Laboratory Capper/Decapper Coupler With Sensor-Guided Ejection
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Solution Overview
Problem
Existing container capping and decapping systems in laboratory environments are complex, unreliable, and inefficient in adapting to various container sizes and shapes, requiring labor-intensive manual operations and lacking sensor capabilities for precise positioning.
Innovation Solution
A bi-directional motor-driven coupler assembly with mechanically-biased splines and concentrically positioned ejector nut and ejector, controlled by sensors, allows for quick adaptation to different container configurations without complex linkages, enabling precise torque application and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex linkages and control systems are used to provide gripping force and mechanical dexterity, then the system can effectively grip and torque containers, but the device complexity increases and reliability decreases
Solution Approach 1:
The patent removes complex linkages and control systems from the capping/decapping mechanism, retaining only the essential threaded shaft and coupler assembly. The motor directly drives the threaded shaft without intermediate mechanical linkages, extracting unnecessary complexity while maintaining the core gripping and torquing functions.
Solution Approach 2:
The coupler assembly is designed as a universal interface that can accommodate various container sizes and configurations through simple sensor feedback and control adjustments, rather than requiring complex mechanical adaptors or linkages for each container type.
2Manufacturing precision
If elongated fingers are used as guides to prevent misalignment, then alignment between splines and receiving bore is achieved, but the device complexity increases
Solution Approach 1:
The patent replaces mechanical alignment guides (elongated fingers) with a sensor-based detection system. Sensors monitor the position and alignment of the coupler assembly relative to the container, providing feedback for precise alignment without requiring complex mechanical guiding structures.
3Productivity
If manually operated systems are used for capping and decapping, then the system is simple in design, but labor intensity increases and productivity decreases
Solution Approach 1:
The system performs the capping and decapping operations autonomously through motor-driven rotation of the threaded shaft, which automatically engages the coupler assembly with the container and applies the necessary torque. The sensor system monitors and controls the process without requiring manual intervention, making the system self-sufficient.
Solution Approach 2:
Manual mechanical operations are replaced with an automated motor-driven system controlled by sensors. The motor rotates the threaded shaft to drive the capping/decapping process, while sensors provide feedback for precise control, eliminating the need for manual labor while maintaining operational simplicity.
4Measurement precision
If systems lack sensor capabilities for monitoring ejector assembly position, then the mechanical arrangement is simpler, but the precision and control of the operation deteriorates
Solution Approach 1:
Sensors are integrated into the coupler assembly to monitor the position of the ejector assembly and the rotational position of the coupler. This feedback is transmitted to the control system, which adjusts the motor operation to achieve precise positioning and torque application, ensuring accurate and repeatable capping/decapping operations.
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 efficiently and reliably caps and decaps containers of varying sizes and shapes with minimal mechanical complexity, enhancing adaptability and reducing labor, while ensuring precise positioning and torque control.
Implementation Method 1
mechanically-biased splines that are actuated without any complex linkages
Implementation Method 2
The coupler assembly is configured to engage with a cap or container via mechanically-biased splines that are actuated without any complex linkages, or operative connection to the motor or other powered components. The system employs an ejector nut and an ejector, both of which are concentrically positioned about the threaded shaft. The ejector nut translates along the shaft as a function of the shaft's rotation
Implementation Method 3
The sensors may include multiple optical, magnetic or mechanical means for monitoring one or more of the positions of the ejector nut and ejector along the threaded shaft and/or the rotational position of the coupler assembly
Implementation Method 4
The sensors may include multiple optical, magnetic or mechanical means for monitoring one or more of the positions of the ejector nut and ejector along the threaded shaft and/or the rotational position of the coupler assembly
Data Source
Figure 1A
Figure 1B
Figure 2A~2D
AI summary
A system and method for gripping, torqueing and releasing an element so as to cap and/or decap a container, such as those typically utilized to house specimens in laboratory environments. The system is driven by a single bi-directional motor linked to a coupler assembly via a rotating threaded shaft. The coupler assembly is configured to engage with an element, such as a cap or container, via mechanically-biased splines that are actuated without any complex linkages, or operative connection to the motor or other powered components. The system employs an ejector nut and an ejector, both of which are concentrically positioned about the threaded shaft. The ejector nut translates along the shaft as a function of the shaft's rotation, so as to permit the retraction of the ejector when an element is engaged in the coupler assembly or cause the ejector to extend into the coupler assembly to disengage the element. The direction and rotation of the motor is controlled by a system coupled to sensors positioned within the system. Such control system may include one or more processors, component interfaces, and data storage/memory. The sensors may include multiple optical, magnetic or mechanical means for monitoring one or more of the positions of the ejector nut and ejector along the threaded shaft, and/or the rotational position of the coupler assembly.