Automated Cascade Impactor with Segmented Gripper
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Solution Overview
Problem
Conventional cascade impactors used for determining particle size distribution and mass concentration of aerosols are labor-intensive, error-prone, and time-consuming, leading to inconsistencies in data due to manual operations, which delays drug approval and increases costs.
Innovation Solution
An automated cascade impactor system with a vertically oriented array of impactor and isolation stages, where impactor plates are sandwiched between pairs of isolation stages, allowing for efficient drug collection and reduced solvent use, with a programmable logic computer controlling actuator movements for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used in conventional cascade impactors, then device complexity is reduced, but productivity decreases and measurement precision deteriorates due to operator-induced variability
Solution Approach 1:
The impactor system is divided into multiple stages with isolation stages separating impactor stages. Each impactor stage can be independently manipulated by actuators, allowing automated sequential access to each stage for sample collection without manual disassembly. The gripper mechanism is segmented to handle multiple components (impactor plates, isolation stages) through standardized gripping actions.
Solution Approach 2:
The automated system performs its own setup, sample collection, and disassembly operations without human intervention. Actuators automatically position impactor stages, grippers automatically collect samples from impactor plates, and the system autonomously transitions between measurement cycles, eliminating operator-induced variability and increasing throughput.
2Productivity
If impactor stages are kept in compressed state for continuous operation, then productivity is improved, but isolation between stages becomes difficult and measurement precision may deteriorate
Solution Approach 1:
The system dynamically transitions impactor stages between compressed and separated states using actuators. During continuous operation, stages remain compressed for efficient throughput. When sample collection is needed, actuators automatically separate specific stages, collect samples, and return them to compressed position, maintaining both productivity and measurement precision through automated dynamic control.
Solution Approach 2:
The control system monitors the positions and states of impactor stages and actuators, automatically adjusting the system to maintain proper isolation during measurement and optimal compression during operation. Feedback ensures that automated operations achieve the same measurement precision as manual operations while maintaining continuous productivity.
3Productivity
If solvent is used for collecting drug from impactor stages, then drug collection efficiency is improved, but loss of substance increases due to solvent consumption
Solution Approach 1:
The system extracts and removes impactor plates from impactor stages using automated grippers, transferring them to collection positions where drugs are eluted into separate vials. This extraction approach allows complete recovery of drug from each plate with minimal solvent volume, eliminating the need for large-scale solvent flushing of entire impactor stages and reducing solvent consumption while maintaining collection efficiency.
Data Source
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AI summary
An automated cascade impactor is disclosed and comprises a vertical array of a plurality of impactor stages, and a vertical array of isolation stages, wherein the vertical array of the isolation stages comprises pairs of isolation stages between which impactor plates, removed from respective ones of the impactor stages are effectively sandwiched between each pair of isolation stages. Still further, each compactor stage is likewise sandwiched between and upper and a lower pair of the isolation stages.