Robotic Probe Alignment Using Hunting Tool and Optical Sensing
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Solution Overview
Problem
Current automation systems for aligning pipetting probes with sample tubes on puck-based tracks are inefficient and lack precision, requiring manual intervention due to the repetitive and precise nature of the process.
Innovation Solution
An automated probe switch alignment system using a robotic arm with a pressure-sensitive hunting tool and a probe runout sensor, which detects the location and runout of the hunting tool to accurately align the probe with a target, allowing for precise and consistent alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used with visual inspection and tooling pins, then alignment precision can be achieved, but the process becomes slow and costly
Solution Approach 1:
The patent replaces manual visual inspection and mechanical tooling pins with an automated optical sensing system. The sensor device detects the position of the hunting tool tip relative to the target aperture using optical beams, eliminating the need for manual measurement and alignment while maintaining high precision.
Solution Approach 2:
The system enables self-alignment by automatically detecting the hunting tool tip position and calculating runout parameters without human intervention. The robotic arm performs the alignment adjustments based on sensor feedback, making the system self-correcting and eliminating manual alignment operations.
2Productivity
If full automation is implemented for pipetting probe alignment, then productivity increases, but measurement precision and reliability decrease
Solution Approach 1:
The patent introduces a specialized hunting tool as an intermediary device that bridges the robotic arm and the target aperture. This tool with its pressure-sensitive tip provides a reliable mechanical interface that can be precisely detected by the optical sensor, ensuring both automation and measurement precision.
Solution Approach 2:
The sensor device uses optical beams that detect changes in light transmission or reflection as the hunting tool tip approaches and contacts the target aperture. This optical detection method provides precise measurement feedback for automated alignment while maintaining high speed.
3Difficulty of detecting and measuring
If manual alignment procedures are used, then measurement and detection can be performed, but the process complexity and time consumption increase
Solution Approach 1:
The system performs preliminary detection by having the robotic arm position the hunting tool near the target aperture before actual contact. The sensor device pre-detects the position and calculates runout parameters in advance, allowing for rapid correction and alignment without time-consuming manual measurements.
Solution Approach 2:
The patent implements a closed-loop feedback system where the sensor device continuously monitors the hunting tool tip position relative to the target aperture. This real-time feedback allows the robotic arm to make precise adjustments and verify alignment, dramatically reducing the time and complexity of the alignment process.
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
The system enables robust and efficient alignment of robotic pipetting probes, ensuring reproducible results by simplifying the alignment process and improving the accuracy and consistency of the alignment, reducing the need for manual intervention.
Implementation Method 1
the hunting tool having a pressure sensitive tip; wherein the sampling tip of the probe is aligned with a predetermined target, based on the alignment of the hunting tool; and wherein the hunting tool alignment is determined based on force detected at the pressure sensitive tip
Implementation Method 2
one or more sensing beams running across the aperture; wherein the one or more sensing beams detect the location of an object passing through the aperture
Data Source
AI summary
One embodiment provides a method of automatically aligning an indexing machine with a robotic end effector including: inserting, using a robotic arm, a hunting tool into an aperture, the hunting tool comprising a pressure sensitive tip; detecting, using a plurality of sensing beams, a first location of the hunting tool within the aperture; rotating, using the robotic arm, the hunting tool 180 degrees; detecting, using the plurality of sensing beams, a second location of the hunting tool within the aperture; calculating a runout magnitude and a runout direction based on the first location, the second location, and the robotic arm; inserting, using the robotic arm, the hunting tool into a target; determining, using the pressure sensitive tip, a location of the hunting tool with respect to the target; and thereafter, adjusting the location of the hunting tool with respect to the aperture and target based on said determined location and said calculated runout magnitude and direction. Other aspects are described and claimed herein.