Wash Station Overflow Prevention Using Fill-Level Sensor
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Solution Overview
Problem
Conventional wash stations for pipetting needles in automated analysis devices are prone to overflow due to blocked drains or uncontrolled fill levels, which can cause damage to the analysis device.
Innovation Solution
A method utilizing a fill-level sensor on the pipetting needle to monitor the wash liquid level in the wash station, comparing it to predefined thresholds to prevent overflow by stopping wash liquid supply when the level exceeds a maximum threshold and ensuring sufficient cleaning by maintaining a minimum wash liquid level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wash station is provided for cleaning pipetting needle tips, then the pipetting needle can be cleaned effectively, but the wash station is prone to overflow due to blocked drains or uncontrolled fill levels
Solution Approach 1:
The fill-level sensor is positioned to detect the fill level before overflow occurs. The sensor triggers a stop signal to the wash liquid supply pump when the liquid reaches a predetermined safe level, preventing overflow before it happens. This preliminary detection and intervention resolves the contradiction by maintaining cleaning functionality while preventing the harmful overflow effect.
Solution Approach 2:
The system implements a feedback mechanism where the fill-level sensor continuously monitors the wash liquid level and provides real-time information to the control unit. When the liquid level approaches the overflow threshold, the control unit automatically stops the wash liquid supply pump. This closed-loop feedback system ensures reliable overflow prevention while maintaining effective cleaning operation.
2Quantity of substance
If the wash liquid supply is continuously maintained, then sufficient wash liquid is available for cleaning, but the wash station may overflow causing damage to the analysis device
Solution Approach 1:
The fill-level sensor is positioned to detect the fill level before overflow occurs. The sensor triggers a stop signal to the wash liquid supply pump when the liquid reaches a predetermined safe level, preventing overflow before it happens. This preliminary detection and intervention resolves the contradiction by maintaining cleaning functionality while preventing the harmful overflow effect.
Solution Approach 2:
The system applies preliminary anti-action by stopping the wash liquid supply pump before overflow can occur. The fill-level sensor detects when the liquid reaches a critical level and the control unit preemptively stops the supply, counteracting the potential harmful effect of overflow before it manifests. This ensures continuous wash liquid availability for cleaning while preventing damage.
3Reliability
If a fill-level sensor is added to monitor wash liquid level, then overflow can be prevented, but the device complexity increases
Solution Approach 1:
The fill-level sensor serves multiple functions: it monitors wash liquid level, triggers overflow prevention, and can potentially provide information for cleaning process optimization. By making the sensor multi-functional, the patent justifies the added complexity through enhanced reliability and additional operational benefits, resolving the contradiction between reliability improvement and device complexity.
Solution Approach 2:
The system implements self-service by having the fill-level sensor automatically detect critical levels and trigger the control unit to stop wash liquid supply without human intervention. This automated self-monitoring and self-protection mechanism reduces the need for complex manual monitoring systems while maintaining high reliability, effectively managing the complexity-reliability trade-off.
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 method effectively identifies potential overflows and ensures adequate wash liquid levels, preventing damage to the analysis device and ensuring proper cleaning of pipetting needle tips without requiring structural modifications to the analysis device.
Implementation Method 1
The fill level can be determined continuously from the change in the electric capacitance between the pipetting needle and the reference electrode
Implementation Method 2
In the case of immersion, the light is refracted by the liquid and it no longer reaches the light sensor, or it only reaches the latter in attenuated form. The fill level can be determined from the attenuation of the light signal
Data Source
AI summary
The present invention lies in the field of automated analysis devices and relates to a method for monitoring the functionality of a wash station (1) for pipetting needles (2).