Sample Processing Apparatus Interrupt Control for Reliability
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Solution Overview
Problem
Existing sample processing apparatuses face long suspension times when abnormalities occur, as they cannot resume processes for samples that were temporarily stopped until all optical measurement operations are finished for other samples, leading to inefficiencies and resource wastage.
Innovation Solution
A sample processing apparatus and method that includes a controller to interrupt and retry operations for samples that have not reached the faulty unit, allowing for resumed processing when the operation is successful, while continuing processes for samples that have already passed the unit, thereby minimizing downtime and resource wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the automatic analyzer stops all parts except optical measurement operations when an abnormality occurs, then the reliability of measurement operations is maintained, but the productivity of sample processing deteriorates due to long suspension time
Solution Approach 1:
The automatic analyzer is divided into multiple independent functional units (sample introduction unit, reagent addition unit, mixing unit, optical measurement unit, etc.). When an abnormality occurs in one unit, only that specific unit is stopped while other units continue to process samples that have already passed the faulty unit, thereby maintaining overall productivity while ensuring measurement reliability.
Solution Approach 2:
The system dynamically adjusts the operation state of different units based on the location and nature of the abnormality. Samples that have already passed the faulty unit are allowed to continue through the remaining process steps, while samples upstream of the abnormality are stopped. This dynamic control minimizes suspension time and maintains productivity.
2Reliability
If all parts are stopped until optical measurement operations are finished for all samples, then the reliability of the system is maintained, but the loss of time increases due to extended suspension period
Solution Approach 1:
The system identifies and stops processing for samples upstream of the abnormality before they reach the faulty unit, while allowing samples that have already passed the faulty unit to complete their processing. This preliminary differentiation of sample states reduces the overall suspension time while maintaining system reliability.
Solution Approach 2:
The system maintains continuous processing for samples that can still be processed (those downstream of the abnormality) while interrupting only the necessary samples upstream of the fault. This continuity principle ensures that useful actions are not unnecessarily interrupted, minimizing time loss.
3Manufacturing precision
If the process is interrupted for all samples when an abnormality occurs, then the manufacturing precision of sample processing is maintained, but the productivity deteriorates due to complete stoppage
Solution Approach 1:
The system applies different quality control measures to different samples based on their position relative to the abnormality. Samples upstream of the faulty unit are stopped to maintain processing precision, while samples downstream are allowed to continue, applying local quality control rather than universal stoppage.
Solution Approach 2:
The sample processing stream is segmented into two groups: samples upstream of the abnormality (stopped) and samples downstream of the abnormality (continued). This segmentation allows precision maintenance for affected samples while preserving productivity through continued processing of unaffected samples.
Data Source
AI summary
A sample processing apparatus for performing a process including a plurality of steps on a sample, the sample processing apparatus sequentially processing a plurality of samples, is disclosed. The apparatus comprises a plurality of units corresponding to the respective steps in the process; a transfer section which transfers a sample to the units according to a flow of the steps; and a controller. Specifically, when an operation was not performed successfully, the controller interrupts the process for a sample that had not reached the location where the unsuccessful operation was performed while continuing the process for a sample that had already passed the location, retries the operation that was not performed successfully, and resumes the interrupted process when the retried operation has been performed successfully.