the analytical PnP actuator (61). Step (271) then optionally proceeds to step (243) to report the result, while simultaneously proceeding to step (245). Similarly, if no leak is detected, step (269) proceeds to step (245).

[0083] The blue line sensor (55) is used to perform each leak determination and pressure measurement in the blue line system inspection step (205). Therefore, a single sensor, namely the blue line sensor (55), can be used to detect and locate leaks at any location within the blue line (51) and determine pressure decay.

[0084] B. Green Line System Inspection

[0085] exist Figure 9The green line system inspection steps (207) are described in more detail below. The green line system inspection steps (207) begin with step (273), which requests a leak diagnosis. Step (273) then proceeds to step (275). In step (275), the cylinder element (79) is moved to the cylinder in position. Step (275) then proceeds to step (277). In step (277), a leak detection method such as method (115) is performed, and it is determined whether a leak exists between the manifold (47) and the bulk feeder valve (81), or between the bulk feeder valve (81) and the cylinder inlet fitting (not shown) associated with the cylinder element (79). If a leak is detected, step (277) proceeds to step (279) to indicate the existence of a leak between the manifold (47) and the bulk feeder valve (81), or between the bulk feeder valve (81) and the cylinder outlet fitting. Subsequently, step (279) optionally proceeds to step (281) to report the result, and simultaneously proceeds to step (283). Similarly, if no leak is detected, step (277) proceeds to step (283). Steps (275, 277, 279) are generally reflected in... Figure 7 In step (223).

[0086] In step (283), the cylinder element (79) is moved to the cylinder outlet position. Thereafter, step (283) proceeds to step (285). In step (285), a leak detection method such as method (115) is performed, and it is determined whether a leak exists between the manifold (47) and the bulk feeder valve (81), or between the bulk feeder valve (81) and the cylinder outlet fitting (not shown) associated with the cylinder element (79). If a leak is detected, step (285) proceeds to step (287) to indicate the existence of a leak between the manifold (47) and the bulk feeder valve (81), or between the bulk feeder valve (81) and the cylinder outlet fitting. Thereafter, step (287) optionally proceeds to step (281) to report the result, and simultaneously proceeds to step (289) to restore the default hardware configuration of the green line (71) and end the green-blue line system check step (207). Similarly, if no leak is detected, step (285) proceeds to step (289). Steps (283, 285, 287) are generally reflected in Figure 7 In step (225).

[0087] The greenline sensor (75) is used to perform each leak determination and pressure measurement in the greenline system inspection step (207). Therefore, a single sensor, namely the greenline sensor (75), can be used to detect and locate leaks at any location within the greenline (71) and determine pressure decay.

[0088] C. Yellow Line System Inspection

[0089] existFigures 10A to 10C The yellow line system inspection procedure (209) is described in more detail. The yellow line system inspection procedure (209) is described in... Figure 10A The process begins at step (291), whereby a leak diagnosis is requested. Step (291) then proceeds to step (293). In step (293), the pneumatic components of the yellow line (85) are set to their default positions, i.e., the gripper element (97) is in the open position, the door element (99) is in the closed position, and the washer arm element (101) is in the upward position. This default position of the pneumatic components of the yellow line (85) is exemplary. In other versions of the yellow line inspection step (209), other positions of the pneumatic components may be used for the default position. The default position may also be referred to as the first configuration. After the pneumatic components of the yellow line (85) are set to their default positions, step (293) proceeds to step (295).

[0090] In step (295), a leak detection method such as method (115) is performed, and it is determined whether there is a leak in the yellow line (85) in the default position, and a leak measurement value (M1) is collected. Afterward, step (295) proceeds to step (297). In step (297), the pneumatic components of the yellow line (85) are set to a non-default position, i.e., the gripper element (97) is in the closed position, the door element (99) is in the open position, and the washer arm element (101) is in the downward position. This non-default position of the pneumatic components of the yellow line (85) is exemplary. In other versions of the yellow line inspection step (209), other positions of the pneumatic components can be used for the non-default position. The non-default position can also be referred to as a second configuration. After the pneumatic components of the yellow line (85) are set to a non-default position, step (297) proceeds to step (299).

[0091] In step (299), a leak detection method such as method (115) is performed, and it is determined whether there is a leak in the yellow line (85) at the non-default position, and a leak measurement value (M2) is collected. Thereafter, step (295) proceeds to step (301).

[0092] In step (301), the leakage measurement value (M1) is compared with a first configuration threshold, and the leakage measurement value (M2) is compared with a second configuration threshold. If step (301) determines that the leakage measurement value (M1) is greater than the first configuration threshold and the leakage measurement value (M2) is greater than the second configuration threshold, then step (301) proceeds to step (303). Step (303) indicates that there is a leakage between one of the valves in the manifold (47) and the yellow line (85), namely the clamp valve (103), the gate valve (105), and / or the wheel valve (107). Thereafter, step (303) may optionally proceed to step (305) to report / display the results, and simultaneously proceed to step (307) to restore the default hardware configuration of the yellow line (85) and end the yellow line system check step (209).

[0093] If step (301) determines that the leakage measurement value (M1) is not greater than the first configuration threshold or the leakage measurement value (M2) is not greater than the second configuration threshold, then step (301) proceeds to step (309). In step (309), the leakage measurement value (M1) is compared with the first configuration threshold, and the leakage measurement value (M2) is compared with the second configuration threshold. If step (309) determines that the leakage measurement value (M1) is not greater than the first configuration threshold and the leakage measurement value (M2) is greater than the second configuration threshold, then step (309) proceeds to step (311). Step (311) indicates that there is a leakage between one of the valves marked with yellow line (85), namely the clamp valve (103), the gate valve (105), and / or the wheel valve (107), and one of the pneumatic components in a non-default configuration, namely the clamp element (97), the gate element (99), and / or the washer wheel element (101).

[0094] If step (309) determines that the leakage measurement value (M1) is greater than the first configuration threshold or the leakage measurement value (M2) is not greater than the second configuration threshold, then step (309) proceeds to step (313). In step (313), the leakage measurement value (M1) is compared with the first configuration threshold, and the leakage measurement value (M2) is compared with the second configuration threshold. If step (313) determines that the leakage measurement value (M1) is greater than the first configuration threshold and the leakage measurement value (M2) is not greater than the second configuration threshold, then step (313) proceeds to step (315). Step (315) indicates that there is a leakage between one of the valves in the yellow line (85), namely the clamp valve (103), the gate valve (105), and / or the wheel valve (107), and one of the pneumatic components in the default configuration, namely the clamp element (97), the gate element (99), and / or the washer wheel element (101).

[0095] If step (313) determines that the leakage measurement value (M1) is not greater than the first configuration threshold or the leakage measurement value (M2) is greater than the second configuration threshold, then step (313) proceeds to step (317). Step (317) indicates that the pneumatic check of the yellow line (85) has passed and no leakage has been detected in the yellow line (85). Thereafter, step (317) may optionally proceed to step (305) to report / display the results, and simultaneously proceed to step (307) to restore the default hardware configuration of the yellow line (85) and end the yellow line system check step (209).

[0096] Step (311) proceeds to step (319), thereby setting the pneumatic components of the yellow line (85) to their default positions, i.e., the gripper element (97) is in the open position, the door element (99) is in the closed position, and the washing wheel arm element (101) is in the upward position. Afterward, step (319) proceeds to... Figure 10B Step (321) moves the gripper element (97) to the closed position. Thereafter, step (321) proceeds to step (323). In step (323), a leak detection method such as method (115) is performed, and it is determined whether a leak exists in the yellow line (85) of the current configuration, and a leak measurement value (M3) is collected. The leak measurement value (M3) is compared with a third configuration threshold. If the leak measurement value (M3) is greater than the third configuration threshold, step (323) proceeds to step (325). Step (325) indicates that a leak exists on the closed side of the gripper element (97). Step (325) optionally proceeds to step (305) to report / display the result, and simultaneously proceeds to step (327). If the leak measurement value (M3) is not greater than the third configuration threshold, step (323) proceeds to step (327).

[0097] In step (327), the clamp element (97) is moved to the open position, and the washing wheel arm element (101) is moved to the downward position. Thereafter, step (327) proceeds to step (329). In step (329), a leak detection method such as method (115) is performed, and it is determined whether a leak exists in the yellow line (85) of the current configuration, and a leak measurement value (M4) is collected. The leak measurement value (M4) is compared with a fourth configuration threshold. If the leak measurement value (M4) is greater than the fourth configuration threshold, step (329) proceeds to step (331). Step (331) indicates that a leak exists on the underside of the washing wheel arm element (101). Step (331) optionally proceeds to step (305) to report / display the result, and simultaneously proceeds to step (333). If the leak measurement value (M4) is not greater than the fourth configuration threshold, step (327) proceeds to step (333).

[0098] In step (333), the washing wheel arm element (101) is moved to the upward position, and the door element (99) is moved to the open position. Thereafter, step (333) proceeds to step (335). In step (335), a leak detection method such as method (115) is performed, and it is determined whether a leak exists in the yellow line (85) of the current configuration, and a leak measurement value (M5) is collected. The leak measurement value (M5) is compared with a fifth configuration threshold. If the leak measurement value (M5) is greater than the fifth configuration threshold, step (335) proceeds to step (337). Step (337) indicates that a leak exists on the open side of the door element (99). Step (337) optionally proceeds to step (305) to report / display the result, and simultaneously proceeds to step (307). If the leak measurement value (M5) is not greater than the fifth configuration threshold, step (335) proceeds to step (307).

[0099] Step (315) proceeds to step (339), thereby setting the pneumatic components of the yellow line (85) to a non-default position, i.e., the gripper element (97) is in the closed position, the door element (99) is in the open position, and the washing wheel arm element (101) is in the downward position. Afterwards, step (339) proceeds to... Figure 10C Step (341) moves the door element (99) to the closed position. After that, step (341) proceeds to step (343).

[0100] In step (343), a leak detection method such as method (115) is performed, and it is determined whether a leak exists in the yellow line (85) of the current configuration, and a leak measurement value (M6) is collected. The leak measurement value (M6) is compared with a sixth configuration threshold. If the leak measurement value (M6) is greater than the sixth configuration threshold, step (343) proceeds to step (345). Step (345) indicates that a leak exists on the closed side of the door element (99). Step (345) may optionally proceed to step (305) to report / display the results, and simultaneously proceeds to step (347). If the leak measurement value (M6) is not greater than the sixth configuration threshold, step (343) proceeds to step (347).

[0101] In step (347), the door element (99) is moved to the open position, and the washing wheel arm element (101) is moved to the upward position. Thereafter, step (347) proceeds to step (349). In step (349), a leak detection method such as method (115) is performed, and it is determined whether a leak exists in the yellow line (85) of the current configuration, and a leak measurement value (M7) is collected. The leak measurement value (M7) is compared with a seventh configuration threshold. If the leak measurement value (M7) is greater than the seventh configuration threshold, step (349) proceeds to step (351). Step (351) indicates that a leak exists on the upper side of the washing wheel arm element (101). Step (351) optionally proceeds to step (305) to report / display the result, and simultaneously proceeds to step (353). If the leak measurement value (M7) is not greater than the seventh configuration threshold, step (349) proceeds to step (353).

[0102] In step (353), the washing wheel arm element (101) is moved to the downward position, and the gripper element (97) is moved to the open position. Thereafter, step (353) proceeds to step (355). In step (355), a leak detection method such as method (115) is performed, and it is determined whether a leak exists in the yellow line (85) of the current configuration, and a leak measurement value (M8) is collected. The leak measurement value (M8) is compared with an eighth configuration threshold. If the leak measurement value (M8) is greater than the eighth configuration threshold, step (355) proceeds to step (357). Step (357) indicates that a leak exists on the open side of the gripper element (97). Step (357) may optionally proceed to step (305) to report / display the result, and simultaneously proceeds to step (307). If the leak measurement value (M8) is not greater than the eighth configuration threshold, step (355) proceeds to step (307).

[0103] The yellow line sensor (89) is used to perform each leak determination and pressure measurement in the yellow line system inspection step (209). Therefore, a single sensor, namely the yellow line sensor (89), can be used to detect, locate leaks at any location within the yellow line (85), and determine pressure decay.

[0104] D. Other pneumatic system diagnostic methods

[0105] Another exemplary pneumatic system diagnostic system method in Figure 11 The description is as method (401). Method (401) begins with step (403). Step (403) uses multiple corresponding valves to set multiple components servoed by a common branch of the pneumatic system into a first configuration. Thereafter, step (403) proceeds to step (405). Step (405) collectively measures the leakage of the multiple components in the first configuration. Thereafter, step (405) proceeds to step (407).

[0106] Step (407) uses multiple corresponding valves to set multiple components servoed by the common branch of the pneumatic system to a second configuration. Afterwards, step (407) proceeds to step (409). Step (409) jointly measures the leakage of the multiple components in the second configuration. Afterwards, step (409) proceeds to step (411).

[0107] Step (411) determines whether the leakage measured when the multiple components are in a first position is less than a first condition threshold, and if it is not less than the first condition threshold, proceeds to step (413). If it is less than the first condition threshold, step (411) proceeds to step (415). Step (413) determines whether the leakage measured when the multiple components are in a second position is less than a second condition threshold, and if it is not less than the second condition threshold, proceeds to step (417). If it is less than the second condition threshold, step (413) proceeds to step (419). Step (417) reports a leakage failure result for leakage between the manifold and at least one of the multiple corresponding valves. Thereafter, step (417) proceeds to step (425). Step (425) reports the determined leakage failure result. Thereafter, method (401) proceeds to the end.

[0108] Step (419) involves individually testing each of the multiple components by switching the component out of the first configuration state and keeping the state of the remaining components in the first configuration state to determine the leakage failure result. Step (419) then proceeds to step (425).

[0109] Step (415) determines whether the leakage measured when the multiple components are in the second position is less than a second condition threshold, and if it is not less than the second condition threshold, proceeds to step (421). If it is less than the second condition threshold, step (415) proceeds to step (423). Step (423) reports the pass result, and thereafter the method (401) proceeds to the end.

[0110] Step (421) involves individually testing each of the multiple components by switching the component out of the second configuration state and keeping the remaining components in the second configuration state to determine the leakage failure result. Afterward, step (421) proceeds to step (425).

[0111] Another exemplary pneumatic system diagnostic system method in Figure 12The method is described as method (501). Method (501) begins with step (503). In step (503), a first channel is pressurized, wherein the first channel extends from the manifold through a valve to a first fitting. Thereafter, step (503) proceeds to step (505). In step (505), a first pressure decay in the first channel is measured, wherein the first pressure decay is at least partially based on the change in pressure in the first channel over a first time period. Thereafter, step (505) proceeds to step (507). In step (507), a second channel is pressurized, wherein the second channel extends from the manifold through a valve to a second fitting. Thereafter, step (507) proceeds to step (509). In step (509), a second pressure decay in the second channel is measured, wherein the second pressure decay is at least partially based on the change in pressure in the second channel over a second time period. Thereafter, step (509) proceeds to step (511). In step (511), the first pressure decay and the second pressure decay are compared with a limit threshold. After that, step (511) proceeds to step (513).

[0112] In step (513), it is determined whether the first pressure decay is greater than a limit threshold. If it is not greater than the limit threshold, step (513) proceeds to step (515). If it is greater than the limit threshold, step (513) proceeds to step (521). In step (515), it is determined whether the second pressure decay is greater than a limit threshold. If it is not greater than the limit threshold, step (515) proceeds to step (517). If it is greater than the limit threshold, step (515) proceeds to step (519). In step (517), method (501) has determined that no leakage has been detected, and method (501) proceeds to the end. In step (519), method (501) has determined that there is a leakage between the valve and the second fitting, and method (501) proceeds to the end.

[0113] In step (521), it is determined whether the second pressure decay is greater than a limit threshold. If it is not greater than the limit threshold, step (521) proceeds to step (523). If it is greater than the limit threshold, step (521) proceeds to step (525). In step (525), method (501) has determined that there is a leak between the manifold and the valve, and method (501) proceeds to the end. In step (523), method (501) has determined that there is a leak between the valve and the first fitting, and method (501) proceeds to the end.

[0114] IV. Exemplary Combinations

[0115] The following examples illustrate various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to limit the scope of any claims that may be set forth at any time in this application or in subsequent documents thereof. No disclaimer. The following examples are provided for illustrative purposes only. It is conceivable that the various teachings herein may be arranged and applied in many other ways. It is also conceivable that some variations may omit certain features mentioned in the following examples. Therefore, no aspect or feature mentioned below should be considered critical unless the inventor or successor of the inventor expressly instructs so at a later date. If any claims are set forth in this application or in subsequent documents relating to this application that include additional features beyond those mentioned below, such additional features should not be considered added for any reason related to patentability.

[0116] Example 1

[0117] A method for diagnosing leakage faults in a pneumatic system, the method comprising: setting multiple components servicing a common branch of the pneumatic system to a first configuration using multiple corresponding valves; jointly measuring leakage of the multiple components in the first configuration; setting multiple components servicing a common branch of the pneumatic system to a second configuration using multiple corresponding valves; jointly measuring leakage of the multiple components in the second configuration; and reporting a pass result if the leakage measured when the multiple components are in the first configuration is less than a first configuration threshold, and the leakage measured when the multiple components are in the second configuration is less than a second configuration threshold.

[0118] Example 2

[0119] The method according to Example 1 or any of the following examples, wherein at least one of the plurality of components is a pneumatic actuator of a laboratory instrument, and wherein the pneumatic system is adapted to selectively drive at least one actuator.

[0120] Example 3

[0121] According to any one of the foregoing or subsequent examples, the leakage failure includes at least one leakage above at least one corresponding threshold.

[0122] Example 4

[0123] According to any one of the foregoing or subsequent examples, in the method, at least one corresponding threshold is substantially zero.

[0124] Example 5

[0125] According to any of the foregoing or subsequent examples, the method wherein at least one corresponding threshold is substantially higher than one or more worst-case leaks from one or more valves, manifolds and / or actuators, and substantially lower than one or more worst-case leaks from one or more flexible lines.

[0126] Example 6

[0127] According to any one of the foregoing or subsequent examples, the method wherein common leakage measurement is achieved by pressure sensors connected to a common branch, the number of pressure sensors being less than the number of components servoed by the common branch.

[0128] Example 7

[0129] According to any one of the foregoing or subsequent examples, the method wherein common leakage measurement is achieved by a single pressure sensor connected to a common branch.

[0130] Example 8

[0131] According to any one of the foregoing or subsequent examples, in all configurations of at least one of a plurality of respective valves, the at least one valve allows pneumatic flow from the supply side of the valve through the at least one valve to the component side of the valve.

[0132] Example 9

[0133] According to any one of the foregoing or subsequent examples, in all configurations of the valves in a plurality of respective valves, all valves always allow pneumatic flow from the supply side of the valve through each valve to the component side of the valve.

[0134] Example 10

[0135] According to any one of the foregoing or subsequent examples, in all configurations of at least one of a plurality of respective valves, the at least one valve includes a single port on the component side of the valve and allows pneumatic flow from the supply side of the valve through the at least one valve to the component side of the valve.

[0136] Example 11

[0137] According to any one of the foregoing or subsequent examples, in all configurations of the valves in a plurality of respective valves, all valves include a single port on the component side of the valve, and pneumatic flow is always allowed from the supply side of the valve through each valve to the component side of the valve.

[0138] Example 12

[0139] According to any one of the foregoing or subsequent examples, in all configurations of at least one of a plurality of respective valves, the at least one valve includes a dual port on the component side of the valve and allows pneumatic flow from the supply side of the valve through the at least one valve to the component side of the valve.

[0140] Example 13

[0141] According to any one of the foregoing or subsequent examples, in all configurations of the valves in a plurality of respective valves, all valves include a dual port on the component side of the valve, and always allow pneumatic flow from the supply side of the valve through each valve to the component side of the valve.

[0142] Example 14

[0143] The method according to any one of the foregoing or subsequent examples, wherein the first configuration is the default configuration and the second configuration is a non-default configuration.

[0144] Example 15

[0145] According to any one of the foregoing or subsequent examples, each of the plurality of components is a dual-state component having two states, each of the plurality of corresponding valves is a dual-state valve having two corresponding states, and the states of each of the dual-state valves are opposite between a first configuration and a second configuration.

[0146] Example 16

[0147] The method according to any one of the foregoing or subsequent examples further includes: if the leakage measured when the plurality of components are in a first configuration is less than a first configuration threshold and the leakage measured when the plurality of components are in a second configuration is greater than a second configuration threshold, then individually testing each of the plurality of components by switching the component out of the state of the second configuration and putting the state of the remaining components in the state of the second configuration, and reporting the determined leakage failure result.

[0148] Example 17

[0149] The method according to any one of the foregoing or subsequent examples further includes: if the leakage measured when the plurality of components are in a first configuration is greater than a first configuration threshold and the leakage measured when the plurality of components are in a second configuration is less than a second configuration threshold, then individually testing each of the plurality of components by switching the component out of the state of the first configuration and putting the state of the remaining components in the state of the first configuration, and reporting the determined leakage failure result.

[0150] Example 18

[0151] The method according to any one of the foregoing or subsequent examples further includes: if the leakage measured when the plurality of components are in a first configuration is greater than a first configuration threshold, and the leakage measured when the plurality of components are in a second configuration is greater than a second configuration threshold, then reporting a leakage failure result of leakage between the manifold and at least one of the plurality of corresponding valves.

[0152] Example 19

[0153] The method according to any one of the foregoing or subsequent examples further includes: repeatedly testing the pneumatic system to detect the leak when the leak occurs and before any additional leak may occur.

[0154] Example 20

[0155] A method for detecting leaks in a pneumatic system of a diagnostic laboratory instrument, the method comprising: (a) pressurizing a first channel, wherein the first channel extends from a manifold through a valve to a first fitting; (b) measuring a first pressure decay within the first channel, wherein the first pressure decay is based at least in part on a change in pressure within the first channel over a first time period; (c) pressurizing a second channel, wherein the second channel extends from a manifold through a valve to a second fitting; (d) measuring a second pressure decay within the second channel, wherein the second pressure decay is based at least in part on a change in pressure within the second channel over a second time period; (e) comparing the first pressure decay and the second pressure decay with the limit threshold; (f) determining, in response to determining that the first pressure decay and the second pressure decay are greater than the limit threshold, a leak exists between the manifold and the valve; (g) determining, in response to determining that the first pressure decay is greater than the limit threshold and the second pressure decay is less than the limit threshold, a leak exists between the valve and the first fitting; and (h) determining, in response to determining that the first pressure decay is less than the limit threshold and the second pressure decay is greater than the limit threshold, a leak exists between the valve and the second fitting.

[0156] Example 21

[0157] The method according to any one of the foregoing or subsequent examples, wherein the valve comprises a three-way valve.

[0158] Example 22

[0159] The method according to any one of the foregoing or subsequent examples further includes: providing a cylinder between the first component and the second component.

[0160] Example 23

[0161] The method according to any one of the foregoing or subsequent examples further includes: (a) driving the cylinder to a first position in response to pressurizing the first channel; and (b) driving the cylinder to a second position in response to pressurizing the second channel.

[0162] Example 24

[0163] The method according to any one of the foregoing or subsequent examples further includes storing the first pressure decay and the second pressure decay in the computer memory of the laboratory instrument.

[0164] Example 25

[0165] The method according to any one of the foregoing or subsequent examples further includes: storing the first pressure decay and the second pressure decay in the memory of a computer system, wherein the computer system is located remotely from the laboratory instrument.

[0166] Example 26

[0167] The method according to any one of the foregoing or subsequent examples, wherein the method for automatically diagnosing leaks is initiated at periodic intervals.

[0168] Example 27

[0169] According to any one of the foregoing or subsequent examples, measuring the first pressure decay includes: (a) measuring a first pressure in a first channel; (b) waiting for a first time period; (c) measuring a second pressure in the first channel; and (d) calculating the first pressure decay as the difference between the first pressure and the second pressure.

[0170] Example 28

[0171] According to any one of the foregoing or subsequent examples, the method of measuring the second pressure decay includes: (a) measuring the third pressure in the second channel; (b) waiting for a second time period; (c) measuring the fourth pressure in the second channel; and (d) calculating the second pressure decay as the difference between the third pressure and the fourth pressure.

[0172] Example 29

[0173] The method according to any one of the foregoing or subsequent examples further includes: generating an alarm in response to determining that a leak exists between the manifold and the valve.

[0174] Example 30

[0175] A method for detecting and locating a leak in a pneumatic system includes: (a) pneumatically associating a sensor with a branch of the pneumatic system, wherein the branch includes at least two three-way four-port valves, each valve being pneumatically associated with a pneumatic component, wherein each pneumatic component is pneumatically actuated to transition between a first state and a second state; (b) iteratively actuating each pneumatic component in the branch to pressurize a plurality of channels within the branch; (c) in response to pressurizing a channel in the plurality of channels, measuring the pressure in the channel over a period of time with a sensor to determine a pressure decay; and (d) determining the location of a leak within the branch, wherein the determination is at least partially based on the measured pressure decay.

[0176] V. Other

[0177] It should be understood that any example described herein may include various other features besides or in lieu of the features described above. By way of example only, any example described herein may also include one or more of the various features disclosed by reference in any of the various references incorporated herein.

[0178] It should be understood that any one or more of the teachings, expressions, implementations, examples, etc., described herein can be combined with any one or more of the other teachings, expressions, implementations, examples, etc., described herein. Therefore, the teachings, expressions, implementations, examples, etc., described above should not be viewed in isolation from each other. Given the teachings herein, various suitable ways in which the teachings can be combined will be apparent to those skilled in the art. Such modifications and variations are intended to be included within the scope of the claims.

[0179] It should be understood that any patent, publication, or other disclosure referred to as incorporated herein by reference, in whole or in part, is incorporated herein only to the extent that the incorporated material does not conflict with any existing definitions, statements, or other disclosures set forth in this disclosure. Therefore, and to the extent necessary, any conflicting material incorporated herein by reference as expressly set forth herein supersedes any conflicting material. Any material, or a portion thereof, referred to as incorporated herein by reference that conflicts with any existing definitions, statements, or other disclosures set forth herein will be incorporated only to the extent that the incorporated material does not conflict with any existing disclosures.

[0180] Various versions of the invention have been shown and described. Further improvements to the methods and systems described herein can be made by those skilled in the art through appropriate modifications without departing from the scope of the invention. Some such possible modifications have been mentioned, and others will be apparent to those skilled in the art. For example, the examples, versions, geometries, materials, dimensions, ratios, steps, etc., discussed above are illustrative and not essential. Therefore, the scope of the invention should be considered in accordance with the appended claims and should be understood as not being limited to the details of the structures and operations shown and described in the specification and drawings.

Claims

1. A method (201, 401, 501) for diagnosing leakage faults in a pneumatic system (5), the method comprising: (a) Using a plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), a plurality of components (57, 59, 61, 77, 91, 93, 95) servoed by a common branch (51, 71, 85) of the pneumatic system (5) are configured in a first configuration, wherein at least one of the plurality of components (57, 59, 61, 77, 91, 93, 95) is a pneumatic actuator of a laboratory instrument (3), and wherein the pneumatic system (5) is adapted to selectively drive the actuator; (b) jointly measure the leakage of the plurality of components (57, 59, 61, 77, 91, 93, 95) in the first configuration; (c) Using the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), the plurality of components (57, 59, 61, 77, 91, 93, 95) serviced by the common branch (51, 71, 85) of the pneumatic system (5) are configured in a second configuration. (d) jointly measure the leakage of the plurality of components (57, 59, 61, 77, 91, 93, 95) in the second configuration; (e) If the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the first configuration is less than a first configuration threshold and the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the second configuration is less than a second configuration threshold, then report a pass result; and If the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the first configuration is less than the first configuration threshold, and the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the second configuration is greater than the second configuration threshold, then each of the plurality of components (57, 59, 61, 77, 91, 93, 95) is tested individually, and the determined leakage failure result is reported. The individual testing of each target component is performed by switching that target component (57, 59, 61, 77, 91, 93, 95) out of the state of the second configuration and putting the remaining components (57, 59, 61, 77, 91, 93, 95) in the state of the second configuration, wherein the first configuration is the default configuration and the second configuration is a non-default configuration.

2. The method (201, 401, 501) according to claim 1, wherein, The leakage fault includes at least one leakage that is above at least one corresponding threshold.

3. The method (201, 401, 501) according to claim 2, wherein, The at least one corresponding threshold is zero.

4. The method (201, 401, 501) according to claim 2, wherein, The at least one corresponding threshold is higher than one or more worst-case leaks from one or more valves (63, 65, 67, 81, 103, 105, 107), manifold (47) and / or actuator, and lower than one or more worst-case leaks from one or more flexible lines.

5. The method (201, 401, 501) according to any one of claims 1 to 4, wherein, Leakage is jointly measured by pressure sensors (55, 75, 89) connected to the common branch (51, 71, 85), the number of which is less than the number of components (57, 59, 61, 77, 91, 93, 95) servicing the common branch (51, 71, 85).

6. The method (201, 401, 501) according to claim 5, wherein, Leakage is measured jointly by a single pressure sensor (55, 75, 89) connected to the common branch (51, 71, 85).

7. The method (201, 401, 501) according to any one of claims 1 to 4, wherein, In all configurations of at least one of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), the at least one valve (63, 65, 67, 81, 103, 105, 107) allows pneumatic flow from the supply side of the valve (63, 65, 67, 81, 103, 105, 107) through the at least one valve (63, 65, 67, 81, 103, 105, 107) to the component side of the valve (63, 65, 67, 81, 103, 105, 107).

8. The method (201, 401, 501) according to claim 7, wherein, In all configurations of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), all of the valves (63, 65, 67, 81, 103, 105, 107) always allow pneumatic flow from the supply side of the valves (63, 65, 67, 81, 103, 105, 107) through each of the valves (63, 65, 67, 81, 103, 105, 107) to the component side of the valves (63, 65, 67, 81, 103, 105, 107).

9. The method (201, 401, 501) according to any one of claims 1 to 4, wherein, In all configurations of at least one of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), the at least one valve (63, 65, 67, 81, 103, 105, 107) includes a single port on the component side of the valve (63, 65, 67, 81, 103, 105, 107) and allows pneumatic flow from the supply side of the valve (63, 65, 67, 81, 103, 105, 107) through the at least one valve (63, 65, 67, 81, 103, 105, 107) to the component side of the valve (63, 65, 67, 81, 103, 105, 107).

10. The method (201, 401, 501) according to claim 9, wherein, In all configurations of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), all of the valves (63, 65, 67, 81, 103, 105, 107) include the single port on the component side of the valve (63, 65, 67, 81, 103, 105, 107), and always allow pneumatic flow from the supply side of the valve (63, 65, 67, 81, 103, 105, 107) through each of the valves (63, 65, 67, 81, 103, 105, 107) to reach the component side of the valve.

11. The method (201, 401, 501) according to any one of claims 1 to 4, wherein, In all configurations of at least one of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), the at least one valve (63, 65, 67, 81, 103, 105, 107) includes a dual-port on the component side of the valve (63, 65, 67, 81, 103, 105, 107) and allows pneumatic flow from the supply side of the valve (63, 65, 67, 81, 103, 105, 107) through the at least one valve (63, 65, 67, 81, 103, 105, 107) to the component side of the valve (63, 65, 67, 81, 103, 105, 107).

12. The method (201, 401, 501) according to claim 11, wherein, In all configurations of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107), all of the valves (63, 65, 67, 81, 103, 105, 107) include the dual ports on the component side of the valves (63, 65, 67, 81, 103, 105, 107), and always allow pneumatic flow from the supply side of the valves (63, 65, 67, 81, 103, 105, 107) through each of the valves (63, 65, 67, 81, 103, 105, 107) to the component side of the valves (63, 65, 67, 81, 103, 105, 107).

13. The method (201, 401, 501) according to any one of claims 1 to 4, wherein, Each of the plurality of components (57, 59, 61, 77, 91, 93, 95) is a dual-state component (57, 59, 61, 77, 91, 93, 95) having two states, wherein each of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107) is a dual-state valve (63, 65, 67, 81, 103, 105, 107) having two corresponding states, and wherein the state of each of the dual-state valves (63, 65, 67, 81, 103, 105, 107) is opposite between the first configuration and the second configuration.

14. The method (201, 401, 501) according to any one of claims 1 to 4, further comprising: If the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the first configuration is greater than the first configuration threshold, and the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the second configuration is less than the second configuration threshold, then each of the plurality of components (57, 59, 61, 77, 91, 93, 95) is tested individually, and the determined leakage failure result is reported. The individual testing of each target component is performed by switching the target component (57, 59, 61, 77, 91, 93, 95) out of the state of the first configuration and keeping the state of the remaining components (57, 59, 61, 77, 91, 93, 95) in the state of the first configuration.

15. The method (201, 401, 501) according to any one of claims 1 to 4, further comprising: If the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the first configuration is greater than the first configuration threshold, and the leakage measured when the plurality of components (57, 59, 61, 77, 91, 93, 95) is in the second configuration is greater than the second configuration threshold, then a leakage failure result is reported between the manifold (47) and at least one of the plurality of corresponding valves (63, 65, 67, 81, 103, 105, 107).

16. The method (201, 401, 501) according to any one of claims 1 to 4, further comprising: The pneumatic system (5) is repeatedly tested to detect the leak when the leak occurs and before other leaks may occur.

Images