Disposable Endoscope Sensor Calibration and Inventory Tracking
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Solution Overview
Problem
Current endoscope technologies face challenges in efficiently managing inventory levels, ensuring sterility, and providing reliable image processing, particularly in minimally invasive surgeries, where reusable components are costly to re-sterilize and optics degrade over time.
Innovation Solution
A computer-based system that reads machine-readable serial numbers to track and reorder medical devices, combined with an endoscope design featuring a partially reusable and partially disposable structure, including an image sensor with normalized video processing and optical correction, to enhance inventory management and image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If reusable endoscope components are used to reduce costs, then manufacturing costs are reduced, but sterility cannot be ensured and image quality degrades over time
Solution Approach 1:
The endoscope system is divided into reusable components (handle, image processor) and disposable components (insertion tube with image sensor). This segmentation allows the disposable portion to maintain sterility while the reusable portion can be sterilized and reused, resolving the contradiction between cost reduction and sterility assurance.
Solution Approach 2:
The patent implements a disposable insertion tube containing the image sensor and optical components. This disposable component is discarded after single use, ensuring sterility without the need for re-sterilization while keeping manufacturing costs lower than fully reusable systems.
2Quantity of substance
If reusable endoscope components are used to reduce costs, then manufacturing costs are reduced, but image quality degrades over time
Solution Approach 1:
By separating the image sensor and optical components into the disposable insertion tube, each unit can be individually calibrated and tested during manufacturing. This ensures consistent image quality for each disposable unit while maintaining lower overall manufacturing costs compared to fully reusable systems requiring complex sterilization and quality control processes.
Solution Approach 2:
The disposable nature of the insertion tube allows for individual quality control and calibration of each unit during manufacturing, ensuring consistent image quality without the degradation issues that accumulate in reusable components over multiple sterilization cycles.
3Reliability
If disposable endoscope components are used to ensure sterility, then sterility is maintained, but inventory management complexity increases
Solution Approach 1:
The system incorporates usage tracking that monitors the number of times each endoscope is used. This feedback mechanism automatically triggers reordering when inventory levels need replenishment, simplifying inventory management despite the disposable nature of components.
Solution Approach 2:
The endoscope system automatically tracks its own usage and generates reordering requests, reducing the manual inventory management burden. The system self-monitors sterility status and usage counts, automatically initiating replenishment processes when needed.
4Ease of manufacture
If image sensor properties vary within manufacturing tolerances, then manufacturing costs are reduced, but image quality consistency worsens
Solution Approach 1:
The image processor is configured with the ability to adjust imaging parameters based on the specific characteristics of each image sensor. By measuring and storing the actual properties of each sensor, the system compensates for manufacturing variations through parameter adjustments, maintaining consistent image quality despite tolerances in sensor production.
Solution Approach 2:
The system performs preliminary measurement and characterization of each image sensor's properties during initial setup or calibration. This preliminary action allows the system to compensate for manufacturing variations before actual use, ensuring consistent image quality while maintaining manufacturing flexibility.
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
The system effectively manages inventory and ensures consistent image quality by tracking device usage and reordering, while the endoscope design improves sterility and reduces manufacturing costs through disposability and advanced image processing.
Implementation Method 1
The endoscope has an image sensor designed to gather photons to produce video
Implementation Method 2
An optical reader reads 2D identification codes on packaging of the medical devices
Data Source
AI summary
During manufacture of a medical device, parameters if the device are measured, and results of that measurement are stored in a database. For example, parameters of an endoscope's image sensor may be measured and stored in the database. The medical device has a machine-readable serial number. A computer reads the serial number and records a reduction of an on-hand inventory of the medical devices. When the on-hand inventory warrants reordering to replenish the on-hand inventory. When warranted, the computer places an order with a supplier of medical devices of the class to replenish inventory. A computer controlling the medical device may read the database to obtain the measured properties. The obtained data may be used to calibrate or adjust the device's function. For example, white balance and color correction of an endoscope may be used to compute normalized video.