Deck Image Verification for Biological Sample Setup Errors
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Solution Overview
Problem
Automated biological sample analysis systems are prone to failure due to human errors in preparing the deck staging area, where components are often misplaced or incorrectly configured, leading to inefficiencies and malfunctions.
Innovation Solution
An imaging device captures images of the deck before and after component setup, comparing them to identify discrepancies and highlighting differences to the operator for quick correction, using real-world images for intuitive error correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grid-like illustrations and virtual representations are used to guide component placement, then operators can understand where components should be placed, but operators still make mistakes by placing components in wrong locations
Solution Approach 1:
The system creates a digital twin or virtual model of the deck that mirrors the physical layout. The imaging device captures images of the actual deck, and software compares the captured image with the virtual model to verify component placement accuracy, providing real-time feedback to operators
Solution Approach 2:
The system provides immediate visual feedback by highlighting discrepancies between the actual component placement and the expected placement. The software identifies misplaced components and alerts operators, allowing for rapid correction of errors
2Reliability
If scanners are introduced to check component placement, then component verification can be performed, but the scanning process takes too much time to efficiently check the entire staging area
Solution Approach 1:
The system replaces mechanical scanning devices with an imaging-based verification system. An imaging device captures images of the deck, and software algorithms automatically analyze the images to verify component placement, eliminating the need for physical scanning and significantly reducing verification time
Solution Approach 2:
The system performs preliminary verification by capturing images of the deck as components are being placed. The software continuously monitors and compares the current state with the expected state, allowing for early detection and correction of placement errors before the entire setup is complete
3Extent of automation
If fully automated scanning or recognition systems are used to identify components, then component identification can be performed, but acceptable alternative components may be incorrectly identified as different from requirements
Solution Approach 1:
The system introduces an intermediary layer of image capture and visual comparison between the automated recognition system and the expected component layout. The imaging device captures images that are then compared with the virtual model, allowing for more nuanced interpretation of component identity and acceptance of valid alternatives
Data Source
AI summary
A method for preparing a deck for a process is disclosed. The deck can be prepared with any necessary components, and then an imaging device can capture an image of the deck. This image can be compared with a reference image and any differences identified. The differences can be indicated in the image and shown to an operator, such that the operator can correct any errors associated with the differences.