Electromagnetic PCB Track Crossroads for Uniform Magnetic Path Switching
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Solution Overview
Problem
Conventional liquid handler systems face challenges with the cost and complexity of wound-coil based linear synchronous motor (LSM) systems used in automation tracks, particularly at intersections where uniform magnetic fields are difficult to manage, leading to reduced coupling efficiency and the need for mechanical assistance.
Innovation Solution
The use of multilayer printed circuit boards (PCBs) with stacked, single-layer spirals forming multilayer coils allows for a more efficient and cost-effective magnetic field generation, enabling smooth vessel movement without mechanical guides, by arranging coils in a way that allows for continuous paths and branching without compromising magnetic field uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wound-coil based linear synchronous motor systems are used in automation tracks, then magnetic field generation is achieved, but cost and complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical wound-coil system with an electromagnetic PCB-based system. The PCBs with integrated conductive traces eliminate the need for separate mechanical coil assemblies, reducing structural complexity while maintaining magnetic field generation capability through electromagnetic induction.
Solution Approach 2:
The PCBs serve multiple functions: they provide the track surface for vessel mover movement, generate magnetic fields through integrated conductive traces, and eliminate the need for separate mechanical guides. This multi-functionality reduces overall system complexity and component count.
2Adaptability or versatility
If wound-coil systems are used at track intersections, then path switching is enabled, but magnetic field uniformity deteriorates
Solution Approach 1:
The patent applies different PCB configurations locally at intersection points versus straight track sections. At intersections, specific PCB arrangements with adjusted conductive trace patterns create appropriate magnetic field distributions for path switching, while maintaining overall field uniformity through localized optimization.
Solution Approach 2:
The system dynamically controls magnetic field generation at intersections by selectively activating specific PCB conductive traces based on the desired path. This dynamic control enables smooth vessel mover redirection while maintaining magnetic field uniformity through precise temporal and spatial activation patterns.
3Ease of manufacture
If conventional PCB configurations are used at intersections, then manufacturing is simplified, but coupling efficiency reduces
Solution Approach 1:
The patent utilizes the vertical dimension by stacking multiple PCBs with complementary conductive trace patterns. This 3D arrangement of conductive traces on stacked PCBs creates optimized magnetic field distributions at intersections while maintaining standard PCB manufacturing processes, thereby preserving both ease of manufacture and coupling efficiency.
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 enhances the efficiency and reliability of sample transport in liquid handler systems by reducing costs, eliminating the need for mechanical guides, and maintaining uniform magnetic fields across different track sections, including intersections, thereby improving the overall automation track system's performance.
Implementation Method 1
A processor controls selective application of currents to the plurality of multi-layer coils to create a magnetic field to propel the one or more magnetic vessel movers along the track
Implementation Method 2
the coils and the magnet in the vessel mover together forming a linear synchronous motor (LSM)... synchronizing the fields to the movement of the magnets, causing movement along a plane
Data Source
AI summary
A vessel transport system in a liquid handler system includes vessel movers that transport a sample vessel using a magnetic base. A track provides a selective magnetic field to propel the magnetic base of each vessel mover along the track using a plurality of multilayer printed circuit boards (PCB) arranged along a transport path. Each PCB has a plurality of multi-layer conductive coils within layers of the PCB and each coil has a plurality of single-layer spirals electrically coupled with one another to form a multilayer coil. A processor is configured to control selective application of currents to the plurality of multi-layer coils to create the selective magnetic field. At least a subset of the multi-layer conductive coils are stacked relative to one another below a surface of the track, such that the selective application of currents selects one of a plurality of branching paths along the track.