Automation Tube Positioning via Carrier Characterization
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Solution Overview
Problem
Conventional automation systems for in vitro diagnostics face challenges in precisely positioning sample tubes due to manufacturing tolerances and variability, leading to inconsistent alignment with instruments like pipettes, which affects the accuracy of sample handling and processing.
Innovation Solution
The implementation of intelligent carriers with characterization stations that measure and adjust for physical deviations in sample vessel positions, allowing for precise alignment by calculating and applying offsets to ensure accurate positioning relative to processing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard stops are used to position carriers, then positioning repeatability is improved, but manufacturing tolerances between carriers cause variation in sample location relative to instruments
Solution Approach 1:
The system performs preliminary characterization of each carrier's actual geometry and sample position offset before use. This advance measurement and storage of carrier-specific parameters allows the control system to pre-calculate compensation values, eliminating the need for mechanical precision in carrier manufacturing while ensuring accurate sample positioning at instruments.
Solution Approach 2:
The system implements feedback by measuring the actual position of samples on carriers using imaging or sensing systems, comparing these measurements to ideal positions, and using the derived offset information to adjust carrier stopping positions or instrument positioning dynamically, thereby compensating for manufacturing variations.
2Manufacturing precision
If self-centering springs are used to position tubes, then tube centering is improved, but the mechanism is expensive and has limited tube size range
Solution Approach 1:
The system replaces complex mechanical self-centering spring mechanisms with a characterization-based approach using imaging systems or sensors to detect tube position and control systems to calculate and apply digital offsets. This substitution eliminates the need for expensive precision mechanical components while accommodating a wider range of tube sizes through software-based adaptation.
3Device complexity
If passive carriers are used on friction tracks, then system simplicity is improved, but positioning precision is insufficient for precise sample alignment
Solution Approach 1:
The system enables carriers to effectively self-correct their positioning by characterizing each carrier's unique geometry and sample position offsets, then using this information to dynamically adjust stopping positions or instrument alignment. This self-characterization approach maintains simple passive carrier design while achieving precise sample alignment through intelligent control.
Data Source
AI summary
Methods and systems allow characterization of sample vessels and carriers in an automation system to determine any physical deviation from nominal positions. In response, an offset can be calculated and applied when positioning a carrier relative to a station, such as a testing or processing stations (or vice-versa). This may allow for precise operation of an instrument with a sample vessel on an automation track, while compensating for deviation in manufacturing and other tolerances.