Pneumatic Conveyor for Analytical Instrument Sample Distribution
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Solution Overview
Problem
In large analytical laboratories, inefficiencies arise due to uneven sample distribution among gas chromatographs and mass spectrometers, leading to reduced throughput and reliability concerns, particularly in medical laboratories where incorrect test results can be catastrophic.
Innovation Solution
A conveyor system that monitors and optimally distributes sample vials among analytical instruments based on their operational status and capabilities, using a pneumatic system to ensure efficient sample handling and automatic retrieval of calibration samples, thereby enhancing the operational efficiency and reliability of the instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual delivery of sample vials is used from preparation station to analytical instruments, then device complexity is reduced, but productivity decreases due to uneven sample distribution and instrument idle time
Solution Approach 1:
The system uses instrument status information to automatically direct sample vials to appropriate instruments without manual intervention. The conveyor system and control unit work together to autonomously distribute samples based on real-time instrument availability and test requirements, eliminating manual delivery while maintaining efficient operation.
Solution Approach 2:
The control unit continuously monitors instrument status, sample queue conditions, and test progress to dynamically adjust sample distribution. This feedback mechanism ensures samples are routed to instruments that can process them most efficiently, optimizing throughput while adapting to changing system conditions.
2Reliability
If samples are distributed manually to analytical instruments, then ease of operation is maintained, but reliability decreases due to potential miscorrelation of samples with tests
Solution Approach 1:
The automated conveyor system with control unit handles sample distribution without manual intervention, eliminating human error in sample-instrument correlation. The system automatically matches samples with appropriate instruments based on test requirements and instrument capabilities, ensuring reliable correlation while reducing manual handling.
Solution Approach 2:
The patent replaces manual mechanical handling of sample vials with an automated conveyor system controlled by electronic signals. This substitution eliminates manual correlation errors while maintaining simple operation through automated control, improving both reliability and operational simplicity.
3Productivity
If a conveyor system is implemented to automatically deliver samples, then productivity increases by at least 20%, but device complexity increases
Solution Approach 1:
The conveyor system serves multiple functions: it transports sample vials, distributes them to appropriate instruments, collects completed samples, and coordinates with instrument status. This multi-functionality consolidates what would otherwise require multiple separate systems into a single integrated unit, improving productivity while limiting complexity increase.
Solution Approach 2:
The patent combines the conveyor mechanism, control unit, instrument monitoring, and sample distribution functions into a single integrated system. This merging reduces the number of separate components needed compared to independent manual delivery systems, achieving automated high-throughput operation with controlled complexity.
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 increases the operational efficiency of a bank of analytical instruments by at least 20% and improves reliability by ensuring that samples are correctly correlated with the appropriate tests, reducing the risk of errors in medical laboratories.
Implementation Method 1
The conveyor system is preferably a pneumatic system in which differential air pressure, either positive or negative, moves the vials from the inlet through a distributor to the inlet of an appropriate one of the analytical instruments
Data Source
AI summary
A control system for a bank of analytical instruments operates the instruments as a group rather than singly. The system includes an autoloader at a sample preparation station into which an individual loads sample vials of unknown material. A second autoloader provides sample vials of known material that can be used to calibrate instruments. A computer controls the autoloader and a conveyor system to deliver a selected one of the vials to a selected instrument. The conveyor system includes a group of distributors, typically in series, to deliver a vial to any one of a large group of instruments. The conveyor system is preferably a pneumatic system including a receiver and technique for slowing the vials down when they approach the receiver. The receiver is positioned to deliver the vial to an autoinjector of the instrument. A computer monitors and communicates with the analytical instrument to obtain inputs to control components of the system.