Histology Embedding Workstation With Real-Time Cassette Prioritization
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Solution Overview
Problem
Existing histological sample embedding processes are manual, leading to low productivity, potential errors, and lack of traceability, with risks of sample misorientation, misidentification, and inconsistent embedding material control.
Innovation Solution
An automated workstation and process that includes a handling device to manage cassettes and moulds, a monitoring system for traceability, and precise control of embedding material dispensing, allowing manual sample orientation and automated handling to ensure accurate embedding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and processing of histological samples is used, then flexibility and adaptability are maintained, but productivity is low and labor intensity is high
Solution Approach 1:
The automated workstation is divided into multiple independent modules (sample processing module, embedding module, staining module, etc.), each performing a specific function. This segmentation allows the system to achieve high productivity through automation while maintaining manageable complexity through modular design, where each module can be independently optimized and maintained.
Solution Approach 2:
The workstation is designed as a universal platform that can handle various histological sample types and processing requirements through programmable control. The system integrates multiple functions (processing, embedding, staining, sectioning) in a single automated workflow, increasing productivity without proportionally increasing overall system complexity.
2Productivity
If automated processing is implemented, then productivity increases and labor intensity decreases, but measurement precision and control accuracy become more challenging
Solution Approach 1:
The system incorporates feedback mechanisms where sensors monitor sample position, processing parameters, and quality indicators in real-time. This feedback is fed to the control unit which automatically adjusts processing parameters to maintain measurement precision and control accuracy despite the automated high-speed operation.
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanical systems controlled by precision motors and programmable logic. The control unit manages positioning, handling, and processing parameters with high precision through electronic control rather than manual operation, maintaining accuracy while increasing productivity.
3Adaptability or versatility
If multiple sample types are handled in a single workflow, then versatility increases, but device complexity and operational difficulty increase
Solution Approach 1:
The workstation features dynamic, programmable control that can adapt workflows based on sample type. The system can automatically adjust processing parameters, module activation sequences, and handling procedures through software control, enabling versatility across multiple sample types without permanently increasing hardware complexity.
Solution Approach 2:
The system is designed as a universal platform with standardized interfaces and modular components that can be reconfigured for different sample types. The same basic infrastructure handles various histological samples through programmable control, achieving versatility without proportionally increasing overall device complexity.
4Reliability
If automated embedding processing is used, then consistency and reproducibility improve, but loss of time for setup and calibration increases
Solution Approach 1:
The system performs preliminary calibration and setup operations automatically during initial system initialization or when sample types change. This preliminary action is performed once and stored as parameters, allowing subsequent processing to proceed quickly without repeated manual calibration, thus achieving high consistency while minimizing time loss.
Solution Approach 2:
The workstation is designed to self-calibrate and self-maintain through automated sensors and control systems. The system automatically monitors its own performance and adjusts parameters to maintain consistency, reducing the need for manual intervention and minimizing time loss while ensuring reliable, consistent embedding processing.
Data Source
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AI summary
An automated workstation for an operator, for embedding histological samples with embedding material (P), comprising a workbench for an operator, defining a working area (W). On one side of the working area (W) of the operator an input area (A) is arranged which receives and accumulates in an automated way cassettes (2) containing histological samples (S). A first handling device (12) picks up cassettes (2) from the input area (A) and feeds them, one at a time, to the working area (W), according to a priority sequence determined in real time as a function of the information associated with the histological samples of the cassettes (2), which are detected on codes indicated on the cassettes. For each new cassette (2) that reaches the working area (W), the operator removes the histological sample (S) from the cassette (2), obtains the dispensing of a first layer of embedding material within a mould (5), by means of a first dispensing device (14), places the histological sample (S), with a selected orientation, within the mould (5) and then applies the cassette (2) over the mould. A transfer device (15) receives, one at a time, from the operator, the moulds (5) containing the oriented histological samples (S). The passage of each new cassette (2) on the transfer device (15) generates a signal which indicates that the working area (W) of the operator is free to receive a new cassette from the input area (A). A second embedding material dispensing device (16) fills each mould (5) and the associated cassette (2) placed thereon, with a volume of embedding material (P). A cooling area (B) arranged downstream of the transfer device (15), receives in an automated way the moulds (5), each one with the respective histological sample covered by the embedding material, in such a way that the embedding material (P) containing each histological sample (S) forms a solidified body (7), in which the histological sample is embedded.