Biological Sample Sorting With Collision-Free Carrier Diverters
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Solution Overview
Problem
Existing laboratory automation systems face challenges in efficiently routing biological samples to multiple destinations without stopping the flow, managing different types of carriers, and preventing spillage of biological material during diversion.
Innovation Solution
A modular sorting apparatus with a diverter member and a single upstream detector, using a diverter member with a side wing to intercept carriers and push them into sorting lines, and a stop gate to manage carrier flow, synchronized by an electronic controller to ensure precise diversion without collision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical blocking and diversion methods are used to route carriers to different lanes, then carriers can be sorted to multiple destinations, but the system requires stopping the flow of samples and using complex mechanical details that only allow diversion at two distinct passages
Solution Approach 1:
The patent replaces complex mechanical blocking and diversion systems with a pneumatic propulsion system. Instead of using mechanical blocks to stop and redirect carriers, the invention uses air jets to propel carriers directly into desired lanes, eliminating the need for mechanical blocking mechanisms and enabling diversion at any point along the transport line.
Solution Approach 2:
The patent segments the carrier diversion function into independent pneumatic actuators positioned along the transport line. Each diverter point operates independently with its own air jet mechanism, allowing flexible routing to multiple lanes without requiring a complex centralized mechanical blocking system.
2Reliability
If detector devices are placed upstream of each diversion point to manage carrier routing, then correct diversion can be achieved, but the cost increases due to replication of hardware components at each diversion point
Solution Approach 1:
The patent employs a single upstream detector device that serves multiple diversion points along the transport line. The detector identifies carriers that need diversion, and the system uses this information to control multiple pneumatic actuators at different locations, eliminating the need to replicate detector devices at each diversion point while maintaining accurate routing.
Solution Approach 2:
The patent introduces a central control system as an intermediary between the single upstream detector and the multiple pneumatic diverters. The control system processes detection signals and coordinates the activation of appropriate diverters, enabling one detector to manage multiple diversion points without direct one-to-one pairing.
3Productivity
If known diverter systems push carriers from one lane to another, then carrier diversion can be achieved, but biological material may leak from test tubes housed in the carriers
Solution Approach 1:
The patent uses pneumatic air jets to propel carriers into the desired lane instead of mechanical pushing. The air jets provide a contactless, gentle force that moves carriers without the harsh mechanical contact that causes test tubes to shift and biological material to spill, while still achieving efficient diversion.
Solution Approach 2:
The patent introduces air as an intermediary medium to transfer momentum to the carriers. Instead of direct mechanical contact between diverter mechanisms and carriers, compressed air serves as the mediator, delivering the necessary force for lane changes without the mechanical impact that causes spillage.
4Adaptability or versatility
If a single apparatus manages different types of carriers, then versatility is improved, but the system must handle various carrier configurations and dimensions
Solution Approach 1:
The patent designs the pneumatic diverter system with universal applicability to different carrier types. The air jet mechanisms can accommodate various carrier dimensions and configurations by adjusting the positioning and timing of air jets, allowing a single apparatus to handle multiple carrier types without requiring type-specific mechanical adaptations.
Data Source
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AI summary
An apparatus (1) for sorting containers of biological samples, for an automation system (2) of an analysis laboratory, comprises a transport line (21) of containers of biological samples, including a conveyor belt (210) on which are transported, in an aligned succession along a transport direction (X), a plurality of carriers (5) each arranged to receive and stably support a container (4) for a biological sample. A plurality of parallel sorting lines (100) spaced apart from each other extend from a succession of areas of the transport line (21). Each sorting line (100) is associated with a respective a diverter member (12) transversely movable to the transport line (21) from an inoperative backward position to an advanced position in which it is able to divert a carrier (5) from the transport line (21) to the sorting line (100). Each diverter member, when activated, has a forward movement which includes a first movement up to a first position in the middle of the transport line (21), and a second further movement up to the aforesaid advanced position, to push the intercepted carrier (5) in the respective sorting line (100). In this way when the diverter member intercepts a carrier (5), the diverter member is static in the middle of the transport line and does not produce any cross collision with the intercepted carrier (5). This avoids the risk that part of the biological sample may come out of the container.