Optical Differential Fluid-Level Measurement at Sample Receptacle Rims
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Solution Overview
Problem
Automated analytical systems face challenges in accurately measuring fluid levels in sample receptacles due to mechanical tolerance stack uncertainties, leading to potential spilling and cross-contamination, which can result in false positives and inefficient processing.
Innovation Solution
An automated system employs a sensor to perform differential measurements by calculating the distance between the fluid surface and the receptacle rim, refining measurements through filtering and averaging, and quarantining receptacles with fluid levels outside acceptable ranges to prevent spilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor measures fluid level in a sample receptacle, then the fluid level can be detected, but mechanical tolerance stack uncertainties cause measurement inaccuracies leading to potential spilling and cross-contamination
Solution Approach 1:
The patent replaces mechanical contact-based level sensing with optical sensing. The optical sensor detects fluid level by measuring light properties (absorption, reflection, refraction) without mechanical contact, thereby eliminating mechanical tolerance stack uncertainties and improving both measurement precision and reliability.
Solution Approach 2:
The patent introduces an optical field as an intermediary between the sensor and the fluid. Instead of direct mechanical contact, the optical field mediates the measurement process, allowing accurate detection of fluid level while avoiding mechanical errors and contamination risks.
2Manufacturing precision
If the fluid level is measured with high precision, then spilling can be prevented, but the system complexity increases due to additional sensors and processing requirements
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a simpler optical sensing system. The optical sensor and associated processing electronics provide high-precision fluid level detection without the mechanical complexity, tolerance stacking, and maintenance requirements of traditional mechanical systems.
Solution Approach 2:
The optical sensor system automatically detects and reports fluid level conditions without requiring manual intervention or complex mechanical adjustment mechanisms. The system self-regulates by providing continuous feedback on fluid level, enabling automatic control and reducing overall system complexity.
3Object-affected harmful factors
If sample receptacles are quarantined to prevent spilling, then cross-contamination is reduced, but processing efficiency decreases due to unnecessary quarantine of acceptable samples
Solution Approach 1:
The patent uses optical sensing to provide more accurate and reliable fluid level measurements, reducing false positives that lead to unnecessary quarantine. By eliminating mechanical tolerance uncertainties, the system can confidently distinguish between truly overfilled receptacles and those within acceptable ranges, maintaining contamination prevention while improving processing efficiency.
Solution Approach 2:
The patent implements continuous optical feedback on fluid level conditions, enabling real-time monitoring and more accurate determination of when quarantine is actually necessary. This feedback mechanism reduces unnecessary quarantine actions while maintaining adequate protection against cross-contamination.
Data Source
AI summary
Automated systems and methods determine a level of fluid relative to a rim of a sample receptacle defining an open top of the sample receptacle. The systems and methods utilize a distance sensor to measure the distance between the rim of the sample receptacle and the surface of a fluid sample contained in the sample receptacle, where at least one of the sensor and the sample receptacle is moved relative to the other to enable the sensor to obtain a sequence of discrete measurements of distances between the sensor and the rim of the sample receptacle and between the sensor and the surface of the fluid sample. A controller processes an output signal from the sensor to determine a level of the fluid relative to the rim of the sample receptacle. The derivative of the sequence of discrete measurements may be used to identify the rim and the fluid surface in the output signal.