Sample Container Leveling for Accurate Automated Particle Counting
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Solution Overview
Problem
Automated particle counters face challenges in accurately measuring particle counts in liquid samples, particularly due to particle co-incidence and high viscosity issues, which are exacerbated by the labor-intensive and error-prone manual pipetting process required for sample dilution, limiting the widespread adoption of standardized testing protocols like ASTM-D7647.
Innovation Solution
A novel apparatus featuring a base member and container positioning system with ultrasonic measurement for accurate volume determination and automated diluent addition, allowing for batch testing of liquid samples in identical containers, thereby eliminating the need for manual pipetting and reducing labor and error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual pipetting is used for sample dilution, then sample preparation can be performed, but labor intensity increases and measurement precision decreases due to errors
Solution Approach 1:
The patent replaces manual mechanical pipetting with an automated liquid handling system that uses peristaltic pumps and programmed syringes to dispense diluent and sample. This automation eliminates human error in volume measurement while maintaining ease of operation through computer-controlled batch processing of multiple samples.
Solution Approach 2:
The system performs self-service by automatically calculating required diluent volumes based on input sample volumes and target dilution ratios, then autonomously dispensing the correct amounts without human intervention. The apparatus independently completes the entire dilution process for multiple samples in batch mode.
2Productivity
If automated particle counting is implemented, then productivity increases, but measurement precision is compromised due to particle co-incidence and high viscosity issues
Solution Approach 1:
The patent changes the viscosity parameter by adding diluent to high viscosity samples, reducing their viscosity to a level suitable for automated particle counting. This parameter modification enables the particle counter to accurately measure particles in samples that would otherwise be unsuitable due to their viscous nature.
Solution Approach 2:
The system performs preliminary dilution of samples before particle counting to eliminate interference from soft particles and reduce viscosity. By preparing samples in advance with the correct dilution ratio, the system ensures that subsequent automated particle counting produces accurate results without co-incidence errors.
3Measurement precision
If standardized testing protocols like ASTM-D7647 are adopted, then measurement precision improves, but device complexity increases due to required dilution procedures
Solution Approach 1:
The patent implements a multi-functional apparatus that can handle multiple samples simultaneously, perform dilution calculations, dispense diluent and sample, mix solutions, and present diluted samples for particle counting. This universal device consolidates multiple functions into one system, making standardized protocols easier to implement without proportionally increasing complexity.
Solution Approach 2:
The apparatus is divided into distinct functional modules: a diluent reservoir, a sample presentation tray for holding multiple samples, automated dispensing systems with peristaltic pumps and syringes, and a particle counter. This segmentation allows each component to be optimized independently while working together to achieve precise measurements according to standardized protocols.
4Ease of manufacture
If manual sample preparation is used, then ease of manufacture is maintained, but productivity decreases due to labor-intensive processes
Solution Approach 1:
The patent enables continuous processing by implementing batch dilution of multiple samples in sequence without manual intervention between samples. The automated system maintains continuous useful action by programmatically processing one sample after another, eliminating idle time and manual setup between measurements, thereby significantly increasing productivity while keeping the apparatus construction straightforward.
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 apparatus enables accurate and efficient automated particle counting with reduced labor intensity, minimizing repetitive strain injuries and improving testing accuracy, while allowing for prompt and precise sample presentation, thus facilitating the adoption of standardized testing protocols on a larger scale.
Implementation Method 1
an automated particle counter that performs automated particle counts of the liquid samples and includes an ultrasonic measuring device for measuring a volume of the liquid in the sample containers
Data Source
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Figure 3A~3B
AI summary
The apparatus comprises a levelling mechanism having an upwardly directed reference surface adjustably mounted on a frame for supporting the base of liquid sample containers in substantially level orientation. The apparatus further comprises a container positioning member having a horizontally extending main body formed with a plurality of substantially vertical container- receiving sockets. These sockets are each open at their bottom ends, so as to allow the bases of liquid sample containers to project therethrough while held within the sockets adjacent their top rims. In this manner, when the container positioning member is placed down upon the levelling mechanism, the bases of the sample containers come to rest in contact with the reference surface. Such action levels the containers to facilitate accurate automated volume measurements of liquid samples within the containers to be taken, which accuracy, in turn, increases the accuracy of automated particle counts subsequently made with the liquid samples.