Automated Sample Testing System With Parallel Empty Rack Transport Line
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Solution Overview
Problem
Conventional automated sample testing systems face challenges in processing large numbers of samples efficiently due to complexity, size, and complications in transport control, particularly when trying to maintain high-speed processing without increasing system size and avoiding transport line intersections.
Innovation Solution
The system employs a configuration with separate transport lines for sample racks and empty racks, using a main transport line, a fast emergency line, and reverse line, along with parallel empty rack transport lines to optimize the number of racks and prevent line crossings, allowing for efficient supply and collection of empty racks without increasing system size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of sample racks are prepared and stored in the system to process hundreds to thousands of samples, then the system can handle high sample volume, but the system size becomes large and requires significant installation space
Solution Approach 1:
The patent transitions from horizontal stacking of multiple sample racks to vertical stacking using a single tall sample rack. The rack height is increased to accommodate multiple levels of sample slots, effectively utilizing the vertical dimension to store a large number of samples without expanding the horizontal footprint of the system.
Solution Approach 2:
The patent implements a nested structure where multiple sample slots are arranged vertically within a single sample rack frame. Each level of the rack contains sample slots, and these levels are stacked one above another, creating a nested configuration that maximizes storage capacity within a compact vertical space.
2Device complexity
If empty sample racks and sample racks holding samples share the same transport line, then the system uses fewer transport lines, but the transport line becomes congested and processing speed decreases
Solution Approach 1:
The patent divides the transport system into two separate transport lines: one dedicated to transporting sample racks containing samples, and another dedicated to transporting empty sample racks. This segmentation prevents mixing of different rack types on the same line, eliminating congestion and allowing each line to operate efficiently at high speed.
3Productivity
If separate transport lines are used for sample racks and empty racks to maintain high-speed processing, then processing speed is maintained, but the system becomes more complicated and control becomes difficult
Solution Approach 1:
The system automatically determines whether a sample rack contains samples or is empty by reading barcode information, and automatically directs the rack to the appropriate transport line without requiring manual intervention or complex control logic. The rack itself carries the information needed for its own routing, simplifying the control system.
4Productivity
If multiple sample racks are loaded in advance into the system to enable batch processing, then processing efficiency is improved, but an operator is required to replenish a large number of sample racks
Solution Approach 1:
The patent designs a universal sample rack that can be repeatedly used after empty racks are collected and returned to the loading area. The same rack structure serves multiple cycles of sample transport, and the system automatically manages the rack lifecycle, eliminating the need for operators to handle and replenish large numbers of racks.
Data Source
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AI summary
When a sample rack loops in a system and is used many times in order to avoid an increase in the size system and complicating the system, a processing speed is reduced due to an intersection of transport lines. In order to avoid the intersection, a complicated mechanism such as an elevator mechanism or a robot hand mechanism is required. An empty rack transport line is arranged at a lower stage and independent of a main transport line, a fast emergency line and a reverse line. In a rack stocker, an inclined transport line connects the empty rack transport line to the rack stocker. The rack stocker is arranged between a storage module and a loading module. The rack stocker is capable of continuously supplying and collecting empty racks, while transport lines do not cross each other. It is, therefore, possible to continuously supply and collect empty racks in a simple configuration, without an increase in the size system, an intersection of transport lines and a reduction in processing capability. In addition, it is possible to provide an automated sample testing system that is highly extendable for a facility size.