Sample Tube Nozzle Alignment Using Slit Edge Calibration
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Solution Overview
Problem
Existing sample collection apparatuses face issues with nozzle misalignment due to pulse motor malfunctions, requiring manual adjustment and reducing operational accuracy, which complicates production and installation.
Innovation Solution
A sample collection apparatus with a slit plate and photo-interrupter system that guides the nozzle to a precise position, using a pulse motor to move the nozzle horizontally, and a controller to adjust the nozzle's movement based on edge signals from the slit plate, allowing for automated alignment without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment and calibration are performed to ensure accurate nozzle positioning, then positioning accuracy is improved, but production and installation costs increase and more manpower is required
Solution Approach 1:
The system performs self-calibration by automatically detecting the relationship between the nozzle position and the sample tube insertion opening position during operation. The control unit stores the detected positional relationship and uses it for automatic positioning, eliminating the need for manual adjustment and calibration by operators.
Solution Approach 2:
The system performs preliminary calibration by detecting and storing the positional relationship between the nozzle and sample tube insertion opening before actual sample collection operations begin. This preliminary detection creates a reference framework that enables accurate positioning without manual intervention during subsequent operations.
2Manufacturing precision
If manual adjustment and calibration are performed to ensure accurate nozzle positioning, then positioning accuracy is improved, but installation time and complexity increase
Solution Approach 1:
The system performs self-calibration by automatically detecting the relationship between the nozzle position and the sample tube insertion opening position during operation. The control unit stores the detected positional relationship and uses it for automatic positioning, eliminating the need for manual adjustment and calibration by operators.
3Device complexity
If design limitations and mechanical variations are not accounted for, then device complexity is reduced, but operational errors increase
Solution Approach 1:
The system uses optical sensors to detect the actual position of the nozzle relative to the sample tube insertion opening and provides feedback to the control unit. The control unit adjusts the nozzle position based on this feedback to ensure accurate alignment, compensating for mechanical variations and design tolerances.
Solution Approach 2:
The system performs preliminary calibration by detecting and storing the positional relationship between the nozzle and sample tube insertion opening before actual sample collection operations begin. This preliminary detection creates a reference framework that enables accurate positioning without manual intervention during subsequent operations.
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
Ensures accurate and automated nozzle positioning, simplifying production and installation by eliminating the need for manual adjustments, thereby enhancing operational reliability and efficiency.
Implementation Method 1
a photo-interrupter that moves in conjunction with the nozzle unit to recognize the slits
Data Source
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AI summary
A method of producing a sample collection apparatus (40), including steps of: attaching a holding member (80) to a support (70) of a nozzle unit (60) such that, in slits (72) provided with N edges (N ≥ 3), a collection range (11B) w of a sample tube (11) is included within a range from a lower-limit position (94) at a distance w/2 from a 1st edge (73a) toward an initial-position (90), to an upper-limit position (96) at a distance w/2 from an Nth edge away from the initial position (90); loading the sample tube (11) on the holding member (80); counting the number of pulses with which a pulse motor (50) is driven to move a nozzle (61) to the center of the collection range (11B); identifying the signal corresponding to the last edge recognized by a photo-interrupter (62) before the nozzle (61) reaches the center of the collection range (11B); and storing the number of pulses and the signal corresponding to the last edge in a storage device (150).