Sample Tube Decapper with Motor-Driven Latch and Adaptive Grippers
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Solution Overview
Problem
Existing automated systems for removing caps from sample tubes are complex, require additional cleaning operations, and often cannot accommodate varying sample tube heights and cap sizes.
Innovation Solution
A decapping device with a motor-driven latch mechanism and grippers that can adapt to varying tube and cap sizes, using a single motor to perform multi-stage decapping operations, including gripping, cap removal, and ejection, without requiring pre-configuration or additional cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated sample processing systems are implemented to improve productivity, then sample processing speed increases, but the risk of sample contamination increases due to additional handling steps
Solution Approach 1:
The system divides the sample processing workflow into distinct automated segments: the decapper automatically removes caps, the transfer mechanism moves samples, and the vial holder positions them. This segmentation eliminates manual handling steps that cause contamination while maintaining high throughput.
Solution Approach 2:
The patent introduces an automated decapping mechanism as an intermediary device between the sample source and the analysis instrument. This intermediary performs the decapping function without human contact, thereby preventing contamination while enabling automated processing.
2Object-affected harmful factors
If manual decapping is performed to maintain sample integrity, then contamination risk is reduced, but processing time increases and productivity decreases
Solution Approach 1:
The automated decapping system performs the decapping operation autonomously without requiring operator intervention. The mechanism inserts, actuates, and removes the cap automatically, enabling continuous high-speed processing while maintaining sample integrity through contamination-free operation.
Solution Approach 2:
The patent replaces the manual mechanical action of hand-decapping with an automated mechanical decapping mechanism. This substitution eliminates the time-consuming manual process while preventing contamination through contactless or minimized-contact operation.
3Productivity
If frequent cap removal and replacement is performed during sample processing, then sample analysis can proceed, but cap loss and misplacement occur reducing reliability
Solution Approach 1:
The decapped samples are transferred into a vial holder that nests multiple vials in an organized array. This nesting structure keeps caps securely associated with their corresponding vials, preventing loss and misplacement while enabling efficient batch processing of multiple samples.
Solution Approach 2:
The system incorporates a cap detection mechanism that monitors whether caps are properly in place before and after processing. This feedback system alerts operators to any cap loss or misplacement, ensuring high reliability in sample management during automated processing.
Data Source
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AI summary
A decapping device may be integrated with an automated biochemical analyzer or biological testing system to aid in sample testing. The exemplary decapper, includes a motor that is operable to lower a latch mechanism to engage with a cap of a sample tube and then raise the latch mechanism to remove the engaged cap. As the latch mechanism is lowered, a retractor portion also descends and causes a set of grippers to extend and grip the sample tube. As the latch mechanism is raised, the set of grippers apply a corresponding pressure to hold the sample tube in place while the cap is removed. Once removed, the cap rests within the latch mechanism and the set of grippers are retracted by the raising retractor. As the latch mechanism returns to its origin position, an ejector arm is operated causing the cap to be ejected from the latch mechanism.