Robotic Arm Tissue Processing System for Parallel Sample Handling
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Solution Overview
Problem
Conventional tissue processing equipment has limitations in processing multiple sample baskets simultaneously, leading to low throughput, inefficient liquid utilization, and potential toxicity issues, with manual methods being time-consuming and labor-intensive.
Innovation Solution
A tissue processing and slide staining system with a robotic arm having three degrees of freedom that can perform simultaneous tissue processing and slide staining for multiple sample baskets, independent of lids and baskets, allowing for higher throughput, reduced liquid evaporation, and integration of a filtration system to prevent toxic gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional tissue processing equipment uses sequential processing with robotic arm connected to lids and baskets, then device complexity is reduced, but productivity is significantly limited and liquid utilization becomes inefficient
Solution Approach 1:
The system divides the robotic arm into three independent degrees of freedom (X-axis, Y-axis, Z-axis) that can operate independently. This segmentation allows the arm to move baskets and containers separately, enabling simultaneous processing of multiple samples without requiring the arm to be connected to lids and baskets, thereby resolving the contradiction between productivity and device complexity
Solution Approach 2:
The patent introduces a three-dimensional coordinate system (X, Y, Z axes) for robotic arm movement, adding spatial dimensionality to the processing system. This dimensional approach allows parallel operation in different spatial locations, dramatically increasing throughput while maintaining manageable device complexity through modular axis control
2Productivity
If higher volume containers are used to compensate for low throughput, then productivity is maintained, but liquid consumption increases and processing quality decreases
Solution Approach 1:
The system uses multiple smaller containers (2-10) arranged in parallel rather than one large container. Each container can be independently processed by the robotic arm, allowing efficient liquid usage in each container while maintaining high overall throughput through parallel processing, thus reducing total liquid consumption compared to using fewer large containers
Solution Approach 2:
The robotic arm continuously moves baskets between multiple containers in parallel processing streams, ensuring that liquid in each container is continuously utilized. This continuous action eliminates idle liquid volume and maximizes the useful action of each liquid unit, reducing overall consumption while maintaining productivity
3Ease of operation
If robotic arm frequently opens/closes container lids for each move, then ease of operation is improved, but liquid evaporation increases and loss of substance worsens
Solution Approach 1:
The system extracts the lid opening/closing operation from the mandatory sequence of basket transfers. By using containers without lids or with fixed covers, and by designing the robotic arm to transfer baskets between open container positions, the system eliminates the need to open/close lids during normal operation, thereby preventing liquid evaporation while maintaining ease of operation
Solution Approach 2:
The patent introduces intermediate transfer positions where baskets are temporarily held between container stations. This intermediary approach allows the robotic arm to move baskets without requiring lid operations at each container, using the intermediate position as a buffer that eliminates the need for frequent lid opening/closing, thus reducing evaporation while keeping the system easy to operate
4Productivity
If manual tissue processing methods are used, then device complexity is reduced, but productivity is low and labor intensity is high
Solution Approach 1:
The robotic arm system is designed to autonomously perform basket transfers between containers without human intervention. The three-degree-of-freedom arm self-manages the complex coordination of movements along X, Y, and Z axes, and self-regulates the processing sequence, thereby achieving high productivity while keeping the control system relatively simple through autonomous operation
Solution Approach 2:
The robotic arm is designed as a universal device that can handle multiple types of baskets and transfer them between various container positions. This multi-functionality allows a single device to perform diverse processing tasks (fixation, dehydration, clearing, impregnation) across multiple samples simultaneously, increasing productivity without proportionally increasing device complexity
Data Source
AI summary
The embodiments herein provide a tissue processing and slide staining equipment with a three degree freedom robotic arm that simultaneously performs tissue processing and slide staining for several sample baskets with similar or different processing methods. The equipment comprises two dimensional array of cylindrical containers with lids to hold sample baskets in position. The arm moves freely in X, Y, and Z axis using rails and stepper motors. The arm is not connected to lids and baskets and accepts new baskets of samples while processing previous samples. The arm grips the basket containing samples and leaves the basket in proximity to the reagent. The equipment comprises a user friendly interface having appropriate callouts to guide a user during process programming/running. The interface allows the user to freely design and modify each step of the processing method. The equipment comprises an intelligent rule database that automatically handles human-induced errors.