Needle Counting Tray With Optical Detection
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Solution Overview
Problem
In clinical settings, particularly in operating rooms, there is a challenge in efficiently collecting and counting needles used during procedures, leading to delays and inefficiencies when a needle is lost, requiring extended use of the operating room and additional equipment for localization.
Innovation Solution
A needle collection and counting tray with an optically transmissive body, collimating film, reflective layers, and a magnetic sheet, combined with an automated counting system using edge light assemblies and sensors to illuminate and detect needles, allowing for accurate counting and identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual needle counting is performed, then the process is simple and requires minimal equipment, but it is time-consuming and prone to errors leading to lost needles
Solution Approach 1:
The patent replaces manual mechanical needle counting with an automated optical detection system. The machine vision system uses cameras, light sources, and image processing algorithms to automatically detect, count, and track needles, eliminating the need for manual visual inspection and significantly reducing counting time and operating room downtime.
Solution Approach 2:
The needle collection tray is designed with built-in optical features (reflective layers, collimating films, gridlines) that enable the tray itself to facilitate automated detection. The tray structure actively participates in the counting process by providing reference markers and enhancing light interaction, allowing the system to self-identify needle positions without external intervention.
2Measurement precision
If automated machine vision counting is implemented, then needle counting speed and accuracy improve, but the device complexity and cost increase
Solution Approach 1:
The needle collection tray is designed to serve multiple functions: it collects needles during surgery, provides structural reference markers for detection, enhances light interaction for imaging, and facilitates automated counting. This multi-functionality reduces the need for separate specialized equipment, thereby managing device complexity while maintaining high measurement precision.
Solution Approach 2:
The patent optimizes optical parameters such as light wavelength, intensity, and angle of incidence to enhance needle detection contrast. By carefully selecting and adjusting these parameters, the system achieves high detection accuracy using standard off-the-shelf components rather than requiring complex custom-built equipment.
3Illumination intensity
If light is directed through the tray body, then needle silhouettes are enhanced for detection, but light scattering may reduce image quality
Solution Approach 1:
The patent introduces a collimating film as an intermediary element between the light source and the needle collection area. This film directs and uniformizes the light transmission through the tray body, reducing scattering effects while maintaining enhanced illumination. The collimating film acts as a mediator that optimizes the interaction between light and the tray structure, preserving image quality.
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 tray and automated system enable efficient collection, counting, and identification of needles, reducing delays and optimizing operating room usage by ensuring accurate accounting of surgical implements, thus minimizing downtime and improving operational efficiency.
Implementation Method 1
an optically transmissive body having a lower surface, an upper surface, and one or more edges disposed about a periphery of the body. At least one of the lower surface and the one or more edges is configured to receive light from an adjacent light source, wherein the body is configured to emit at least a portion of the received light through the upper surface
Implementation Method 2
the tray is configured to direct light exiting the upper surface thereof in a collimated direction away from the upper surface. There is provided a collimating film on the upper surface of the optically transmissive body effective to direct the light exiting the upper surface in the collimated direction
Implementation Method 3
There is provided a reflective layer at the lower surface of the optically transmissive body that is adapted to redirect light incident thereon toward the upper surface
Implementation Method 4
a magnetic sheet disposed beneath the reflective layer and adapted to attract ferromagnetic surgical implements disposed in the receiving areas of the tray via magnetic interaction therewith through the optically transmissive body and the reflective layer
Data Source
AI summary
A needle collection and counting tray for use in a clinical setting, such as an operating room, into which a user deposits used needles. The tray is then placed into a counting and identification machine the utilizes object recognition technology to identify and count the needles on the tray.