Ultrasonic Sensor Consumable Detection for Clinical Analyzer
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Solution Overview
Problem
Modern automated clinical analyzers face issues with consumables being misplaced or missing due to human error during manual preloading, leading to interruptions and inefficiencies in fluid processing, particularly in high-throughput systems where frequent preloading is required.
Innovation Solution
A system utilizing ultrasonic sensors and a programmable control computer to determine the presence and correct positioning of consumables in a processing area, ensuring reliable fluid processing by generating control signals for the ultrasonic sensors and displaying user-guided messages for loading errors, thereby preventing interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual preloading of consumables is performed, then the system can be operated with simple loading procedures, but human error causes consumables to be misplaced or missing leading to run interruptions
Solution Approach 1:
The patent replaces manual visual inspection and mechanical positioning with an optical detection system. A sensor array scans the processing area to automatically detect the presence and position of consumables, substituting human mechanical operations with automated optical sensing to eliminate positioning errors while maintaining simple loading procedures.
Solution Approach 2:
The system implements feedback by continuously monitoring consumable positions using the sensor array and comparing detected positions against the process operation plan. When mismatches are detected, the system provides feedback signals to alert operators and can automatically adjust operations to prevent run interruptions, creating a closed-loop control system that maintains reliability.
2Reliability
If automated preloading is implemented to eliminate human error, then consumable positioning accuracy improves, but the risk of dropping or misplacing objects due to misalignment errors persists
Solution Approach 1:
The patent applies preliminary action by performing detection of consumable positions before the automated preloading operation begins. The sensor array scans and verifies the correct placement of consumables in advance, allowing the system to detect and correct positioning errors before they cause dropping or misplacement during the actual loading process.
Solution Approach 2:
The patent introduces an intermediary detection system between the automated preloading mechanism and the consumables. The sensor array acts as an intermediary that verifies positions and provides real-time monitoring, mediating between the mechanical loading system and the consumables to prevent dropping errors without requiring direct complex interaction between the loader and each consumable.
3Productivity
If frequent preloading operations are performed to meet high sample throughput demands, then productivity increases, but the probability of missing or misplaced consumables increases
Solution Approach 1:
The patent ensures continuity of useful action by implementing continuous monitoring of consumable positions throughout the high-throughput processing operations. The sensor array operates continuously during frequent preloading cycles, detecting and alerting to positioning errors in real-time, ensuring that the increased loading frequency does not compromise processing continuity through missed or misplaced consumables.
Solution Approach 2:
The system applies self-service by automatically detecting and identifying positioning errors without requiring external intervention during high-speed operations. The sensor array autonomously monitors consumable positions and can trigger automatic corrections or alerts, allowing the system to maintain reliability during frequent preloading operations without adding manual verification steps that would reduce productivity.
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
The system ensures highly reliable automated processing of fluids by accurately determining the presence and correct positioning of consumables, reducing errors and maintaining continuous operation, even in high-consumption environments, thus enhancing sample throughput and reducing the need for fluid sample discarding.
Implementation Method 1
at least one ultrasonic sensor, adapted for determining the presence of objects in said processing area by means of acoustic waves
Data Source
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AI summary
The present invention pertains to a system for the automated processing of fluids according to a process operation plan involving the use of preloaded objects, said process operation plan defining preloaded objects to be present in target object positions, said system comprising: a processing area in which objects to be used for the processing of fluids are located; at least one ultrasonic sensor, adapted for determining the presence of objects by means of acoustical waves; a positioning device to which the ultrasonic sensor is fixed, adapted to move the ultrasonic sensor in at least one direction relative to said processing area; a control computer being configured to determine the presence of objects and determining if objects are present in target object positions in said processing area as defined by said process operation plan; a pipetting device for pipetting of fluids between cavities located in said processing area; an analytical or pre-analytical processing device for processing of fluids located in said processing area.