Optical Characterization Station for Sample Tube Positioning
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Solution Overview
Problem
Current automation systems for in vitro diagnostics face challenges in precisely positioning and handling various sizes of sample tubes due to limitations in precision and adaptability, leading to inefficiencies and bottlenecks in sample processing.
Innovation Solution
An automation system equipped with a characterization station that uses optical devices to analyze images of sample vessels and carriers, determining physical attributes such as orientation, size, and type, allowing for precise positioning and handling of samples through automated adjustment and routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If passive carriers with hard stops are used for positioning samples, then the positioning is simple and repeatable, but the precision and adaptability for various tube sizes are insufficient
Solution Approach 1:
The system performs preliminary characterization of each carrier's physical attributes (size, shape, orientation) using optical sensors before the carrier reaches the interaction station. This advance information allows the system to pre-calculate positioning offsets and prepare appropriate handling parameters, achieving high precision without complex real-time adjustment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical positioning adjustment mechanisms with an optical sensing and computational system. Instead of using adjustable mechanical stops or complex actuation systems, the invention uses optical sensors to characterize carriers and software algorithms to calculate positioning offsets, substituting mechanical complexity with optical and computational simplicity.
2Manufacturing precision
If self-centering springs are used to position tubes, then positioning precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The system replaces expensive self-centering spring mechanisms with optical sensing and computational positioning. Optical sensors characterize the tube's position and orientation, and software calculates the necessary positioning offsets, eliminating the need for precision-manufactured self-centering springs and their associated costs.
Solution Approach 2:
The invention creates a digital model (optical characterization) of the physical tube's attributes and uses this information to determine positioning parameters. This digital copy allows the system to plan and execute precise positioning without requiring complex physical centering mechanisms.
3Measurement precision
If multiple sensors are added to each interaction station for precise positioning, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent consolidates positioning measurement functionality into a single characterization station with optical sensors that characterize all carriers passing through it. This single location performs the measurement function for the entire system, eliminating the need for multiple sensors distributed across different interaction stations while maintaining high measurement precision.
Solution Approach 2:
The characterization station with optical sensors serves multiple purposes: it characterizes carrier physical attributes for positioning, identifies tube types, and provides data for routing decisions. This universal measurement system replaces multiple specialized sensors that would otherwise be needed at different stations.
4Adaptability or versatility
If manual adjustments are made for different tube sizes, then adaptability is improved, but processing time and productivity are reduced
Solution Approach 1:
The system automatically characterizes each carrier's attributes and calculates positioning parameters without human intervention. The optical sensors and software work together to self-determine the appropriate handling parameters for each tube size and type, eliminating the need for manual adjustments while maintaining high adaptability to various tube configurations.
Solution Approach 2:
The characterization station provides real-time feedback on carrier physical attributes to the control system, which automatically adjusts positioning parameters based on this feedback. This closed-loop system enables automatic adaptation to different tube sizes without manual intervention, maintaining both versatility and high throughput.
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
This solution enables efficient and precise handling of diverse sample tubes, reducing processing time and increasing throughput by eliminating the need for manual adjustments and additional sensors, thereby improving the overall efficiency of the automation system.
Implementation Method 1
a plurality of optical devices configured to capture one or more images of a carrier on an automation track
Implementation Method 2
a plurality of optical devices configured to capture one or more images of a carrier on an automation track
Data Source
AI summary
Systems and methods for use in an in vitro diagnostics setting may include an automation track, a plurality of carriers configured to carry a plurality of sample vessels along the automation track, and a characterization station including a plurality of optical devices. A processor, in communication with the characterization station, can be configured to analyze images to automatically characterize physical attributes related to each carrier and/or sample vessel. A method may include receiving a plurality of images from a plurality of optical devices of a characterization station, wherein the plurality of images comprise images from a plurality of perspectives of a sample vessel being transported by a carrier, automatically analyzing the plurality of images, using a processor, to determine certain characteristics of the sample vessel, and automatically associating the characteristics of the sample vessel with the carrier in a database.