Dual Conveyance Lines for Automated Sample Rack Management
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Solution Overview
Problem
Existing automated sample test systems face challenges in managing a high throughput and complexity in conveyance control due to the need for large quantities of sample racks, leading to congestion and reduced processing efficiency.
Innovation Solution
The system employs a dual conveyance line configuration with a main conveyance line for samples and a separate, lower-positioned conveyance line for empty racks, using a connecting line and a controller to manage the supply and recovery of empty racks, ensuring continuous operation and flexibility without upsizing the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large quantity of samples racks are set up in the apparatus to conduct appropriate processing according to the type of sample, then the system can handle high throughput, but the system size and complexity increase
Solution Approach 1:
The patent divides the conveyance system into two separate conveyance lines: one for transporting loaded sample racks and another for empty sample racks. This segmentation allows independent control and optimization of each line, reducing overall system complexity while maintaining high throughput capability.
Solution Approach 2:
The patent introduces a vertical dimension by positioning the empty rack conveyance line below the loaded rack conveyance line. This spatial arrangement allows both conveyance lines to coexist without interference, enabling high throughput without increasing horizontal system footprint or complexity.
2Productivity
If a large quantity of samples racks are set up in the apparatus, then the system can handle high throughput, but the placement area required increases
Solution Approach 1:
The patent utilizes vertical space by arranging the empty rack conveyance line below the loaded rack conveyance line. This three-dimensional arrangement allows the system to handle large quantities of sample racks without proportionally increasing the horizontal placement area, thus maintaining high throughput in a compact footprint.
3Device complexity
If empty racks and loaded racks are conveyed on the same conveyance line, then the system is simpler, but congestion occurs and processing efficiency reduces
Solution Approach 1:
The patent separates the conveyance of empty racks and loaded racks into distinct conveyance lines. This segmentation eliminates congestion that would occur on a shared line, as each line can be optimized for its specific traffic pattern and controlled independently, thereby maintaining high processing efficiency.
Solution Approach 2:
The system prepares empty racks in advance on a dedicated conveyance line and positions them for immediate loading onto processed samples. This preliminary preparation ensures that loaded racks never wait for empty racks, preventing congestion and maintaining continuous high-speed processing.
4Productivity
If the system is upsized to accommodate more sample racks, then congestion is prevented, but the system becomes less extendible and more complex
Solution Approach 1:
The patent creates modular, independently controllable conveyance lines for empty and loaded racks. This segmentation allows the system to be easily extended or scaled by adding capacity to individual lines without redesigning the entire system, thereby maintaining high throughput while improving extendibility and reducing complexity.
Data Source
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AI summary
When samples racks in a system are reused by circulating these racks in a loop in order to avoid upsizing and complexity of the system, variations in a stock volume of empty samples racks between a plurality of processing units that require samples racks have caused difficulty in building a system having high throughput. Disclosed is a method for controlling an automated sample test system including a samples conveyance line for conveying samples racks, each holding samples, to a plurality of processing units, and an empty-rack stock section in which to stock samples racks not holding a sample. The control method is designed to collect information on whether the processing units are in need of a supply of empty samples racks, and then supply empty samples racks from the empty-rack stock section to the processing units based on the information. Decreases in throughput can be prevented by leveling the number of empty samples racks supplied to the processing units that require empty samples racks.