Sensor Threshold Tuning for Drug Delivery Devices
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Solution Overview
Problem
Drug delivery devices face challenges in ensuring consistent and accurate dosing due to natural variations in sensors and components, leading to inconsistent operation and potential errors in medicament delivery.
Innovation Solution
A method and manufacturing setup rig for tuning sensor thresholds in drug delivery devices by calibrating a reference sensor and converting the setting into a threshold factor, which is then used to calculate and program the thresholds for production devices, thereby accounting for manufacturing tolerances and device characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If each sensor of each single production device is calibrated individually, then measurement precision and reliability are improved, but manufacturing time and complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-calibrating a reference sensor during manufacturing setup to establish a threshold factor. This reference calibration is performed once before production, and the resulting threshold factor is then used to tune all production sensors without requiring individual calibration of each device. This resolves the contradiction by preparing the calibration reference in advance, enabling rapid production while maintaining measurement precision.
Solution Approach 2:
The patent uses copying by creating a threshold factor from a reference sensor calibration and applying this copied calibration parameter to all production sensors. Instead of repeating the full calibration process for each sensor, the threshold factor derived from the reference sensor is copied and applied universally, significantly reducing manufacturing time while maintaining consistent measurement accuracy across all devices.
2Reliability
If individual sensor calibration is performed for each device, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies parameter changes by transforming the individual sensor calibration process into a parameter-based tuning approach. A threshold factor parameter is derived from reference sensor calibration and applied to all production sensors. This changes the calibration approach from individualized complex procedures to a standardized parameter application process, reducing complexity while maintaining reliability through consistent parameter usage across all devices.
3Ease of manufacture
If natural variations in sensors are not accounted for, then manufacturing simplicity is maintained, but measurement precision and dosing accuracy deteriorate
Solution Approach 1:
The patent introduces an intermediary element - the threshold factor - that mediates between the reference sensor calibration and production sensor tuning. This threshold factor accounts for natural variations in sensors by serving as a calibration bridge. It allows manufacturing to remain simple through standardized application while compensating for sensor variations, thus maintaining both ease of manufacture and measurement precision.
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
This approach ensures consistent and accurate operation of sensors across production devices, reducing errors and improving the reliability of medicament delivery by efficiently tuning thresholds rather than recalibrating each device individually.
Implementation Method 1
a sensor arrangement configured to detect movement of a movable dosage programming component of the injection device relative to the data collection device during delivery of a medicament, and a processor arrangement configured to, based on said detected movement, determine a medicament dosage administered by the injection device. The sensor arrangement may include an optical sensor, for example, an optical encoder unit, particularly including a light source, such as a light emitting diode (LED) and a light detector, such as an optical transducer.
Data Source
AI summary
A method for tuning of at least one threshold of a sensor of a drug delivery device or of a drug delivery add-on device is disclosed. wherein the drug delivery device comprises a movable dosage programming component and the sensor is provided and configured to detect movement of the movable dosage programming component relative to the sensor during dosing of a drug by comparing an output signal of the sensor with at least one threshold, and wherein the method comprises the following steps: calibrating a manufacturing setup rig for sensors of drug delivery devices or drug delivery add-on devices by determining a setting of a threshold for a reference sensor by means of a reference movable dosage programming component and an electronic system configured for processing a signal generated by the reference sensor upon movement of the reference movable dosage programming component and converting the determined setting into a threshold factor; and tuning a threshold of a sensor of a production drug delivery device or of a production drug delivery add-on device by collecting data of the output signal of the sensor by sampling the moving reference movable dosage programming component and calculating at least one threshold based on the collected data using the threshold factor and programming a further electronic system configured for usage with the sensor with the calculated at least one threshold.