Working Wire Coating Feedback Control for Thickness Accuracy
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Solution Overview
Problem
The high cost and inefficiency of manufacturing working wires for continuous glucose monitors, coupled with the need for precise manufacturing to ensure accurate results, hinder widespread adoption of these devices among patients who could benefit from continuous glucose monitoring.
Innovation Solution
An automated system measures working wire dimensions during the dipping process and adjusts parameters in real-time to optimize the coating thickness, using environmental and solution factors to minimize the number of dips required, thereby improving accuracy and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for working wires, then manufacturing cost and time are reduced, but manufacturing precision and accuracy of results deteriorate
Solution Approach 1:
The patent implements real-time feedback control by measuring the coating thickness during the dipping process and automatically adjusting dipping parameters based on the measured values. This closed-loop system ensures manufacturing precision while maintaining productivity through automated control.
Solution Approach 2:
The patent performs preliminary measurements and adjustments during the dipping process itself, rather than after completion. By measuring coating thickness in real-time and adjusting parameters before the dipping process finishes, the system prevents defects rather than correcting them later, improving both precision and efficiency.
2Productivity
If multiple manual process steps are used for coating, then manufacturing precision can be maintained, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces manual mechanical operations with an automated system that controls the dipping process. The automated system adjusts dipping parameters based on real-time measurements, eliminating manual intervention while maintaining or improving coating uniformity through precise electronic control.
Solution Approach 2:
The patent dynamically changes dipping parameters such as dipping speed, withdrawal speed, and immersion depth based on real-time coating thickness measurements. This adaptive parameter adjustment ensures uniform coating quality while optimizing the manufacturing process for higher productivity.
3Manufacturing precision
If real-time measurement and adjustment is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single automated system that performs dipping, real-time measurement, and parameter adjustment simultaneously. This multi-functional approach reduces the need for separate manual operations and equipment, managing device complexity while improving 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 reduces manufacturing costs and defects, enhances the efficiency of producing working wires for continuous glucose monitors, and improves the accuracy of glucose level measurements.
Implementation Method 1
A plurality of diameters is measured, as an in-line process of the overall dipping process, along a length of at least two coated wires of the plurality of wires in the fixture, using an automated measurement system
Implementation Method 2
dipping the plurality of wires into a coating solution according to parameters for a dipping process
Data Source
AI summary
Systems for manufacturing a working wire for a continuous biological sensor include an automated measurement system configured to measure, as an in-line process with a dipping station, a plurality of diameters along a length of a working wire. Systems also include a controller in communication with the automated measurement system, wherein the controller is configured to determine a thickness difference, the thickness difference being a difference between a thickness setpoint and an aggregate criteria for the plurality of diameters. The systems may include the dipping station, that is configured to hold a coating solution, and may include a robot positioned to move the fixture to the automated measurement system.