Vision-Based Cartridge Liquid Level Detection for Overflow Control
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Solution Overview
Problem
Conventional cell processing systems face inefficiencies due to labor-intensive processes, human error, and lack of end-to-end process flexibility, scalability, and operational robustness, necessitating improved systems for monitoring liquid levels and fluid transfer within cell processing cartridges.
Innovation Solution
The implementation of a vision system with fiducial markers and cameras to calibrate and monitor liquid levels and fluid transfer parameters within cell processing cartridges, using a calibration cartridge to define regions of interest and generate alignment maps, enabling precise liquid volume determination and flow rate control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automated cell processing systems are used, then some processing steps are automated, but the systems lack end-to-end process flexibility, process robustness, and process scalability
Solution Approach 1:
The cell processing system is designed as a universal automated platform that can perform multiple cell processing steps (harvesting, washing, resuspension, etc.) across different cartridge types and configurations. The system includes reusable instruments that can interface with various disposable cartridges, enabling end-to-end automation of diverse cell therapy manufacturing workflows while maintaining flexibility through standardized interfaces and programmable control.
2Ease of manufacture
If pre-configured instrumentation and tubing sets are used, then system setup is simplified, but operational flexibility is limited and process failure due to human error cannot be reliably prevented
Solution Approach 1:
The system is segmented into reusable instrument components and disposable cartridge components. The disposable cartridges are pre-configured with tubing and reagents for specific cell processing steps, while the reusable instruments provide programmable control and can be reconfigured for different protocols. This segmentation allows simplified setup by replacing entire cartridges rather than reconfiguring individual tubing connections, while maintaining operational flexibility through software control of the reusable components.
Solution Approach 2:
The system incorporates sensors and vision systems that provide real-time feedback on liquid levels, flow rates, and cartridge positioning. This feedback enables automated adjustment of processing parameters and detection of anomalies, preventing process failures due to human error while maintaining operational flexibility through closed-loop control that can adapt to actual process conditions.
3Ease of operation
If manual operations are performed in biosafety cabinets and cleanrooms, then operator control is maintained, but labor intensity increases and human error risk increases
Solution Approach 1:
The system enables operators to load cartridges and initiate processing, after which the system autonomously performs cell harvesting, washing, resuspension, and transfer operations without requiring continuous manual intervention. The automated liquid handling, pumping, and mixing functions operate independently, significantly reducing labor intensity while maintaining operator control through programmable protocols and real-time monitoring capabilities.
4Device complexity
If liquid level monitoring is not implemented, then system complexity is reduced, but overflow risk increases and system damage may occur
Solution Approach 1:
The system incorporates liquid level sensors and vision systems that continuously monitor liquid levels in cartridges and provide real-time feedback to the control system. When liquid levels approach critical thresholds, the system automatically adjusts pumping rates or stops fluid transfer to prevent overflow. This feedback-based monitoring adds minimal complexity while significantly improving reliability by preventing overflow-related system damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the precision and safety of cell processing by preventing overflow and ensuring accurate fluid transfer, reducing system damage, and facilitating high-throughput, scalable manufacturing.
Implementation Method 1
detecting a location of each of the one or more fiducial markers using the vision system and generating a calibration result using the locations of each of the one or more fiducial markers
Implementation Method 2
a pump configured to transfer the liquid from the first module to the second module at a flow rate
Implementation Method 3
a sensor configured to detect a liquid level within the second module
Data Source
AI summary
The present disclosure relates to systems and methods for monitoring liquid levels within cartridges of automated cell processing systems during cell processing. A method for automated cell processing may first include coupling a cell processing cartridge to an instrument configured to perform a cell processing operation with at least one module of the cartridge. Next, the method may include detecting, via a vision system of the instrument, a liquid level of a liquid within one or more cell processing modules of the cartridge. Finally, the method may include determining a volume of the liquid based on the liquid level.