A high-precision automatic dilution system

Abstract

This invention relates to a high-precision automatic dilution system, comprising a diluent inlet valve, a pump body, a working fluid filling valve, and a valve body. The inlet end of the diluent inlet valve is connected to a diluent fluid, the outlet end of the diluent inlet valve is connected to the inlet end of the pump body, the outlet end of the pump body is connected to the inlet end of the working fluid filling valve, and the outlet end of the working fluid filling valve is connected to a concentrate storage device and a component to be cleaned via the valve body. The beneficial effects of this invention are: 1. Significantly extends the service life of core components and system reliability; 2. Meets the needs of various application scenarios; 3. Significantly improves system response speed and simplifies the structure and reduces volume; 4. Ensures the accuracy and reliability of the entire dilution and filling process; 5. Significantly reduces manufacturing costs and subsequent maintenance expenses; 6. Improves the overall system efficiency.

Description

Technical Field

[0001] This invention relates to the field of in vitro diagnostics, and more specifically to a high-precision automated dilution system. Background Technology

[0002] In the field of in vitro diagnostics (IVD), fully automated diagnostic equipment is increasingly demanding higher testing efficiency, accuracy, and automation. To ensure the continuity and reliability of test results, the equipment needs to automatically clean the reaction vessels after each reaction. During this process, the performance of the specialized detergent is crucial, and its concentration must be precisely controlled to ensure stable and reproducible cleaning results. To reduce transportation and storage costs, detergents are typically supplied in concentrated form and then precisely diluted before use.

[0003] Current mainstream dilution methods have significant shortcomings:

[0004] One method is manual dilution, where operators manually mix the concentrate and diluent according to a set ratio to obtain the working solution. This method is inefficient and labor-intensive; it not only makes it difficult to guarantee the dilution accuracy and mixing uniformity of the working solution, leading to unstable cleaning results and affecting test accuracy, but it can also cause the supply of working solution to be interrupted due to untimely preparation, resulting in instrument downtime and reduced work efficiency.

[0005] The second type is the automatic dilution system, which pumps the concentrate and diluent into a mixing container separately. The dosing ratio is controlled by a proportioning pump or level sensor. After mixing, the solution is transferred to a buffer for later use. When needed, the prepared working solution is pumped to the unit to be cleaned. Although this system achieves automated operation, it still suffers from problems such as large system size, complex structure, high cost, limited dilution accuracy, and inflexible ratio adjustment.

[0006] Therefore, there is an urgent need in this field for an automated dilution solution that is compact, highly accurate, low-cost, and reliable in operation. Summary of the Invention

[0007] In summary, to overcome the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a high-precision automatic dilution system, which integrates dilution, mixing and dispensing functions through innovative flow path design and control logic, eliminating the need for independent mixing units and buffer devices, and achieving a compact, high-precision, and highly reliable dilution operation at a low cost.

[0008] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A high-precision automatic dilution system includes a diluent inlet valve, a pump body, a working fluid filling valve, and a valve body; the inlet end of the diluent inlet valve is connected to the diluent fluid, the outlet end of the diluent inlet valve is connected to the inlet end of the pump body, the outlet end of the pump body is connected to the inlet end of the working fluid filling valve, and the outlet end of the working fluid filling valve is connected to a concentrate storage device and a component to be cleaned through the valve body.

[0009] Based on the above technical solution, the present invention can be further improved as follows:

[0010] Furthermore, the pump body is a plunger pump.

[0011] The beneficial effects of adopting the above-mentioned further technical solution are as follows: by using a precision plunger pump as the core control unit, the liquid volume can be directly and accurately controlled without the need for additional metering devices such as liquid level sensors, thus realizing the high-precision preparation of working fluid in any proportion.

[0012] Furthermore, an optical coupler sensor is provided at the initial position of the plunger in the pump body.

[0013] The beneficial effects of adopting the above-mentioned further technical solution are as follows: The plunger is monitored in real time by an optocoupler sensor to determine if it has reset. If the reset status is abnormal, the plunger moves upward to attempt reset and calibration. This feedback mechanism constitutes a closed-loop control, ensuring the accurate execution of each dilution and dispensing cycle and effectively preventing dilution ratio deviations and missed dilution.

[0014] Furthermore, the valve body is a diaphragm three-way valve, and the common end of the valve body is connected to the outlet end of the working fluid filling valve, the normally open port is connected to the concentrated liquid storage device, and the normally closed port is connected to the component to be cleaned.

[0015] The beneficial effects of adopting the above-mentioned further technical solution are as follows: the diaphragm of the valve body completely isolates the valve core from the flow medium. This design has excellent chemical resistance, effectively avoids corrosion from the concentrate, extends the service life of the valve body, and improves system reliability.

[0016] Furthermore, the concentrated liquid storage device is equipped with a float switch for detecting the liquid level.

[0017] The beneficial effect of adopting the above-mentioned further technical solution is that when the liquid level in the concentrate storage device is lower than the set threshold, the float switch sends a signal to the control unit, prompting the user to perform replacement or replenishment operations. This avoids dilution or cleaning failures due to insufficient concentrate.

[0018] Furthermore, it also includes a control unit, which is electrically connected to the diluent inlet valve, the pump body, the working fluid filling valve, the valve body, and the float switch.

[0019] The beneficial effect of adopting the above-mentioned further technical solutions is that it enables the coordination system to operate.

[0020] Furthermore, the outlet end of the diluent inlet valve is connected to the inlet end of different pump bodies, the outlet end of each pump body is connected to the inlet end of a working fluid filling valve, and the outlet end of each working fluid filling valve is connected to a concentrate storage device and a component to be cleaned through a valve body.

[0021] The beneficial effect of adopting the above-mentioned further technical solution is that it supports independent automatic dilution and cleaning of multiple concentrates.

[0022] The beneficial effects of this invention are:

[0023] 1. The innovative flow path design ensures that the diluent inlet valve, plunger pump, and working fluid filling valve only come into contact with the diluent, fundamentally avoiding problems such as corrosion and crystallization that may be caused by the concentrate or working fluid, greatly extending the service life of core components and system reliability.

[0024] 2. By combining a high-precision plunger pump with programmed control, continuous and high-precision dilution can be achieved within a wide range (such as 0-2000 times), with flexible ratio settings to meet the needs of various application scenarios.

[0025] 3. By eliminating the need for a separate mixing chamber and buffer device, the working fluid can be "formed and added instantly," which significantly improves the system response speed and simplifies the structure and reduces the volume.

[0026] 4. A complete closed-loop control system was constructed through liquid level monitoring and plunger pump photoelectric feedback mechanism to monitor and calibrate each step of the operation in real time, ensuring the accuracy and reliability of the entire dilution and filling process.

[0027] 5. Because the core components are protected, the system can use conventional plunger pumps and solenoid valves, which significantly reduces manufacturing costs and subsequent maintenance expenses.

[0028] 6. The modular flow path design allows for easy multi-channel parallel expansion to support the simultaneous processing of various concentrates and improve the overall system efficiency. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the present invention (independent automatic dilution of two concentrates);

[0030] Figure 2 A schematic diagram showing the connection of the diluent inlet valve, pump body, working fluid filling valve, and valve body;

[0031] Figure 3 This is a schematic diagram of the control method of the present invention.

[0032] The attached diagram lists the components represented by each number as follows:

[0033] 1. Diluent inlet valve, 2. Pump body, 3. Working fluid filling valve, 4. Valve body, 5. Concentrate storage device, 6. Parts to be cleaned, 7. Float switch. Detailed Implementation

[0034] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0035] like Figure 1 As shown, a high-precision automatic dilution system includes a diluent inlet valve 1, a pump body 2, a working fluid filling valve 3, and a valve body 4. The inlet end of the diluent inlet valve 1 is connected to the diluent fluid, the outlet end of the diluent inlet valve 1 is connected to the inlet end of the pump body 2, the outlet end of the pump body 2 is connected to the inlet end of the working fluid filling valve 3, and the outlet end of the working fluid filling valve 3 is connected to a concentrate storage device 5 and a component to be cleaned 6 via the valve body 4.

[0036] Preferably, the pump body 2 is a plunger pump, specifically a precision plunger pump with a full-scale range of 1000 μL, driven by a stepper motor with 2000 microsteps, featuring long lifespan, high reliability, and high sample dispensing accuracy. Its theoretical minimum aspirate volume is 0.5 μL, thus enabling continuous dilutions from 0 to 2000 times. The dilution factor can be precisely set via the main control program in the control unit. The pump body 2 is equipped with an optocoupler sensor at the initial plunger position for real-time monitoring of the pump status.

[0037] like Figure 2 As shown, preferably, the valve body 4 is a diaphragm three-way valve, and the common end COM of the valve body 4 is connected to the outlet end OUT of the working fluid filling valve 3, the normally open port NO is connected to the concentrated liquid storage device 5, and the normally closed port NC is connected to the component to be cleaned 6.

[0038] The concentrate storage device 5 is used to store concentrate, and it is equipped with a float switch 7 for detecting the liquid level.

[0039] The system also includes a control unit, which is electrically connected to the diluent inlet valve 1, the pump body 2, the working fluid filling valve 3, the valve body 4, and the float switch.

[0040] The outlet of the diluent inlet valve 1 is connected to the inlet of different pump bodies 2. The outlet of each pump body 2 is connected to the inlet of a working fluid filling valve 3. The outlet of each working fluid filling valve 3 is connected to a concentrate storage device 5 and a component to be cleaned 6 via a valve body 4. Through this design, the system supports independent automatic dilution and cleaning of two or more concentrates.

[0041] This invention supports the independent automatic dilution of two or more concentrates. For example... Figure 3 As shown, the following describes a complete workflow of the present invention using the automatic dilution of one or two concentrates as examples.

[0042] An automated dilution of a concentrated solution:

[0043] 1) Diluent Aspiration Stage: The control unit opens the diluent inlet valve 1 (SV1) and drives the pump body 2, i.e. the plunger pump (M1), to draw in a set volume V1 of diluent. After completion, SV1 is closed.

[0044] 2) Concentrate Absorption Stage: The control unit opens the working fluid filling valve 3 (SV2), connecting the plunger pump M1 to the corresponding concentrate storage device 5, driving the plunger pump M1 to draw in a set volume V2 of concentrate. After completion, SV2 is closed. This creates a breakpoint working fluid in the NC end of the valve body 4 (concentrate inlet valve SV3) and the downstream pipeline.

[0045] 3) Working fluid filling stage: When cleaning is required, the control unit opens the working fluid filling valve SV2 and the valve body SV3 to connect it with the part to be cleaned 6; the plunger pump M1 is driven to discharge working fluid with a total volume of V1+V2, which is injected into the part to be cleaned 6 at a set flow rate, and the mixing and cleaning functions are achieved by means of fluid kinetic energy.

[0046] 4) Status Feedback and Closed-Loop Control: A photoelectric detection device, i.e., an optocoupler sensor, located at the initial position of plunger pump M1, monitors in real time whether the plunger of plunger pump M1 has reset. If the reset status is abnormal, the plunger moves upward to attempt reset and calibration. This feedback mechanism constitutes closed-loop control, ensuring the accurate execution of each dilution and dispensing cycle and effectively preventing dilution ratio deviations and missed dilution.

[0047] Automatic dilution of the two concentrates:

[0048] When the automatic dilution system is working, the diluent is supplied by the main unit, and there are no special requirements for the inlet pressure. During system initialization, the diluent inlet valve SV1 is first opened, driving the plungers of plunger pumps M1 and M2 to move downwards, either simultaneously or simultaneously, drawing a set volume of diluent. After completion, SV1 is closed. Simultaneously, SV2 / SV3 and SV4 / SV5 are opened, causing the plungers of plunger pumps M1 and M2 to move upwards. This process is repeated to complete the diluent filling of the system, ensuring the pipeline is full of diluent. Similarly, the concentrate filling is performed in a similar manner to ensure the pipeline is full of the corresponding liquid, preparing it for formal operation.

[0049] In summary, this system achieves automatic dilution and filling of the concentrate through the reciprocating motion of the plunger pump and the coordinated opening and closing of various valves. Throughout the entire working cycle, the diluent inlet valve 1, the plunger pump, and the working fluid filling valve 3 do not come into contact with the concentrate or working fluid, thus completely avoiding component damage caused by corrosion or crystallization. Therefore, this system can use conventional plunger pumps and solenoid valves, significantly reducing costs. Its core components include diluent aspiration, concentrate aspiration, working fluid filling, and plunger pump-based status feedback, collectively forming a complete automated dilution control cycle. Through the coordinated flow path switching of the plunger pump and solenoid valves, the entire process of sampling, mixing, and filling is completed, eliminating the need for mixing devices, buffer devices, and related pump and valve components required in traditional systems, greatly simplifying the system structure. The unique flow path design ensures that the concentrate and working fluid do not enter the pump body, fundamentally avoiding pump damage caused by corrosion and crystallization, significantly improving system lifespan and reliability. In addition, the diluent and concentrate are stored in the corresponding tubing before being mixed. Based on the biochemical application, the single cleaning solution dosing volume is about 500ul, and the plunger pump has a full stroke of 1000ul. Therefore, the dilution and dosing of the cleaning solution need to be carried out according to the instrument's test cycle (one dilution and dosing is completed in each test cycle). No buffering is required, so a long tubing is not needed.

[0050] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-precision automatic dilution system, characterized in that, It includes a diluent inlet valve (1), a pump body (2), a working fluid filling valve (3), and a valve body (4); the inlet end of the diluent inlet valve (1) is connected to the diluent fluid, the outlet end of the diluent inlet valve (1) is connected to the inlet end of the pump body (2), the outlet end of the pump body (2) is connected to the inlet end of the working fluid filling valve (3), and the outlet end of the working fluid filling valve (3) is connected to the concentrate storage device (5) and the component to be cleaned (6) respectively through the valve body (4).

2. The high-precision automatic dilution system according to claim 1, characterized in that, The pump body (2) is a plunger pump.

3. The high-precision automatic dilution system according to claim 2, characterized in that, The pump body (2) has an optical coupler sensor at the initial position of the plunger.

4. The high-precision automatic dilution system according to claim 1, characterized in that, The valve body (4) is a diaphragm three-way valve, and the common end of the valve body (4) is connected to the outlet end of the working fluid filling valve (3), the normally open port is connected to the concentrated liquid storage device (5), and the normally closed port is connected to the component to be cleaned (6).

5. The high-precision automatic dilution system according to claim 1, characterized in that, The concentrated liquid storage device (5) is equipped with a float switch (7) for detecting the liquid level.

6. The high-precision automatic dilution system according to claim 5, characterized in that, It also includes a control unit, which is electrically connected to the diluent inlet valve (1), the pump body (2), the working fluid filling valve (3), the valve body (4) and the float switch respectively.

7. The high-precision automatic dilution system according to any one of claims 1 to 6, characterized in that, The outlet end of the diluent inlet valve (1) is connected to the inlet end of different pump bodies (2), the outlet end of each pump body (2) is connected to the inlet end of a working fluid filling valve (3), and the outlet end of each working fluid filling valve (3) is connected to a concentrated liquid storage device (5) and a component to be cleaned (6) through a valve body (4).

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