Patent Description:
Medical patients often have diseases or conditions that require the measurement and reporting of biological conditions. For example, if a patient has diabetes, it is important that the patient have an accurate understanding of the level of glucose in their system. Traditionally, diabetes patients have monitored their glucose levels by sticking their finger with a small lance, allowing a drop of blood to form, and then dipping a test strip into the blood. The test strip is positioned in a handheld monitor that performs an analysis on the blood and visually reports the measured glucose level to the patient. Based upon this reported level, the patient makes important decisions on what food to consume, or how much insulin to inject. Although it would be advantageous for the patient to check glucose levels many times throughout the day, many patients fail to adequately monitor their glucose levels due to the pain and inconvenience. As a result, the patient may eat improperly or inject either too much or too little insulin. Either way, the patient has a reduced quality of life and increased chance of doing permanent damage to their health and body. Diabetes is a devastating disease that if not properly controlled can lead to detrimental physiological conditions such as kidney failure, skin ulcers, bleeding in the eyes and eventually blindness, and pain and the eventual amputation of limbs.

Blood glucose levels can significantly rise or lower quickly due to various causes, which can further complicate glucose monitoring. Accordingly, a single glucose measurement provides only a snapshot of the instantaneous level in a patient's body. Such a single measurement provides little information about how the patient's use of glucose is changing over time, or how the patient reacts to specific dosages of insulin. Even a patient that is adhering to a strict schedule of strip testing will likely be making incorrect decisions as to diet, exercise, and insulin injection. This is exacerbated by a patient that is less consistent on their strip testing. To give the patient a more complete understanding of their diabetic condition and to get a better therapeutic result, some diabetic patients are now using continuous glucose monitoring.

Monitoring of glucose levels is critical for diabetes patients. Continuous glucose monitoring (CGM) sensors are a type of device in which glucose is measured from fluid sampled in an area just under the skin multiple times a day. CGM devices typically involve a small housing in which the electronics are located, and which is adhered to the patient's skin to be worn for a period of time. A small needle within the device delivers the subcutaneous sensor which is often electrochemical. Depending upon the patient's condition, continuous glucose monitoring may be performed at different intervals. For example, some continuous glucose monitors may be set to take multiple readings per minute, whereas in other cases the continuous glucose monitor can be set to take readings every hour or so.

Electrochemical glucose sensors operate by using electrodes which typically detect an amperometric signal caused by oxidation of enzymes during conversion of glucose to gluconolactone. The amperometric signal can then be correlated to a glucose concentration. Two-electrode (also referred to as two-pole) designs use a working electrode and a reference electrode, where the reference electrode provides a reference against which the working electrode is biased. The reference electrodes effectively complete the electron flow in the electrochemical circuit. Three-electrode (or three-pole) designs have a working electrode, a reference electrode, and a counter electrode. The counter electrode replenishes ionic loss at the reference electrode and is part of the ionic circuit.

Unfortunately, the cost of using a continuous glucose monitor can be prohibitive for many patients who could benefit greatly from its use. A continuous glucose monitor has two main components. First, there is a housing for the electronics, processor, memory, wireless communication, and power. The housing is typically reusable over extended periods of time, such as months. This housing then connects or communicates to a disposable CGM sensor that is adhered to the patient's body, which typically uses an introducer needle to subcutaneously insert the sensor into the patient. This sensor must be replaced, sometimes as often as every three days, and likely at least once every other week. Thus, the cost to purchase new disposable sensors represents a significant financial burden to patients and insurance companies. Because of this, a substantial number of patients who could benefit from continuous glucose monitoring are not able to use such systems and are forced to rely on the less reliable finger stick monitoring. The working wires are conventionally time consuming to make due to the number of process steps involved and that they must be precisely manufactured to produce accurate results. Accordingly, a new way of efficiently manufacturing working wires is needed. Document <CIT> discloses a semi automatic coating controlling machine which has automatic film feeding system that is provided with a vertical base plate which is provided with a vertical plate for coating needles or pins.

In some embodiments, an apparatus for coating a working wire of a sensor includes a carousel, a robotic arm, and an optical scanner. The carousel includes a first platform, a second platform, and a ring dipping tool. The first platform has a central axis, the first platform supporting a plurality of stations, all arranged around the central axis. The second platform is positioned above the first platform, with a platform actuator that raises, lowers, and rotates the second platform with respect to the first platform. The ring dipping tool is coupled to an edge of the second platform, the ring dipping tool being oriented vertically with respect to ground, and extending toward the first platform. The robotic arm is configured to transport a fixture to the carousel, the fixture being configured to hold the working wire. The optical scanner is positioned near a wire dipping station of the plurality of stations and configured to scan a position of the working wire and a location of the ring dipping tool.

In some embodiments, an apparatus for coating a working wire of a sensor, includes a ring dipping tool having a ring and a shaft, the shaft is oriented vertically with respect to ground. A robotic arm is configured to transport the working wire. An optical scanner is in communication with the robotic arm and configured to scan a position of the working wire and a location of the ring dipping tool. A wire dipping station has a container configured to hold a coating solution, and a coating station actuator is configured to move the ring dipping tool into the container. The robotic arm uses the position of the working wire and the location of the ring dipping tool to insert the working wire through the ring of the ring dipping tool.

Embodiments disclose systems and processes for manufacturing working wires for sensor, such as a continuous biological sensor, where the embodiments reduce cost and improve accuracy and efficiency compared to known art. The continuous biological sensor may be, for example, a continuous glucose monitor, in which the working wire includes an enzyme layer to detect the level of glucose in a patient's blood. In other embodiments, the biological sensor can be a metabolic sensor for measuring other metabolic characteristics such as ketones, lactates or fatty acids. The sensor uses a working wire (i.e., electrode for the sensor) that has a core and several concentrically formed membrane layers.

In some embodiments, a coating system uses ring dipping for coating working wires. The ring dipping involves holding the working wire horizontally and inserting it through a ring of a dipping tool, where the ring is oriented vertically. The coating system includes multiple stations mounted in a carousel, beneficially enabling the ring dipping to be performed continuously in an automated manner and enabling multiple working wires to be processed in an efficient manner. The stations can include a wire dipping station and various stations for the ring dipping tool, such as a cleaning station, a drying station, and a coating station to reapply coating solution to the tool. The coating system uniquely includes an optical scanner that scans the position of the working wire and the ring dipping tool such that the working wire can accurately be inserted through the ring. Embodiments include an automated measurement tool that measures layer thicknesses of coatings on the working wires after each dip. The measurements are used as feedback for the coating system to adjust dipping parameters such as insertion and withdrawal speed of the working wire through the ring dipping tool, and/or an amount of coating film to be placed on the ring dipping tool. The coating system may be configured to enable multiple fixtures to be processed in parallel, where each fixture has one or more working wires.

The coating systems and methods of the present disclosure provide improved accuracy and increased throughput compared to conventional techniques. In some aspects, the automated system measures dimensions of working wires while they are progressing through a dipping process and uses the measurements to adjust dipping parameters in real-time. The measurement system can take multiple measurements along a length of the working wires and can also measure multiples wires that are mounted in a fixture. By providing thorough monitoring of coating thicknesses and by doing so in real-time, more efficient and accurate dip coating of working wires is achieved compared to conventional methods. The systems and methods may optimize the manufacturing process, such as by reducing (e.g., minimizing) the number of dips required to achieve a desired coating thickness. In other aspects, scanning of the working wire position and ring dipping tool enables the robotic arm to account for positional variances that may occur from wire to wire and/or for non-straightness of an individual wire (e.g., a wire sagging toward its end that is not held by the fixture). The scanning thus improves the accuracy in centering the wire as it is being moved through the ring dipping tool.

Embodiments may also include an environmental chamber for housing the coating system, where the chamber provides highly accurate environmental conditions throughout the chamber. The chamber includes individually controlled fans that can adjust airflow based on humidity sensor feedback from a local region in the chamber. A recirculation path within the chamber along with customizable vent plates enable uniform air flow to be created in the chamber. Ports for dry gas and ambient air are provided, where valves are adjusted based on feedback from humidity sensors to enable relative humidity levels in the chamber to be controlled in a highly accurate manner.

Referring to <FIG>, a cross-sectional view of a working wire <NUM> is illustrated in accordance with some embodiments. In this example, the working wire <NUM> is an elongated wire having a circular cross-section. It will be understood that other cross-sections may be used, such as square, rectangular, triangular, or other geometric shapes. Furthermore, the working wire <NUM> may take other forms, such as a plate or ribbon. The working wire may be used as a working electrode of a continuous biological sensor, such as a working electrode of a continuous glucose monitor.

In the illustrated example, the working wire <NUM> has a substrate <NUM> onto which biological membranes <NUM> may be disposed. The types of biological membranes that may be manufactured by the present methods and systems will not be described herein, but may include biological membranes that are well-known and other types of coating layers on working wires for biological sensors. In one example as illustrated, the biological membranes <NUM> include an interference membrane <NUM> (which may also be referred to as an interference layer) on the substrate <NUM>, an enzyme membrane <NUM> (i.e., enzyme layer) on the interference membrane <NUM>, and a glucose limiting membrane <NUM> (i.e., glucose limiting layer) on the enzyme membrane <NUM>. In some embodiments, a protective or outer coating may be optionally applied over the glucose limiting membrane <NUM>. Although the working wire <NUM> is illustrated as having three membranes <NUM>, it will be understood that the membranes <NUM> may be more or fewer in number.

The substrate <NUM> may be comprised of a core <NUM> with an outer layer <NUM>. In the example of <FIG>, the core <NUM> is an elongated wire that is dense, ductile, very hard, easily fabricated, highly conductive of heat and electricity, and may also be resistant to corrosion. Example materials for core <NUM> include tantalum, carbon, or Co-Cr alloys. The core <NUM> may have the outer layer <NUM>, such as of platinum, deposited or applied using an electroplating process. It will be understood that other processes may be used for applying the outer layer <NUM> to the core <NUM>. For a glucose monitor, the platinum outer layer <NUM> facilitates a reaction where the hydrogen peroxide reacts to produce water and hydrogen ions, and two electrons are generated. The electrons are drawn into the platinum by a bias voltage placed across the platinum wire and a reference electrode. In this way, the magnitude of the electrical current flowing in the platinum is intended to be related to the number of hydrogen peroxide reactions, which in turn is proportional to the number of glucose molecules oxidized. A measurement of the electrical current on the platinum wire can thereby be associated with a particular level of glucose in the patient's blood or interstitial fluid (ISF).

The core <NUM>, outer layer <NUM>, interference membrane <NUM>, and enzyme membrane <NUM> form key aspects of working wire <NUM>. Other layers and/or membranes may be added depending upon the biological substance being tested for, and application-specific requirements. In some cases, the core <NUM> may have an inner core portion (not shown). For example, if the substrate (core <NUM>) is made from tantalum, an inner core of titanium or titanium alloy may be included to provide additional strength and straightness.

In some cases, one or more membranes (i.e., layers) may be provided over the enzyme membrane <NUM>. For example, a glucose limiting membrane <NUM> may be layered on top of the enzyme membrane <NUM>. This glucose limiting membrane <NUM> may limit the number of glucose molecules that can pass through the glucose limiting membrane <NUM> and into the enzyme membrane <NUM>. The glucose limiting membrane <NUM> can be configured as described in <CIT>, entitled "Enhanced Glucose Limiting Membrane for a Working Electrode of a Continuous Biological Sensor," which is owned by the assignee of the present disclosure. In some cases, the addition of the glucose limiting membrane <NUM> has been shown to enable better performance of the overall working wire <NUM>.

An interference membrane <NUM> is applied over the outer layer <NUM>. The interference membrane <NUM> may be disposed between the enzyme membrane <NUM> and the outer layer <NUM>. This interference membrane <NUM> is constructed to fully wrap the outer layer <NUM>, thereby protecting the outer layer <NUM> from further oxidation effects. The interference membrane <NUM> is also constructed to substantially restrict the passage of larger molecules, such as acetaminophen, to reduce contaminants that can reach the platinum and skew results. Further, the interference membrane <NUM> may pass a controlled level of hydrogen peroxide (H<NUM>O<NUM>) from the enzyme membrane <NUM> to the platinum outer layer <NUM>. Compositions for the interference membrane <NUM> and enzyme membrane <NUM> may be as described in <CIT>, entitled "Working Wire for a Continuous Biological Sensor with an Immobilization Network," and <CIT>, entitled "In-Vivo Glucose Specific Sensor," which are owned by the assignee of the present disclosure.

<FIG> is a schematic of a dipping system, as known in the art. An isometric view of a dipping station <NUM> for one type of coating process known in the art is shown, where the parts (e.g., wires <NUM>) to be coated are lowered vertically into a tub <NUM> of coating solution <NUM>. Dipping station <NUM> is shown with a fixture <NUM> and the tub <NUM> with the coating solution <NUM>. One or more wires <NUM> may be mounted into the fixture <NUM>, where the fixture <NUM> is depicted as a block for simplicity. The fixture <NUM> is used for transporting the wires <NUM> through a dipping process during manufacturing. The fixture <NUM> may also be referred to as a holder or tray. Multiple dips in the coating solution <NUM> may be required to build up the number of layers for achieving a desired final thickness of the membrane on the wire <NUM>. In such cases, the wire <NUM> may be dipped to create one layer, then set aside to cure, and then the dipping is repeated to add the next layer.

<FIG> are front and side views, respectively, of another type of dipping process involving a ring dipping tool <NUM>, in accordance with some embodiments. Ring dipping tool <NUM>, which may also be referred to as a ring dipper or dipping tool, has a shaft <NUM> and a ring <NUM> at the end of the shaft <NUM>. The ring <NUM> (and often some of the shaft <NUM>) is immersed in a coating solution <NUM> (as shown in <FIG> and <FIG>, and similar to coating solution <NUM> in <FIG>) to form a film <NUM> of coating across the opening of the ring <NUM>. The part to be coated, such as the wire <NUM> in the embodiment of <FIG>, is inserted through the ring <NUM>. Conventionally, ring dipping is difficult to scale up for commercial manufacturing due to factors such as inconsistent coating film thickness across the ring or inconsistent coating film thickness from one dip to another, which results in inconsistent layers being formed on the part. For a working wire of a biological sensor, these inconsistencies can result in varying sensing properties, which ultimately affects the product performance. Consequently, ring dipping is conventionally not used at a large scale, and/or is used with coating materials having a uniform composition.

In embodiments of the present disclosure, the wires <NUM> may be positioned horizontally when undergoing ring dipping. As can be seen in <FIG>, gravity may cause the wire <NUM> to sag along its length (even if the wire is not horizontal), resulting in the wire <NUM> not being centered when inserted through the ring <NUM> if the wire <NUM> is moved in a straight path. Alternatively, the wire <NUM> itself may not be precisely straight. Either of these scenarios consequently can result in non-uniformities in the coating layer along the length of the wire <NUM> or can create defects if the wire <NUM> touches the ring <NUM> itself. Thus, ring dipping presents further technical challenges that are complex to handle, especially for small parts such as sensor wires <NUM> that are being inserted through rings <NUM> that can have openings of approximately <NUM> to <NUM> wide.

<FIG> show a ring dipping process, in accordance with some embodiments. <FIG> illustrate a type of coating where embodiments of the disclosure uniquely recognize that ring dipping with a horizontal orientation of the wire <NUM> is desirable. In <FIG>, a ring <NUM> is shown with the film <NUM> of the coating solution <NUM>. The ring <NUM> is a rounded square in this embodiment rather than being oval shaped as in <FIG>, demonstrating that different ring shapes can be used. The composition of the coating solution <NUM> in this embodiment is made of both hydrophobic and hydrophilic materials, resulting in a non-uniform composition. In the side view of the film <NUM> shown in <FIG>, the vertical orientation of the ring <NUM> results in hydrophobic regions <NUM> that sandwich a hydrophilic region <NUM> between them. This is due to the hydrophobic materials tending to rise relative to the hydrophilic materials. The hydrophobic regions <NUM> and the hydrophilic regions <NUM> form multiple layer interfaces on the wire <NUM> when the wire <NUM> is inserted into and withdrawn from the coating solution <NUM> during a single dip cycle, as shown in the side cross-sectional view of the wire <NUM> in <FIG>. Having more interfaces in the layers of a membrane of a continuous glucose monitor was found, in relation to the present disclosure, to impart beneficial properties. For example, having more of the hydrophobic-hydrophilic interfaces on the wire <NUM> resulted in a more stable drift profile for the sensitivity of the sensor. In addition, the greater number of interfaces was unexpectedly found to achieve the same sensitivity with less overall membrane thickness than a membrane with less interfaces but a thicker membrane. Achieving a target sensitivity with a thinner membrane beneficially enables the working wire <NUM> to be manufactured in less time than thicker membranes, consequently reducing cost and/or increasing throughput. The present disclosure describes systems and methods that overcome the challenges of ring dipping, particularly with an elongated wire <NUM> being dipped horizontally, to enable various types of compositions to be utilized at a commercially manufacturable scale.

<FIG> are isometric views of a coating system <NUM>, in accordance with some embodiments. Coating system <NUM> is an apparatus for coating a wire <NUM> of a sensor, and includes a carousel <NUM>, a robotic arm <NUM>, and a scanner such as an optical scanner <NUM>. For example, the wire <NUM> or wires <NUM> are work-in-progress ("WIP") wires <NUM> (as shown in <FIG> and <FIG>) being processed by the coating system <NUM>. The coating system <NUM> in this embodiment also includes a cassette area <NUM> having cassettes such as 520a, 520b, 520c. 520n, and a holding area <NUM> for storing or temporarily holding fixtures <NUM> (such as 530a, 530b, 530c, 530d) that have WIP wires <NUM>. A measurement station <NUM> can also be seen in <FIG>. The robotic arm <NUM> moves the fixtures <NUM> to various portions of the coating system <NUM>, such as between the cassette area <NUM>, holding area <NUM>, carousel <NUM>, optical scanner <NUM>, and measurement station <NUM>. The robotic arm <NUM> is configured to transport the fixture <NUM> (such as first fixture 530a) to the carousel <NUM>, the first fixture 530a being configured to hold one or more WIP wires <NUM>. The robotic arm <NUM> may be an articulating robot, such as a <NUM>-axis robot having articulated joints. The robotic arm <NUM> may be moved within the system by a linear stage actuator <NUM> (<FIG>). The system may include a controller <NUM> that controls the robotic arm <NUM> and carousel <NUM>. For example, the controller <NUM> may be configured to automatically and electronically move the robotic arm <NUM> and rotate the carousel <NUM> such that a plurality of WIP wires <NUM> can be processed by the carousel <NUM>, and multiple ring dipping tools <NUM> can be prepared and cleaned in parallel with each other.

The controller <NUM> may be a computer hardware processor (see processor <NUM> in <FIG>) that is separate from and connected to the coating system <NUM>, such as to the robotic arm <NUM>, either physically (e.g., hard-wired), or wirelessly. In other embodiments, the controller <NUM> may comprise one or more processors incorporated into the robotic arm <NUM> and/or other components of the coating system <NUM> such as the carousel <NUM>, optical scanner <NUM> and measurement station <NUM>. The WIP wires <NUM> being processed by the coating system <NUM> may have some or none of the membrane layers applied as the WIP wires <NUM> pass through a plurality of carousel stations <NUM> on the carousel <NUM>. For example, the WIP wires <NUM> may consist of only a substrate <NUM> or may have the substrate <NUM> and an enzyme membrane <NUM>, or may have the substrate <NUM>, an enzyme membrane <NUM> and an interference membrane <NUM>. The coating system <NUM> may apply one or more of the enzyme membrane <NUM>, the interference membrane <NUM>, and/or the glucose limiting membrane <NUM>, all of which may be efficiently and accurately applied through the dipping process.

The cassette area <NUM> serves as a rack for holding fixtures <NUM> containing the WIP wires <NUM>. In the illustrated embodiment of <FIG> there are three cassettes, 520a, 520b and 520c, each one of which is a linear tray into which the fixtures <NUM> can be slid and stacked side by side in the cassette 520a, 520b or 520c. For cassettes 520a, 520b, 520c with uncoated WIP wires <NUM>, the fixtures <NUM> are pre-loaded in the cassette 520a, 520b or 520c and advanced to the front <NUM> of the cassette area <NUM>, to be picked up by the robotic arm <NUM> and processed through the coating system <NUM>. One cassette 520a, 520b or 520c of the cassette area <NUM> can be empty initially, for placing fixtures <NUM> into after the WIP wires <NUM> have been fully completed. The holding area <NUM> (see <FIG>) may be used to temporarily store fixtures <NUM> with partially coated WIP wires <NUM> (i.e., some layers have been dipped but more layers need to be added) while the fixtures <NUM> are waiting to be moved or processed at the next station of the plurality of carousel stations <NUM>.

<FIG> are isometric views of the carousel <NUM> of <FIG>, in accordance with some embodiments. <FIG> is an isometric view of the carousel <NUM> of the coating system <NUM>, showing a first platform <NUM> that supports the various carousel stations <NUM> of the dipping process. A second platform <NUM> is positioned above the first platform <NUM>, with a platform actuator <NUM> that raises, lowers, and rotates the second platform <NUM> with respect to the first platform <NUM>. The platform actuator <NUM> may be located, for example, above the second platform <NUM>, or between the first platform <NUM> and second platform <NUM>, or below the first platform <NUM> and coupled to the second platform <NUM> through a central axis <NUM>. One of the stations of the plurality of carousel stations <NUM> on the first platform <NUM> is a wire dipping station 555a for dipping the WIP wires <NUM> through the ring dipping tool <NUM>. Other carousel stations <NUM> on the first platform <NUM> are for maintaining the ring dipping tool <NUM>, including a first cleaning station 555b, a drying station 555c, and a coating station 555d for applying coating solution <NUM> to the ring dipping tool <NUM>. All of the carousel stations <NUM> for the dipping process are arranged around the central axis <NUM>. Two cleaning stations such as first cleaning station 555b and second cleaning station 555e are shown in this figure, but in other embodiments only one cleaning station may be included, or more than one cleaning station. The cleaning stations 555b and 555e each include cleaning containers <NUM> and <NUM> respectively, for holding a cleaning solution, where the first cleaning container <NUM> of the first cleaning station 555b may hold the same or a different solution from the second cleaning container <NUM> of the second cleaning station 555e. The drying station 555c is visible in <FIG>, showing a fan <NUM> that blows air to dry the cleaning solvents off of the ring dipping tool <NUM>.

One or more ring dipping tools <NUM> are coupled to an edge of the second platform <NUM>, each coupled by a linear stage <NUM> (e.g., a rail) positioned vertically to move the ring dipping tool <NUM> up and down relative to the second platform <NUM>. The ring dipping tool <NUM> is oriented vertically with respect to ground and extends toward the first platform <NUM>. In this embodiment, one ring dipping tool <NUM> is present for each of the carousel stations <NUM> so that usage of the ring dipping tools <NUM> can occur in parallel. For example, a plurality of ring dipping tools <NUM> may be coupled to the edge of the second platform <NUM> and spaced apart from each other at locations corresponding to the coating station 555d, the wire dipping station 555a, the cleaning station 555b and 555e, and the drying station 555c (i.e., five ring dipping tools <NUM>, since there are two cleaning stations 555b and 555e in this embodiment).

In operation, the first platform <NUM> remains fixed in position, and the second platform <NUM> rotates with respect to the first platform <NUM>. The second platform <NUM> is lifted from a nominal height (i.e., baseline distance from the first platform <NUM>) before rotating so that each ring dipping tool <NUM> can be clear from colliding with any of the containers of the carousel stations <NUM> (such as first and second cleaning containers <NUM> and <NUM>) before being moved to the next station. The second platform <NUM> is then lowered back to its nominal height when the ring dipping tools <NUM> have been positioned at the next station. A clean ring dipping tool <NUM> (i.e., no coating solution <NUM> on it) begins at the coating station, 555d where a coating station actuator <NUM> is fixedly positioned opposite the coating station 555d. A decoupler <NUM> is attached to the center axis <NUM> and faces toward the coating station 555d. Although the linear stages <NUM> holding the ring dipping tools <NUM> are normally fixed relative to the second platform <NUM>, when a linear stage <NUM> is at the coating station 555d, the decoupler <NUM> unlocks the linear stage <NUM>. The coating station actuator <NUM> is connectable to the linear stage <NUM> to move (e.g., lower) the ring dipping tool <NUM> into the first coating container <NUM> of the coating station 555d when the linear stage <NUM> is unlocked. The first coating container <NUM> holds a coating solution <NUM> to be applied to the ring dipping tool <NUM>, for creating a layer on the WIP wires <NUM>. The coating solution <NUM> may be used to create layers for a working wire of a sensor, such as the interference membrane <NUM>, enzyme membrane <NUM>, or glucose limiting membrane <NUM> of <FIG>, where each membrane may require several dips (i.e., multiple coating iterations, or layers) to build up a desired thickness of the full membrane. The first coating container <NUM> is shown as a cylinder, but in other embodiments could be a bowl or cup and could have other cross-sectional shapes such as a rectangle. Parameters for the coating station actuator <NUM> such as movement speed and travel distance may be controlled by using feedback from previously dipped wires, as shall be described further below.

After having coating applied to the ring dipping tool <NUM>, the second platform <NUM> is raised and rotated, moving the coated ring dipping tool <NUM> to the wire dipping station 555a. <FIG> is a close-up view of a ring dipping tool <NUM>, in accordance with some embodiments. The ring dipping tool <NUM> is coupled to an edge of the second platform <NUM> and has a shaft <NUM> and ring <NUM> at the end of the shaft <NUM>. <FIG> is a close-up view of a fixture with working wires ready to be dipped by a ring dipping tool <NUM>, in accordance with some embodiments. <FIG> shows WIP wires <NUM> (550a, 550b, 550c, 550d. 550n) positioned to be dipped through the ring <NUM>. In this embodiment, the first fixture 530a is configured to hold a plurality of WIP wires <NUM> to enable more than one wire to be processed by the carousel <NUM> while the robotic arm <NUM> is in place at the dipping station 555a. The WIP wires <NUM> may be secured into the fixture <NUM> such as the first fixture 530a, for example, by clamps, spring-loaded clips, set screws, adhesive fasteners, or other mechanisms. Four WIP wires <NUM> such as 550a, 550b, 550c and 550d, are shown in this embodiment, but the fixture 530a may be configured to hold more or fewer WIP wires <NUM> in other embodiments. The WIP wires <NUM> are mounted in a single row in this embodiment, spaced apart from each other so that each one can be measured individually from various angles. In other embodiments the WIP wires <NUM> may be arranged in other fashions such as in more than one row, aligned or staggered from each other, so long as sufficient space is between the wires to enable each WIP wire <NUM> to be measured separately.

In <FIG>, the robotic arm <NUM> holds the first fixture 530a such that WIP wire 550a is positioned to be dipped. The robotic arm <NUM> moves the WIP wire 550a forward and backward through the ring <NUM>, as indicated by the double-headed arrow <NUM> in the figure, to perform the dipping. After WIP wire 550a has been dipped, another ring dipping tool <NUM> with fresh coating solution <NUM> is placed in front of the first fixture 530a by rotating the carousel <NUM> (having multiple of the ring dipping tools <NUM> mounted on it), and the robotic arm <NUM> is moved upwards as indicated by the upward arrow <NUM> so that WIP wire 550b can be dipped. This cycle is repeated for WIP wire 550c and WIP wire 550d. After all the WIP wires <NUM> on the first fixture 530a have been coated with a layer of coating solution <NUM>, the first fixture 530a can be moved to another area for further processing, such as to be measured, cured, or unloading if the full membrane has been completed.

Returning to <FIG>, after a ring dipping tool <NUM> has been used at the wire dipping station 555a, the second platform <NUM> is rotated again to move the ring dipping tool <NUM> to the first cleaning station 555b. To execute the movement, the second platform <NUM> is raised, rotated, and then lowered to its nominal position (height), where the lowering places the ring <NUM> and generally at least a portion of the shaft <NUM> into the first cleaning container <NUM> at the cleaning station 555b. The first cleaning container <NUM> has a solvent or other solution to remove coating solution <NUM> from the ring <NUM>, such as by submerging the ring dipping tool <NUM> in the solvent for an amount of time such as <NUM> to <NUM> seconds. The cleaning should occur because the coating solution <NUM> cures on the ring <NUM> during the dipping process, leaving a residue. The ring <NUM> should be cleaned after each dip because residual coating solution <NUM> will affect how the next film <NUM> is formed on the ring <NUM>, which can then impact how the coating is laid onto the WIP wire <NUM>. If more than one cleaning station is present, a subsequent immersion of the ring dipping tool <NUM> into a cleaning liquid is performed at the next cleaning station such as cleaning station 555e. Finally, the ring dipping tool <NUM> is dried at the drying station 555c, and then moved to the coating station 555d to begin the cycle again.

While the ring dipping tools <NUM> are rotating, the WIP wires <NUM> are being dipped at the wire dipping station 555a. Each time a freshly coated ring dipping tool <NUM> is rotated to the wire dipping station 555a, the next wire on the first fixture 530a can be moved into place for dipping. For example, referring again to <FIG>, after WIP wire 550a has been dipped, the robotic arm <NUM> moves WIP wire 550b into proper position (as shall be described for <FIG>) relative to the ring dipping tool <NUM>. Then WIP wire 550c is dipped when the next ring dipping tool <NUM> is rotated, and finally WIP wire 550d. After all the WIP wires <NUM> on this first fixture 530a have had a layer of coating applied, the robotic arm <NUM> can move the first fixture 530a to the holding area <NUM> to cure. The robotic arm <NUM> can then pick up a second fixture 530b for processing by the carousel <NUM>. After the first fixture 530a has cured, the robotic arm <NUM> can move the first fixture 530a to a measurement station <NUM> (as shall be described for <FIG>) to determine if dipping parameters need to be adjusted before the next layer of coating is applied to the wires on fixture 530a. If more layers are needed, the first fixture 530a can be returned to the carousel <NUM> while the second fixture 530b is curing. If all layers of the membrane have been fully completed, the robotic arm <NUM> can move the first fixture 530a to the cassette area <NUM>. In some embodiments, a single robot moves multiple fixtures <NUM> through the coating system <NUM>. In some embodiments, more than one robot can be included in the system to perform parallel handling of multiple wire fixtures <NUM>.

<FIG> is a close-up view of the robotic arm <NUM>, the holding area <NUM>, and optical scanner <NUM>, in accordance with some embodiments. The optical scanner <NUM> is positioned near the wire dipping station 555a to scan the three-dimensional positions of the WIP wire <NUM> (e,g. , 550a, 550b, 550c or 550d) and ring dipping tool <NUM> when the WIP wire <NUM> is ready to be dipped (e.g., WIP wire 550a of <FIG>). The optical scanner <NUM> is in communication with the robotic arm <NUM>, via the controller <NUM>, such that the robotic arm <NUM> uses the position of the WIP wire 550a and the location of the ring dipping tool <NUM> while inserting the WIP wire 550a through the ring dipping tool <NUM> at the wire dipping station 555a. For example, the optical scanner <NUM> may provide the lengthwise profile of the WIP wire 550a to the controller <NUM>, which controls the robotic arm <NUM> so that the robotic arm <NUM> can appropriately direct the WIP wire 550a through the ring <NUM> as the WIP wire 550a is advanced and withdrawn. The robotic arm <NUM> inserts the WIP wire 550a into the ring <NUM> on a path that is perpendicular to the plane of the ring <NUM>, adjusting the robotic arm's trajectory to compensate for the information about the lengthwise profile of the WIP wire 550a (e.g., variances due to bending from gravity and/or variance in the innate straightness of the WIP wire 550a) and the ring <NUM> position provided by the optical scanner <NUM>. The inserting of the WIP wire 550a relative to the ring <NUM>, based on the scanned positions, can be highly accurate, such as up to <NUM> microns of a target position. The optical scanner <NUM> also scans the ring <NUM> so that the robotic tool can account for any changes in orientation of the ring <NUM> between cycles with respect to the WIP wire 550a. Inclusion of the optical scanner <NUM> at the wire dipping station 555a, to properly move the WIP wire 550a through the ring dipping tool <NUM>, provides high accuracy of the layers being deposited onto the WIP wire 550a.

<FIG> shows a close-up view of the measurement station <NUM> from <FIG>, in accordance with some embodiments. The measurement station <NUM> may be an automated measurement system in communication with the coating station actuator <NUM>, via the controller <NUM> (as shown in <FIG>). Measurements of coating thicknesses on the WIP wire 550a, taken by the automated measurement system, provide feedback to the controller <NUM> for controlling the coating station actuator <NUM>. The automated measurement system can also provide feedback of layer thicknesses to the controller <NUM>, to control the wire dipping station 555a. This closed-loop feedback can be used to alter parameters for the next layer to be dipped onto the WIP wires <NUM> so that the overall membrane can be precisely built to the desired thickness. For example, the insertion or withdrawal speeds of the WIP wire 550a through the ring <NUM> can be altered to apply a thinner or thicker layer on the WIP wire 550a during the next cycle. In another example, immersion or withdrawal speeds of the ring dipping tool <NUM> into the coating solution <NUM> can be adjusted to create a thinner or thicker film <NUM> on the ring <NUM>. The speeds and even the immersion depth of the ring dipping tool <NUM> in the coating solution <NUM> can affect the film thickness since solution can flow down from the shaft <NUM> into the ring <NUM> area. By adjusting for these complex interactions in-line, after every dip is performed, layer thicknesses of the WIP wire 550a can be controlled to a highly accurate level, such as within <NUM> to <NUM> microns of a target layer thickness. The thicknesses to be created can also be adjusted to achieve the desired membrane thickness within a maximum number of dips.

In embodiments, the automated measurement system is an in-line optical measurement tool <NUM> (i.e., optical measurement tool <NUM> used during the manufacturing process), where the diameter of each WIP wire <NUM> is measured to derive a coating thickness that has accumulated from the last dipping cycle. The optical measurement tool <NUM> may be, for example, an optical micrometer that utilizes a laser beam to measure dimensions in a noncontact manner. The micrometer detects the size of the WIP wire <NUM> by measuring the shadow of the object that is within the path of the laser beam. In the embodiment shown, the optical measurement tool <NUM> is mounted on a stage that has both linear and rotational actuators, which enables the optical measurement tool <NUM> to be moved so that it can measure the WIP wires <NUM> on the fixture <NUM> (e.g., the first fixture 530a in <FIG>) from various angles and at various points along the length of the WIP wires <NUM>. In another embodiment, the robotic arm <NUM> may be utilized to move the first fixture 530a while the WIP wires <NUM> are being scanned by the optical measurement tool <NUM>. In either case, each WIP wire <NUM> in the first fixture 530a may have its thickness measured along its entire length and at different angles around its entire circumference. In this way, thickness is defined for every WIP wire <NUM> at each dip for both length and angular rotation. Measurements can be made at more than one location along a length of the WIP wire <NUM>, and the first fixture 530a can be rotated around a longitudinal axis of the WIP wire <NUM> so that the diameters are measured again along their length from a different orientation. In an example embodiment, each WIP wire <NUM> can be measured at <NUM> to <NUM> points along its length, and from three different angles at each point. When the WIP wires <NUM> have been measured as achieving the desired total coated membrane thickness, within an acceptable target window, the WIP wires <NUM> are unloaded, such as being placed in the cassette area <NUM>.

<FIG> shows ring <NUM> designs that can be used to further customize how the layers are formed on the WIP wires 550a, in accordance with some embodiments. The side profiles <NUM>-<NUM> shown in <FIG> illustrate that in a plane perpendicular to the ring <NUM>, the ring <NUM> can be curved (profile <NUM>), flat (profile <NUM>), inclined downward (profile <NUM>) or inclined upward (profile <NUM>). Because the coating solution <NUM> will flow toward the bottom of the ring <NUM> due to gravity, the different side profiles affect how that flow occurs. In turn, these side profiles will affect how the coating film <NUM> is deposited onto the WIP wire 550a, and thus the thickness of the layer that forms.

<FIG> is a close-up isometric view of the robotic arm <NUM> having a gas supply tube <NUM>, in accordance with some embodiments. The embodiment shows the coating process can be further controlled by supplying gas of a particular relative humidity and/or temperature directly to the wire dipping station 555a. In the figure, a gas supply tube <NUM> is coupled to the robotic arm <NUM> to provide controlled gas such as air to the wire dipping station 555a, with an end <NUM> of the gas supply tube <NUM> being near a working end of the robotic arm <NUM> that holds the fixture 530a. The temperature and humidity of the environment during a dipping process can affect how a coating layer forms by affecting factors such as liquid flow and solvent evaporation. In the embodiment of <FIG>, delivering controlled gas through the gas supply tube <NUM> can help control the dipping environment in a localized manner.

<FIG> are isometric views of an environmental chamber with a coating system <NUM> inside, in accordance with some embodiments. For example, the coating system <NUM> is housed in an environmental chamber <NUM>, to provide highly controlled environmental conditions during the dipping process. <FIG> shows an isometric view of the environmental chamber <NUM> without the coating system <NUM> inside, in accordance with some embodiments. The environmental chamber <NUM> provides highly accurate temperature, humidity, and airflow conditions for the coating system <NUM> through localized control of various parameters.

Conventionally, an environmental chamber is filled with static air, and the humidity is decreased to the desired level by adding dry gas such as nitrogen. One challenge is that the dry gas, which is typically input from one location in the chamber, can create non-uniform conditions (e.g., relative humidity) throughout the chamber. Air mixing within the chamber can also be non-uniform, which creates or exacerbates any uneven conditions in the chamber. Another technical challenge is that sensors typically have a delay in their response time. For example, readings from a relative humidity sensor may have a delay on the order of <NUM> seconds from the real-time conditions, which will then provide inaccurate readings for an environmental controller to respond to. Yet further difficulties are encountered for large chambers, such as having dimensions of several feet per side, in that whenever the chamber is opened, it can take a long time (e.g., at least <NUM> minutes) to re-establish the desired environmental conditions in the chamber.

<FIG> show that the environmental chamber <NUM> is formed by an outer enclosure <NUM> with a door <NUM> through which the interior of the environmental chamber <NUM> can be accessed, such as for loading or removing WIP wires <NUM> for processing, or for maintaining the coating system <NUM>. The outer enclosure <NUM> may be a box, shell, container, or casing that forms the external boundaries of the environmental chamber <NUM>. The environmental chamber <NUM> is illustrated as approximately a rectangular shape in this embodiment but other shapes may be used as needed for the manufacturing system. The environmental chamber <NUM> of the present disclosure incorporates several unique features to provide extremely accurate and responsive environmental conditions. These features include a dry gas port <NUM>, a humid air inlet <NUM> (first gas valve <NUM>), and a carefully designed recirculating airflow path with individually controllable fans <NUM>. A controller <NUM>, shown in <FIG>, is in communication with all these components to provide accurate and uniform conditions in the environmental chamber <NUM> in a highly responsive manner.

A first gas valve <NUM> is on one side wall of the environmental chamber <NUM>. The first gas valve <NUM> serves as an inlet for humid air, such as ambient air, to raise the relative humidity inside the environmental chamber <NUM> when needed. The first gas valve <NUM> may include an actuator <NUM> that adjusts the amount that the first gas valve <NUM> opens when ambient air is needed to be input. The first gas valve <NUM> is coupled to the outer enclosure <NUM>, where the first gas valve <NUM> is configured to adjust an amount of humidity-containing gas that enters the environmental chamber <NUM>. In one embodiment, the first gas valve <NUM> and actuator <NUM> include a gate that controls the size of a port to allow ambient air into the environmental chamber <NUM>. The controller <NUM> causes the first gas valve <NUM> to automatically open when a humidity level in the interior of the environmental chamber <NUM> is lower than a desired setpoint. The degree to which the first gas valve <NUM> opens is based on the change in humidity level needed. A dry gas port <NUM> is shown in <FIG>, connectable to a dry gas source <NUM> (e.g., pure, dry nitrogen having <NUM>% moisture) by a dry gas valve <NUM> and gas tubing <NUM>. The dry gas port <NUM> is illustrated on the opposite wall as the first gas valve <NUM> in this embodiment but may be coupled to a different wall of the environmental chamber <NUM> in other embodiments. The controller <NUM> causes the dry gas valve <NUM> to automatically open when a humidity level in the interior of the environmental chamber <NUM> is higher than a desired setpoint, thereby decreasing the relative humidity inside the environmental chamber <NUM> when needed. The degree to which the dry gas valve <NUM> opens is based on the change in humidity level needed.

A first plurality of fans <NUM> is shown in the upper area of the environmental chamber <NUM>, where the first plurality of fans <NUM> are independently controlled from each other. This individualized control of the first plurality of fans <NUM> enables localized air flow problems to be addressed, such as to counteract low flow in a particular region of the environmental chamber <NUM> (e.g., "dead spots"). Sixteen fans <NUM> are shown in this embodiment in a four-by-four array. In other embodiments, more or fewer fans may be utilized, arranged in other patterns or placed as needed based on air pathways created by the presence of the coating system <NUM> inside the environmental chamber <NUM>. A plurality of vent plates <NUM> (shown in <FIG>) is in a bottom area of the environmental chamber <NUM>, to enable air to recirculate through the environmental chamber <NUM>. The controller <NUM> is in communication with the first gas valve <NUM>, the dry gas valve <NUM> and the first plurality of fans <NUM>.

<FIG> are various views showing a recirculation path of an environmental chamber <NUM>, in accordance with some embodiments. For example, <FIG> show details of the environmental control features of the environmental chamber <NUM>. <FIG> is a side cutaway view, <FIG> is an isometric view of the side and back of the environmental chamber <NUM>, and <FIG> is a cutaway view of <FIG>. A first wall <NUM> is near a top surface of the outer enclosure <NUM>, a second wall <NUM> is near a lateral surface of the outer enclosure <NUM>, and a third wall <NUM> is near a bottom surface of the outer enclosure <NUM>. The first wall <NUM>, the second wall <NUM> and the third wall <NUM> are connected to each other and spaced apart from the outer enclosure <NUM> to form a recirculation path between the outer enclosure <NUM> and the first wall <NUM>, the second wall <NUM> and the third wall <NUM>. This recirculation path formed between the outer enclosure <NUM> and inner walls (first, second and third walls) is indicated by arrows 1350a-d, <NUM>, and 1354a-c.

The first plurality of fans <NUM> blow air as indicated by arrows 1350a,1350b, 1350c, and 1350d toward the bottom of the environmental chamber <NUM>, where the air at the bottom of the environmental chamber <NUM> passes through the vent plates <NUM> as indicated by arrows <NUM>. Air curtain fans <NUM>-shown in the lower and upper corners near the rear wall of the environmental chamber <NUM>-pull the air from the bottom space of the environmental chamber <NUM> (arrow 1354a, between the third wall <NUM> and outer enclosure <NUM>), up the back space (arrow 1354b, between the second wall <NUM> and outer enclosure <NUM>), and into the upper space (arrow 1354c, between the first wall <NUM> and outer enclosure <NUM>) where the air can again be distributed into the interior of the environmental chamber <NUM> by the first plurality of fans <NUM>. The first plurality of fans <NUM> is coupled to the first wall <NUM> and faces an interior of the outer enclosure <NUM>. Each fan in the first plurality of fans <NUM> is individually controllable by the controller <NUM>. The air curtain fans <NUM> are a second plurality of fans located within the recirculation path and are also in electrical communication with the controller <NUM>. This arrangement of fans (the first plurality of fans <NUM> and air curtain fans <NUM>) creates a stable pattern of airflow, such as maintaining laminar airflow within the environmental chamber <NUM> in one embodiment. The different sizes of airflow arrows 1350a, 1350b, 1350c and 1350d from the first plurality of fans <NUM> in <FIG> illustrate that the first plurality of fans <NUM> can be operated independently from each other, to provide more or less airflow in the vicinity of each fan. This varying airflow may be required, for example, to help distribute dry or humid air that is being input into the environmental chamber <NUM>, or to compensate for the presence of the coating system <NUM> within the environmental chamber <NUM> that may be blocking airflow in some areas but not others.

The vent plates <NUM> are coupled to the third wall <NUM> and may be, for example, a mesh, a perforated sheet, or other types of plates having apertures. An example vent <NUM> is shown in <FIG>, having staggered holes in this embodiment. The vents <NUM> across the third wall <NUM> may all be the same or may be customized for their particular location. For example, vents <NUM> may be configured with less open area (e.g., fewer holes or smaller holes) in locations where less airflow is desired, or more open area where more airflow is desired. In a specific example, a vent <NUM> underneath a dense or low airflow area of the coating system <NUM> may be configured with higher open area than in other locations of the third wall <NUM> in order to encourage airflow in that region.

Multiple humidity sensors <NUM> are placed at various locations in the environmental chamber <NUM> to monitor and provide feedback on relative humidity so that the controller <NUM> can achieve a uniform humidity throughout the environmental chamber <NUM>. Examples of humidity sensors <NUM> are shown in <FIG>. Embodiments include a plurality of humidity sensors <NUM>, where the controller <NUM> is in communication with the plurality of humidity sensors <NUM> to individually control each fan in the first plurality of fans <NUM> according to individual humidity sensors <NUM> in the plurality of humidity sensors <NUM>. The humidity sensors <NUM> can be positioned near key locations of the coating system <NUM>, such as near the dry gas port <NUM> or first gas valve <NUM>, the coating station 555d, wire dipping station 555a, holding area <NUM>, and/or cassette area <NUM>. In some embodiments, humidity levels of <NUM>-<NUM>% are desired in the environmental chamber <NUM> to achieve fast flash of volatiles in the coating solution <NUM>, while still having some humidity present. In some embodiments, the controller <NUM> monitors humidity levels as well as rates of change in humidity sensed by the humidity sensors <NUM>. Monitoring a rate of change of humidity can even further improve the accuracy and responsiveness of the environmental chamber <NUM>, compared to monitoring humidity levels alone. Port connections <NUM> in the environmental chamber <NUM> allow cables from an external source to pass through into the environmental chamber <NUM> for electrical connections, pneumatic connections, or the like.

Temperature affects relative humidity, and thus a temperature control system <NUM> is also included in the environmental chamber <NUM>. In the embodiments of <FIG>, two temperature control systems <NUM> are shown, being mounted on the rear surface of the outer enclosure <NUM>. In one example, one temperature control system <NUM> may be for heating and another one may be for cooling. In another example, each temperature control system <NUM> may be configured to provide both heating and cooling. The temperature control systems <NUM> are in fluid communication with the recirculation path (i.e., coupled to the gas flow in the recirculation path) such that as air passes by, the air is heated or cooled as needed. The temperature control systems <NUM> may be, for example a thermoelectric type. The temperature control systems <NUM> are also in electrical communication with the controller <NUM>, to provide heating or cooling as needed based on readings from the humidity sensors <NUM> as well as from temperature sensors (not shown) in the environmental chamber <NUM>. In some embodiments, combination sensors may be used that detect both temperature and humidity.

Every time the door <NUM> of the environmental chamber <NUM> is opened, such as to insert new fixtures <NUM> or to refill coating solutions <NUM> or solvents, the relative humidity and temperature need to be re-established to the desired levels. The environmental chamber <NUM> reduces the time to reset the required environmental conditions compared to conventional systems, which reduces cycle time and labor costs. Because of the unique design of the environmental chamber <NUM> involving features such as independently operating fans <NUM>, a recirculating flow path, configurable vent plates <NUM> and localized feedback from sensors at various locations in the environmental chamber <NUM>, the environmental chamber <NUM> provides a more uniform and accurate environment, and in a more responsive manner, than conventional systems.

Embodiments of systems for coating a working wire <NUM> of a sensor include the coating system <NUM> described herein (e.g., coating system <NUM> of <FIG>) housed in the environmental chamber <NUM> described herein (e.g., the environmental chamber <NUM> of <FIG> and <FIG>). In some embodiments, the environmental chamber <NUM> may be customized according to the configuration of the coating system <NUM>. For example, at least one vent plate <NUM> of the plurality of vent plates <NUM> may have an open surface area that is customized according to its location relative to the apparatus for coating the WIP wires <NUM>. In another example, a humidity sensor of the plurality of humidity sensors <NUM> may be located near the coating station 555d or the wire dipping station 555a.

The coating systems <NUM> and environmental chambers <NUM> described herein achieve highly accurate coating layers on working wires <NUM> with a wire dipping process, which is conventionally very difficult to perform accurately.

<FIG> is a simplified schematic diagram showing an example server <NUM> (representing any combination of one or more of the servers) for use in the controller <NUM>, in accordance with some embodiments. Other embodiments may use other components and combinations of components. For example, the server <NUM> may represent one or more physical computer devices or servers, such as web servers, rack-mounted computers, network storage devices, desktop computers, laptop/notebook computers, etc., depending on the complexity. In some embodiments implemented at least partially in a cloud network potentially with data synchronized across multiple geolocations, the server <NUM> may be referred to as one or more cloud servers. In some embodiments, the functions of the server <NUM> are enabled in a single computer device. In more complex implementations, some of the functions of the computing system are distributed across multiple computer devices, whether within a single server farm facility or multiple physical locations. In some embodiments, the server <NUM> functions as a single virtual machine.

In the illustrated embodiment, the server <NUM> generally includes at least one processor <NUM>, a main electronic memory <NUM>, a data storage <NUM>, a user input/output (I/O) <NUM>, and a network I/O <NUM>, among other components not shown for simplicity, connected or coupled together by a data communication subsystem <NUM>. A non-transitory computer readable medium <NUM> includes instructions that, when executed by the processor <NUM>, cause the processor <NUM> to perform operations including calculations and methods as described herein.

In accordance with the description herein, the various components of the system or method generally represent appropriate hardware and software components for providing the described resources and performing the described functions. The hardware generally includes any appropriate number and combination of computing devices, network communication devices, and peripheral components connected together, including various processors, computer memory (including transitory and non-transitory media), input/output devices, user interface devices, communication adapters, communication channels, etc. The software generally includes any appropriate number and combination of conventional and specially-developed software with computer-readable instructions stored by the computer memory in non-transitory computer-readable or machine-readable media and executed by the various processors to perform the functions described herein.

Claim 1:
An apparatus for coating a working wire (<NUM>)
of a sensor, the apparatus comprising:
a carousel comprising:
a first platform (<NUM>) having a central axis (<NUM>), the first platform supporting a plurality of stations (<NUM>) arranged around the central axis;
a second platform (<NUM>) positioned above the first platform, with a platform actuator (<NUM>) that raises, lowers, and rotates the second platform with respect to the first platform;
a ring dipping tool (<NUM>) coupled to an edge of the second platform, the ring dipping tool being oriented vertically with respect to ground, and extending toward the first platform;
a robotic arm (<NUM>) configured to transport a fixture (<NUM>) to the carousel, the fixture being configured to hold the working wire; and
an optical scanner (<NUM>) positioned near a wire dipping station of the plurality of stations and configured to scan a position of the working wire and a location of the ring dipping tool.