U.S. patent application number 10/488437 was filed with the patent office on 2005-01-20 for matrix storage and retrieval system.
Invention is credited to Cox, David M., Lehto, Dennis A., Vann, Charles S..
Application Number | 20050013734 10/488437 |
Document ID | / |
Family ID | 25496988 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050013734 |
Kind Code |
A1 |
Vann, Charles S. ; et
al. |
January 20, 2005 |
Matrix storage and retrieval system
Abstract
A system for storing and dispensing a plurality of vessels (54).
The system includes an array of storage silos (44) or passages
operable to store the plurality of vessels (54) where the storage
silos have a dispensing end and a reloading end. A retrieval robot
(22) is positioned adjacent to the dispensing end of the array of
storage silos and is operable to retrieve at least one vessel (54)
from at least one silo (44) in the array of storage silos. A reload
robot (26) is positioned adjacent the reload end of the army of
storage silos (44) and is operable to reload at least one vessel
(54) into at least one silo (44) in said array of storage silos
(44).
Inventors: |
Vann, Charles S.;
(Burlingame, CA) ; Cox, David M.; (Foster City,
CA) ; Lehto, Dennis A.; (Santa Clara, CA) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
25496988 |
Appl. No.: |
10/488437 |
Filed: |
March 2, 2004 |
PCT Filed: |
September 9, 2002 |
PCT NO: |
PCT/US02/28597 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10488437 |
Mar 2, 2004 |
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09955554 |
Sep 18, 2001 |
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09955554 |
Sep 18, 2001 |
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09251232 |
Feb 16, 1999 |
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6432719 |
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60318098 |
Sep 7, 2001 |
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60332961 |
Nov 19, 2001 |
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Current U.S.
Class: |
506/17 ; 422/63;
436/43; 506/40 |
Current CPC
Class: |
B01L 2400/0655 20130101;
G01N 35/0099 20130101; B01J 2219/00468 20130101; Y10T 436/2575
20150115; G01N 35/026 20130101; G01N 2035/042 20130101; B01J
2219/00466 20130101; B01L 3/0289 20130101; C40B 70/00 20130101;
G01N 2035/00158 20130101; B01J 2219/00351 20130101; G01N 2035/1041
20130101; B01J 19/0046 20130101; B01J 2219/00409 20130101; B01J
2219/00693 20130101; B01J 2219/00461 20130101; B01L 9/523 20130101;
B01L 2200/0657 20130101; B01J 2219/00596 20130101; B01J 2219/00308
20130101; B01J 2219/00459 20130101; G01N 2035/00752 20130101; B01J
2219/00689 20130101; B01L 2400/0633 20130101; B01L 2300/0829
20130101; B01J 2219/00547 20130101; B01J 2219/00463 20130101; G01N
35/028 20130101; Y10T 436/11 20150115; G01N 35/1002 20130101; B01J
2219/00306 20130101; C40B 60/14 20130101; B01J 2219/00274 20130101;
B01J 2219/0031 20130101; G01N 2035/0425 20130101; B01J 2219/00333
20130101; B01J 2219/00691 20130101; G01N 35/025 20130101; B01J
2219/00322 20130101; B01J 2219/005 20130101 |
Class at
Publication: |
422/063 ;
436/043 |
International
Class: |
G01N 035/00 |
Claims
What is claimed is:
1. A system for storing and dispensing a plurality of vessels
containing biopolymers, said system comprising: an array of storage
passages to store a first plurality of vessels, said array of
storage passages having a dispensing end to dispense the first
plurality of vessels and a reloading end to receive a second
plurality of vessels; a retrieval robot positioned adjacent to said
dispensing end of said array of storage passages, said retrieval
robot retrieves at least one vessel of the first plurality of
vessels from at least one passage in said array of storage
passages; and a reload robot positioned adjacent to said reload end
of said array of storage passages, said reload robot reloads at
least one vessel of the second plurality of vessels into at least
one passage in said array of storage passages.
2. The system as defined in claim 1 wherein said array of storage
passages are formed from a plurality of corrugated sheets
interlocked to one another to form a plurality of separate
passages.
3. The system as defined in claim 2 wherein each of said passages
is shaped as a rhombus.
4. The system as defined in claim 2 wherein each of said passages
is shaped as an elongated cylinder.
5. The system as defined in claim 2 wherein each of said passages
include a movable bar lever that retains a plurality of vessels in
each of said passages.
6. The system as defined in claim 5 wherein each of said levers is
spring loaded to apply a spring force to retain the plurality of
vessels.
7. The system as defined in claim 6 wherein each of said levers
includes a front end that engages a first vessel and a back end
that engages a second vessel, wherein when said spring lever is
unengaged, said first end engages said first vessel, and wherein
when said spring lever is engaged, said back end engages said
second vessel to release said first vessel.
8. The system as defined in claim 1 wherein each dispensing end of
each passage in said array of storage passages is positioned below
its corresponding reloading end to allow gravity to slide the
plurality of vessels out of said storage passages.
9. The system as defined in claim 8 wherein said storage passages
are vertically oriented.
10. The system as defined in claim 8 wherein said storage passages
are oriented at an angle.
11. The system as defined in claim 5 wherein said retrieval robot
actuates each of said levers associated with each of said
passages.
12. The system as defined in claim 11 wherein said retrieval robot
actuates each of said levers upon engaging each of said levers with
a trigger.
13. The system as defined in claim 11 wherein said retrieval robot
actuates each of said levers via an electromagnet.
14. The system as defined in claim 1 wherein said retrieval robot
moves in X and Y directions along a plane adjacent said array of
storage passages.
15. The system as defined in claim 1 wherein said retrieval robot
includes a first set of slide plates to move along a first plane in
X and Y directions and a second set of slide plates to move along a
second plane in X and Y directions.
16. The system as defined in claim 15 wherein said first plane and
said second plane are parallel to one another.
17. The system as defined in claim 15 wherein said first plane and
said second plane intersect at an angle.
18. The system as defined in claim 1 wherein said retrieval robot
identifies the number of vessels retrieved.
19. The system as defined in claim 18 wherein said retrieval robot
identifies the number of vessels retrieved by passing the vessels
through a beam.
20. The system as defined in claim 1 further comprising a plurality
of arrays of storage passages.
21. The system as defined in claim 1 wherein said reload robot
moves in X and Y directions along a plane adjacent said reloading
end of said array of storage passages.
22. The system as defined in claim 1 wherein said reload robot
reloads said array of storage passages from a plurality of reload
passages aligned with said array of storage passages.
23. The system as defined in claim 1 wherein said reload robot
determines the number of vessels delivered to the array of storage
passages.
24. The system as defined in claim 1 wherein said reload robot is
in communication with a tube gun to deliver vessels through a
delivery tube to the reload robot.
25. The system as defined in claim 24 wherein said tube gun moves
along a plane in X and Y directions to select vessels from a rack
containing a plurality of vessels.
26. The system as defined in claim 25 wherein said tube gun
extracts a vessel from the rack, rotates the vessel about
180.degree., and delivers the vessel to the reload robot, via said
delivery tube.
27. The system as defined in claim 1 wherein said retrieval robot
retains at least one rack having a plurality of wells, each well
operable to receive one of said plurality of vessels.
28. The system as defined in claim 27 wherein said retrieval robot
is operable to retain a plurality of racks.
29. The system as defined in claim 1 wherein said plurality of
vessels are a plurality of cylindrical tubes containing DNA.
30. The system as defined in claim 1 wherein said retrieval robot
is positioned below said array of storage passages and said reload
robot is positioned above said array of storage passages.
31. The system as defined in claim 1 wherein said retrieval robot
is positioned on a first vertical side of said array of storage
passages and said reload robot is positioned on a second vertical
side of said array of storage passages.
32. A system for storing and dispensing a plurality of vessels
containing biopolymers, said system comprising: a first corrugated
sheet defining a first plurality of grooves; a second corrugated
sheet defining a second plurality of grooves; and the plurality of
vessels containing biopolymers, wherein said first corrugated sheet
interlocks with said second corrugated sheet to define a storage
module having a plurality of separate passages operable to receive
and store said plurality of vessels containing biopolymers.
33. The system as defined in claim 32 wherein said storage module
includes a dispensing end operable to dispense a plurality of
vessels and a reloading end operable to receive a plurality of
vessels.
34. The system as defined in claim 33 wherein each dispensing end
of each passage in said storage module is positioned below its
corresponding reloading end to allow gravity to slide the plurality
of vessels out of said storage module.
35. The system as defined in claim 34 wherein said storage passages
are vertically oriented.
36. The system as defined in claim 34 wherein said storage passages
are oriented at an angle.
37. The system as defined in claim 32 wherein each of said passages
is shaped as a rhombus.
38. The system as defined in claim 32 wherein each of said passages
is shaped as an elongated cylinder.
39. The system as defined in claim 32 wherein each of said passages
include a movable bar lever that retains a plurality of vessels in
each of said passages.
40. The system as defined in claim 39 wherein each of said levers
is spring loaded to apply a spring force to retain the plurality of
vessels.
41. The system as defined in claim 40 wherein each of said levers
includes a front end that engages a first vessel and a back end
that engages a second vessel, wherein when said spring lever is
unengaged, said first end engages said first vessel, and wherein
when said spring lever is engaged, said back end engages said
second vessel to release said first vessel.
42. The system as defined in claim 32 wherein said plurality of
vessels are a plurality of cylindrical tubes containing DNA.
43. The system as defined in claim 39 wherein said first corrugated
sheet and said second corrugated sheet each define clearance
regions to enable said movable bar levers to be moved.
44. The system as defined in claim 32 wherein said storage module
includes at least a first refrigeration unit to refrigerate the
plurality of vessels stored in said storage module.
45. The system as defined in claim 32 further comprising a
retrieval robot to retrieve at least one vessel of the plurality of
vessels from at least one passage in said storage module.
46. The system as defined in claim 45 wherein said retrieval robot
is positioned adjacent to a dispensing end of said storage
module.
47. The system as defined in claim 39 wherein said retrieval robot
actuates each of said levers associated with each of said
passages.
48. The system as defined in claim 47 wherein said retrieval robot
actuates each of said levers upon engaging each of said levers with
a trigger.
49. The system as defined in claim 47 wherein said retrieval robot
actuates each of said levers via an electromagnet.
50. The system as defined in claim 45 wherein said retrieval robot
moves in X and Y directions along a plane adjacent said storage
module.
51. The system as defined in claim 50 wherein said retrieval robot
includes a first set of slide plates to move along a first plane in
X and Y directions and a second set of slide plates to move along a
second plane in X and Y directions.
52. The system as defined in claim 51 wherein said first plane and
said second plane are parallel to one another.
53. The system as defined in claim 51 wherein said first plane and
said second plane intersect at an angle.
54. The system as defined in claim 32 further comprising a reload
robot to reload at least one vessel of the plurality of vessels
into at least one passage in said storage module.
55. The system as defined in claim 54 wherein said reload robot
moves in X or Y directions along a plane adjacent said storage
module.
56. The system as defined in claim 55 wherein said reload robot
reloads said storage passages from a plurality of reload passages
aligned with said storage passages.
57. The system as defined in claim 54 wherein said reload robot is
in communication with a tube gun to deliver vessels through a
delivery tube to the reload robot.
58. The system as defined in claim 57 wherein said tube gun moves
along a plane in X and Y directions to select vessels from a rack
containing a plurality of vessels.
59. The system as defined in claim 58 wherein said tube gun extract
a vessel from the rack, rotates the vessel about 180.degree., and
delivers the vessel to the reload robot, via said delivery
tube.
60. The system as defined in claim 32 further comprising a
retrieval robot positioned below said storage module and a reload
robot positioned above said storage module.
61. The system as defined in claim 32 further comprising a
retrieval robot positioned on a first vertical side of said storage
module and a reload robot positioned on a second vertical side of
said storage module.
62. A method for storing and dispensing a plurality of vessels
containing a biopolymer, said method comprising: providing a
plurality of corrugated sheets; interlocking the plurality of
corrugated sheets to form a plurality of storage passages; loading
the plurality of vessels into the plurality of storage passages;
and dispensing at least one of the vessels from at least one of the
storage passages by allowing gravity to slide the at least one
vessel out of the at least one storage passage.
63. The method as defined in claim 62 further comprising loading
the plurality of vessels into the plurality of storage passages
with a reload robot.
64. The method as defined in claim 62 further comprising dispensing
the at least one vessel from the at least one passage with a
retrieval robot.
65. The method as defined in claim 62 further comprising vertically
orienting the plurality of storage passages.
66. The method as defined in claim 62 further comprising orienting
the storage passages at an angle.
67. The method as defined in claim 64 further comprising actuating
a movable lever with the retrieval robot to dispense the at least
one vessel from the at least one passage.
68. The method as defined in claim 67 further comprising engaging
the movable lever with a trigger on the retrieval robot.
69. The method as defined in claim 67 further comprising actuating
the movable lever with an electromagnet associated with the
retrieval robot.
70. The method as defined in claim 64 further comprising moving the
retrieval robot in X and Y directions along a plane adjacent the
plurality of storage passages.
71. The method as defined in claim 63 further comprising delivering
the plurality of vessels to the reload robot via a delivery
tube.
72. The method as defined in claim 63 further comprising loading
the plurality of vessels into the plurality of storage passages by
aligning a plurality of reload passages with the plurality of
storage passages.
73. The method as defined in claim 64 further comprising dispensing
the at least one vessel from the at least one passage into a rack
held by the retrieval robot.
74. The method as defined in claim 73 further comprising delivering
the rack to the retrieval robot with a service robot.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No.
09/955,554, filed on Sep. 18, 2001, now pending, which is a
continuation of U.S. Ser. No. 09/251,232, filed on Feb. 16, 1999,
now U.S. Pat. No. 6,432,719, issued on Aug. 13, 2002, and also
claims the benefit of U.S. Provisional Application No. 60/318,098
filed on Sep. 7, 2001 and U.S. Provisional Application No.
60/332,961, filed on Nov. 19, 2001. The disclosure(s) of the above
applications are incorporated herein by reference.
FIELD
[0002] The present invention relates to the storage and dispensing
of substances. More particularly, the invention relates to
providing a system and a method for storing and retrieving
vessels.
BACKGROUND
[0003] In chemical and biological laboratories, storage and
retrieval of vessels containing DNA or other substances is
generally a tedious and time consuming task. Each vessel requires
identification that must be tracked throughout its processing.
Existing manual and automated mechanisms to store and retrieve
vessels containing DNA or other substances are thus relatively
inefficient and cumbersome.
SUMMARY
[0004] In one of the various embodiments, a system for storing and
dispensing a plurality of vessels includes an array of storage
silos or passages, a retrieval robot and a reload robot. The array
of storage passages store a plurality of vessels and have a
dispensing end and a reloading end. The retrieval robot is
positioned adjacent to the dispensing end and retrieves at least
one vessel from at least one passage in the array of storage
passages. The reload robot is positioned adjacent the reload end
and reloads at least one vessel into at least one passage of the
array of storage passages.
[0005] In another of the various embodiments, a system for storing
and dispensing a plurality of vessels includes a first corrugated
sheet and a second corrugated sheet. The first corrugated sheet
defines a first plurality of grooves. The second corrugated sheet
defines a second plurality of grooves. The first corrugated sheet
interlocks with the second corrugated sheet to define a storage
module having a plurality of separate silos or passages, which
receive the plurality of vessels.
[0006] In another of the various embodiments, a method for storing
and dispensing a plurality of vessels is provided. The method
includes providing a plurality of corrugated sheets, interlocking
the plurality of corrugated sheets to form a plurality of storage
silos or passages, loading the plurality of vessels into the
plurality of storage passages, and dispensing at least one of the
vessels from at least one of the storage passages by allowing
gravity to slide the at least one vessel out of at least one
storage passages.
[0007] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The various embodiments of the present invention will become
more fully understood from the detailed description and the
accompanying drawings, wherein:
[0009] FIG. 1 is a perspective view of a matrix storage system
according to one of the various embodiments of the present
invention;
[0010] FIGS. 2A and 2B are side and perspective views of a 1.4 ml
matrix tube;
[0011] FIGS. 3A-3C are side and perspective views of a well
plate;
[0012] FIG. 4 is a perspective view of a matrix storage module
according to one of the various embodiments of the present
invention to be used in the matrix storage system of FIG. 1;
[0013] FIGS. 5A-5B are front and side views of an array of silos or
passages incorporated into the matrix storage module of FIG. 4;
[0014] FIGS. 6A-6C illustrate the releasing of a tube from the
array of silos shown in FIGS. 5A-5B;
[0015] FIG. 7 is a perspective view of a retrieval robot used in
association with the matrix storage module of the matrix storage
system of FIG. 1;
[0016] FIG. 8 is a side view of an end-effector of the retrieval
robot shown in FIG. 7 in association with the silos shown in FIGS.
5 and 6;
[0017] FIG. 9 is a side view of an end-effector of a reload robot
in association with the storage silos of the matrix storage system
of FIG. 1;
[0018] FIG. 10 is a perspective view of a matrix storage system
according to one of the various embodiments of the present
invention;
[0019] FIG. 11 is a perspective view of a storage rack module used
in the matrix storage system of FIG. 10;
[0020] FIG. 12 is a perspective view illustrating in further detail
the storage rack module of FIG. 11;
[0021] FIG. 13 is a perspective view of a single corrugated sheet
forming a portion of the silos in the storage rack module of FIG.
11;
[0022] FIG. 14 is a perspective view of the corrugated sheets
interlocked into a honeycomb bank or array of silos;
[0023] FIGS. 15A and 15B are front and side views of a lever
positioned at the end of each silo to prevent tubes from falling
out;
[0024] FIGS. 16A-16C are side cross-sectional views illustrating a
tube being extracted from a silo by a trigger device;
[0025] FIG. 17 is a side view of a retrieval robot operating
underneath the system and a reload robot operating independently
above the system;
[0026] FIG. 18 is a perspective view of the retrieval robot
illustrating X-Y set of large slides to locate a trigger device
underneath a silo and two small X-Y slides to locate any well of
six well plates underneath the trigger device;
[0027] FIG. 19 is a perspective view of a rack stacker used to
unload and stack filled well plate pallets from the retrieval
robot;
[0028] FIG. 20 is a perspective view of a pallet with six well
plates;
[0029] FIG. 21 is a perspective view of a tube gun, which blows
replacement tubes through a hose into the reload robot; and
[0030] FIG. 22 is a perspective view of the reload robot head,
which slows tubes with belts before loading an empty silo.
DETAILED DESCRIPTION OF THE VARIOUS EMBODIMENTS
[0031] The following description of the various embodiment(s)
concerning a matrix storage and retrieval system are merely
exemplary in nature and are not intended to limit the invention or
its application or uses. Moreover, while the present invention is
described in detail below, generally with respect to transferring
DNA stored in multiple vessels or tubes to well plates, it will be
appreciated by those skilled in the art that the present invention
is clearly not limited to only transferring DNA in tubes, but may
be applied to transferring other types of substances and
biopolymers in other types of containers, including solids, liquids
and gases. Finally, it should further be noted that the dimensions,
times, values, and amounts set forth herein are merely exemplary in
nature and any variation in these values is contemplated by the
various embodiments of the present invention.
[0032] Referring to FIG. 1, a matrix storage system 10 according to
one of the embodiments is shown. The matrix storage system 10 is
used to store and retrieve a large number of vessels (for example,
3,000,000 vessels) of DNA and/or other materials as is desired to
the user. As will be more fully discussed below, the matrix storage
system 10 includes a first matrix storage module 12, a second
matrix storage module 14, a third matrix storage module 16, a
fourth matrix storage module 18 and a fifth matrix storage module
20. The first matrix storage module 12, second matrix storage
module 14, third matrix storage module 16, and fourth matrix
storage module 18 are referred to as Alpha modules, while the fifth
matrix storage module 20 is referred to as a Bravo module. Each of
the storage modules 12-20 can store a large number of vessels or
tubes containing DNA as will be more fully discussed below. For
example, the storage modules 12-20 may each store 600,000 tubes
corresponding to 20,000 unique DNA samples. While four Alpha
modules and one Bravo module are shown with the matrix storage
system 10, any combination of matrix storage modules may be used in
the matrix storage system 10.
[0033] Matrix storage system 10 further includes a first retrieval
robot 22 associated with the Alpha modules and a second retrieval
robot 24 associated with the Bravo module. The matrix storage
system 10 further includes a first reload robot 26, associated with
the Alpha modules, and a second reload robot 28 associated with the
Bravo module. Positioned at either end of the matrix storage system
10 is a first service robot 30 and a second service robot 32. A
track 34 is provided for robot mobility of the retrieval robots 22
and 24 and a track 36 is provided for mobility of reload robots 26
and 28. As will be more fully discussed below, the first and second
retrieval robots 22 and 24, are used to retrieve tubes containing
DNA samples from the matrix storage system 10, while the first and
second reload robots 26 and 28 are used to load new tubes
containing DNA samples into the matrix storage system 10. In
addition, the first and second service robots 30 and 32 are used to
support the retrieval robots 22 and 24 and the reload robots 26 and
28 also as discussed below.
[0034] As more fully discussed below, the vessels or tubes 54 (as
shown in FIGS. 2A and 2B) that are retrieved by the first and
second retrieval robots 22 and 24 are individual vials or vessels
that are used to store frozen DNA. The tubes 54 are delivered to
the well plates 66 (as shown in FIGS. 3A-3C) by the first and
second retrieval robots 22 and 24. The well plates 66 are plastic
racks that holds a large number of tubes 54. The tubes 54 may be
Trakmate 1.4 ml tubes and the well plates 66 may be a Matrix 96
well plates, both supplied by the Matrix Corporation. However, it
is to be understood that any other suitable tubes and well plates
may be used. In addition, the well plates 66 holding the tubes 54
may be used to receive reagents from a system, as set forth in U.S.
Pat. No. 6,432,719, which is hereby incorporated by reference.
[0035] The first service robot 30 collects well plates 66
containing DNA in the tubes 54 from the first retrieval robot 22,
scans identifying codes of all the tubes 54 in the well plates 66
retrieved by the first service robot 30 using a scanner, stacks the
well plates 66 and load an empty well plate 66 into the retrieval
robot 22, further discussed herein. The identifying codes are
etched into the bottom of each tube, and are used to uniquely
identify each product type within the tubes 54. For example, the
identifying codes may be 2D bar codes, which correspond to a random
non-repeating number that identifies the product type. The scanner
is used to scan all of the identifying codes on the tubes 54 in
well plates 66 at once. The scanner, which is used to read the
identifying codes, may be a Matrix scanner available from Matrix
Corporation, however other suitable scanners may be used. The
service robot 32 will independently service the second retrieval
robot 24 in a like manner.
[0036] A central computer (not shown) receives and processes
customer requests, coordinates and optimizes movements of all
robots, and maintains and updates an inventory database. An
inventory database, such as one based upon an Oracle database,
continuously maintains an exact number of tubes per DNA set,
including age, volume, and production-manager for DNA in each tube.
The central computer sends out re-order messages to the DNA
synthesis factory when the inventory of tubes 54 reaches six or
less tubes for a particular DNA set.
[0037] Returning now to FIG. 4, the matrix storage module 12 is
shown in further detail, with the understanding that each matrix
storage module 12, 14, 16, 18 and 20 are substantially similar. The
matrix storage module 12 is about 1.5 meters (5') wide.times.3
meters (10') high.times.1 meters (3') deep. The matrix storage
module 12 includes a base 38 having wheels 40, enabling the matrix
storage module 12 to roll. The matrix storage module 12 further
includes a frame 42 that supports 20,000 silos 44; 100 silos
high.times.200 silos wide. Each silo or passage 44 can hold as many
as thirty stacked matrix tubes, further discussed herein. Each
matrix storage module 12, 14, 16, 18 and 20 are self refrigerated
at a constant -20.degree. C. by two independently operated
refrigerator units. A first refrigerator unit 46 is located in the
rectangular volume at the top of the module 12 and a second
refrigerator unit 48 is located in the rectangular volume at the
bottom of the module 12. If one refrigerator unit 46 or 48 fails,
the other unit is capable of maintaining the required temperature
by itself. Here again, the dimensions and temperatures are merely
provided as exemplary values and other size storage modules, as
well as different temperatures and storage capabilities may be
used.
[0038] Referring now to FIGS. 5A and 5B, an array of silos or
passages 44 are shown in a front view and a side view,
respectively. Each silo or passage 44, may be, for example, 1.35
meters long and oriented in the matrix storage module 12 at about
45.degree. to horizontal with a lower end 50 of each silo in the
front of the module 12. Each silo 44 is in the shape of a rhombus
with each side 1-centimeter long and two corners in the horizontal
plane at about 0.6-centimeters apart, and two corners in the
vertical plane at about 1.6-centimeters apart (see FIG. 5A). The
silos 44 share walls, such that 100 high.times.200 wide assemble
into a silo array of about 1.2 meters wide.times.1.6 meters
tall.
[0039] Each silo or passage 44 has its own lever 52 that releases
one, and only one tube 54 (see FIGS. 2A-2B) when triggered. In its
un-activated state, a spring 56 applies a constant force pushing
the front end 58 of the lever 52 down on the first tube 54,
preventing any tubes 54 from releasing (see FIG. 5B). To release a
tube 54, one of the retrieval robots 22 and/or 24 exerts a trigger
force opposite and greater than the spring force, pushing up the
front end 58 of the lever 52 and releasing the first tube 54 (see
FIG. 6A). Simultaneously, the back end 60 of the lever 52 is pushed
down on the second tube 54, holding it in place. When the trigger
force is removed, the spring 56 again pushes the front end 58 of
the lever 52 down and the rear end 60 of the lever 52 up, allowing
gravity to slide the tubes 54 down the silo 44 (see FIG. 6B). The
lead tube 54 is prevented from the leaving the silo 44 by the front
end 58 of the lever 52 (see FIG. 6C).
[0040] Turning to FIGS. 7-8, the retrieval robot 22 is shown in
further detail in relation to the storage module 12 with the
understanding that the retrieval robot 22 is substantially similar
to the retrieval robot 24. The retrieval robot 22 aligns a trigger
62 (see FIG. 8) with a particular silo or passage 44, triggers the
release of a tube 54, and aligns a particular well 64 of a well
plate 66 (see FIGS. 3A-3C) to receive the tube 54. The retrieval
robot 22 has two axes of motion 68 and 70, allowing it to access
any silo 44 in any of the matrix storage modules 12, 14, 16, 18 and
20 (see FIG. 7). One axis of motion 68 is implemented with a motor
72 that moves the robot 22 along the fixed track 34 and another
motor 74 moves the end-effector 76 (see FIG. 8) of the robot 22 up
and down a vertical post 78, attached to the robot base 80. The
track 34 and post 78 are positioned in front of the silo 44 so the
trigger 62 is always the same distance from a silo 44 when the
robot 22 aligns to it (see FIG. 8).
[0041] A camera 82 on the end-effector 76 calibrates the horizontal
and vertical alignment of the retrieval robot 22, relative to an
alignment spot on each storage module 12, 14, 16, 18 and/or 20.
Calibration may need to be performed each time the retrieval robot
22 moves from one storage module to the next.
[0042] A laser sensor 84, also mounted on the end-effector 76,
counts the number of tubes 54 released from a silo 44 during
retrieval. If other than one tube 54 is counted, an error message
stops the retrieval robot 22 and notify maintenance. The sensor 84
includes a laser positioned, such that its beam 86 passes through
the opening of a funnel 88 to illuminate a photodiode 90. When a
passing tube 54 blocks the beam 86, the diode's 90 electrical
output is reduced for a time corresponding to the number of tubes
54 passing.
[0043] The end-effector 76 of the retrieval robot 22 supports the
trigger 62 and two plate mover motors 92 and 94 positioned on the
plate robot 96 attached to the retrieval robot 22 at approximately
45.degree. (see FIG. 8). The trigger 62 may be magnetic or
mechanical with electromagnetic shown. When the retrieval robot 22
is aligned with the designated silo or passage 44, the
electromagnet 62 is turned-on attracting the desired lever 52
upwards to release one tube 54. The released tube 54 directly
slides by gravity into the funnel 88 that aligns the tube 54 to
fall into the well 64 in the well plate 66. The two motors 92 and
94 on the end-effector 76 position the plate 66, such that the
tubes 54 falls into a particular well 64, one motor 92 for row
placement and the other motor 94 for column placement.
[0044] As discussed above, the first retrieval robot 22 is assigned
to the Alpha modules 12, 14, 16 and 18 and the second retrieval
robot 24 is assigned to the Bravo module 20. However, in the event
of mechanical failure of a retrieval robot 22 or 24, the track 34
layout will enable either retrieval robot 22 or 24 to independently
access any silo 44 in any module 12, 14, 16, 18 and/or 20. The
tracks 34 are also modular, allowing easy disassembly and
transport.
[0045] The service robot 30 extracts a filled well plate 66 from
the retrieval robot 22 and replaces it with an empty one. It also
scans the identifying codes on all of the tubes 54 in a filled well
plate 66 and stacks the filled plate 66 for shipment. The service
robot 30 is a standard robot 30 with a standard plate gripper,
end-effector.
[0046] The reload robot 26 will now be discussed with the
understanding that reload robot 28 is substantially similar. With
reference to FIGS. 1 and 9, the reload robot 26 aligns a reload
silo or passage 100 to a depleted silo or passage 44 and releases
up to twenty-four (24) replacement tubes 54 into the depleted silo
44. The reload robot 26 is constructed the same as the retrieval
robot 22, except that it operates in the rear of the modules 12,
14, 16, 18 and 20 and has a different end-effector 102 (see FIG.
9). The end-effector 102 for the reload robot 26 has several reload
silos or passages 100, each capable of holding twenty-four (24)
tubes 54, with the understanding that various size reload silos or
passages 100 can be provided holding any number of tubes 54. Each
reload silo 100 has a metal trigger 104 to release all of the tubes
54 in a reload silo 100 when current is applied to an
electro-magnet 106 above the trigger 104 to attract and move the
metal trigger 104.
[0047] A camera 108 on the end-effector 102 calibrates horizontal
and vertical alignment of the reload robot 26 relative to an
alignment spot on each storage module 12, 14, 16, 18 and 20.
Calibration may need to be performed each time the retrieval robot
26 moves from one module to the next.
[0048] A laser sensor 109, also mounted on the end-effector 102,
counts the number of tubes 54 released into a silo 44 during
reload. If other than the number of tubes 54 in the transport silo
100 is counted, an error message stops the reload robot 26 and
notifies maintenance. The sensor includes a laser 109 positioned
such that its beam 110 passes through the ends of several transport
silos 100 to illuminate a photodiode 112. When a passing tube 54
blocks the beam 110, the diode's 112 electrical output is reduced
for a time corresponding to the number of tubes 54 passing through
the transport silo 100.
[0049] During operation, the central storage computer orders
replacement tubes 54 when the number of tubes 54 on a particular
silo depletes below a specified number, e.g. six tubes, as
discussed above. The replacement order initiates synthesis of the
product and ultimately the arrival of a lot of replacement tubes 54
at the site of the matrix storage system 10. The lot of replacement
tubes 54 may be any number of tubes 54 that is commercially
desirable. For example, the lot may be eighteen (18) tubes for the
Alpha modules and twenty-four (24) tubes for the Bravo modules, the
difference being the dilution or practical division of the DNA
products between each lot after synthesis. A lot of replacement
tubes 54 arrive in a single 1.35 meters long and one centimeter
diameter transport pipe, and all tubes within the lot having the
same DNA set. A technician empties all of the replacement tubes 54
inside a transport pipe into one of the reload silos or passages
100 while maintaining the order of the tubes. When all of the
reload silos 100 are loaded, the reload robot 26 moves to a fixed
scanner that reads the identifying or 2D bar code of the first tube
in each reload silo 100, identifying the contents. Next, the reload
robot 26 moves to replenish the appropriate silos 44 in the modules
12, 14, 16, 18 and 20, via the silo robot 114 attached to the
reload robot 26.
[0050] As discussed above, one reload robot 26 is assigned the
Alpha modules 12, 14, 16 and 18 and the other reload robot 28 is
assigned to the Bravo module 20. However, in the event of
mechanical failure of a robot, the track layout 36 enables either
reload robot 26 or 28 to independently replenish any silo 44 in any
module 12, 14, 16, 18 and 20. The tracks 36 are modular, allowing
easy dis-assembly and transport.
[0051] The central computer in the system 10 controls the database,
robots, sensors and refrigerators. The computer minimizes robot
travel by optimum ordering of tube retrieval and reloading. The
computer also maintains information on each particular type (each
silo), including number of tubes and contents in each tube to
include synthesis description, date and operator.
[0052] In general, each tube 54 is maintained at a temperature of
about -20.degree. C. or lower. Room temperature where the matrix
storage system 10 is positioned is maintained at an ambient
temperature of 20.degree. C.+/-10.degree. C. Therefore, the matrix
storage modules 12, 14, 16, 18 and 20 are each self-cooled, as
previously described, via refrigerators 46 and 48. In addition, the
storage modules and robots in the matrix storage system 10 are
generally portable so that they can be disassembled and rolled
through standard double doors, having a height of about 16
feet.
[0053] The matrix storage system 10 is capable of loading any
combination of tubes into the well plate 66 at an average rate of
four (4) seconds per tube (384 seconds per well plate). This time
includes time required by the service robot 30 to remove a filled
well plate 66 and replace it with an empty one and any time for
sensing position of the retrieval robot 22. The matrix storage
system 10 is also capable of reloading any combination of storage
silos 44 at an average rate of seventy-two (72) seconds per reload
pipe (eighteen (18) replacement tubes.times.four (4) seconds). This
time includes the time required to load tubes 54 from pipes into
the reload robot 26, the time required for reading the bar codes of
the lot identifier tubes 54, and any time for sensing position of
the reload robot 26.
[0054] In general, because of the simple and straightforward
design, the matrix storage system 10 may randomly retrieve 960
tubes 54 to fill 10 plates 66 from storage without mechanical
jamming or retrieving the wrong tube 54. The matrix storage system
10 can also replace 1800 tubes 54 (100 pipes) without jamming or
loading the wrong silo 44. The matrix storage system 10 can also
provide accurate information on inventory to include timely
reordering of the correct tubes 54.
[0055] The matrix storage system 10 is provided with electrical
power at 110 VAC, 1 phase; and 208 VAC, 3 phase; clean, dry
compressed air to drive the robots; room temperature control of
about 20.degree. C.+/-10.degree. C., and humidity control between
about 30% and 80%. The matrix storage system 10 also provides a
mechanical backup. In other words, it should be practical to
manually remove product from the system 10 by removing tubes 54 if
the mechanical handling system fails or if an emergency, such as an
earthquake requires transfer of the contents to another location.
In the event that one of the robots in the system 10 breaks down,
both retrieval robots 22 and 24 and both reload robots 26 and 28
and their tracks 34 and 36 are constructed to access all storage
modules 12, 14, 16, 18 and 20 and both service-robots 30 and 32.
System 10 also has a back-up refrigeration system that takes over
automatically if the primary refrigeration system fails.
[0056] The matrix storage system 10 is also built into a room that
meets all applicable codes for fire, safety, electrical
construction and structural integrity. Moving mechanisms in the
room, such as the robots, may have guards to limit access to the
matrix storage system 10 during operation. Any guards that can be
removed without tools and doors may have interlock switches,
effectively ceasing movement of the robots. The interlock switches
may be connected to safety-rated relay devices, which will turn off
the main air supply and turn off power to servomotors.
[0057] A matrix storage system 200, according to the teachings of
one of the various embodiments of the present invention is shown in
FIGS. 10-22. The matrix storage system 200 includes a storage unit
202 housing a plurality of storage modules 204. A retrieval robot
206 is positioned underneath the storage unit 202 and a reload
robot 208 is positioned above the storage unit 202. A well plate or
rack pallet stacker 210 and a tube gun 212 are located at one end
of the storage unit 202.
[0058] The matrix storage system 200 stores any number of tubes
(see FIGS. 2A-2B) containing frozen DNA or other substances (for
example 4.5 to 7.5 million tubes) and fills well racks or plates
(see FIGS. 3A-3C) with any combination of these tubes in any
combination of wells. The tube inventory is divided into unique DNA
assay sets (for example 150,000 to 250,000 DNA assay sets) and each
DNA set will have up to thirty tubes 54. Each one of the DNA assay
sets is one of 150,000 to 250,000 unique product types that the
system 200 will store. The system 200 is also designed so that it
can start as a smaller system and add existing storage modules 204
as the need arises. The frame 214 of the storage unit 202 and the
main robot tracks 216 may be initially assembled full size with
additional storage modules 204 added later or may be sized to meet
the number of storage modules 204 utilized.
[0059] The matrix storage system 200 provides a mechanism to remove
filled well plates, scan and check identifier codes of all tubes 54
in a full well plate, stacks up to 72 full well plates, and loads
empty well plates back into the system 200. The system 200 also
replaces tubes 54 at a rate comparable to the expenditure of tubes
54. Replacement tubes 54 will be delivered to the system in-well
plates containing one or several lots of unique DNA sets. The lot
size may be 18 to 24 tubes. The system 200 is also capable of
removing and verifying the removal of all tubes 54 in a set within
a short amount of time (less than five minutes). For example, this
would be necessary when a DNA set becomes outdated or is found in
error.
[0060] The system control software of the matrix storage system 200
receives and processes requests for order fulfillment and controls
all motors, robots, and sensors to respond to those requests. An
inventory database, such as an Oracle database, continuously
maintains an exact number of tubes 54 per DNA assay set and also
include information on the age, volume, sequence, and production
lot of the DNA in those tubes 54. An inventory computer sends a
reorder-message to a DNA synthesis factory when a DNA set is
depleted to a minimum number, such as six or fewer tubes 54. The
individual tubes 54 have identifying or 2D bar codes on the bottom.
Generally, each of the assay types have a unique bar code number.
The standard tubes 54 have a random ten-digit number. These numbers
may also be maintained in the inventory database in order to keep
track of the number of each tube 54.
[0061] The main frame or rack 214 of the storage unit 202 for
holding 7.5 million tubes, (250,000 silos) is about 65 feet long,
11 feet wide, and 8 feet tall. The entire matrix storage system 200
is placed inside a cold room 218 with access around the sides that
is about 74 feet long, 17 feet high, and 10 feet tall. One end of
the main frame 214 can be detached and the storage modules 204 can
be placed on frames 220 with casters or wheels 222 for fast removal
in case of an emergency (see FIGS. 11 and 12). The storage modules
204 include four silo or passage banks 224. The silo banks 224 are
held together by the welded steel frame 220. Each storage module
204 will span the width of the main frame or rack 214. Each storage
module 204 is mounted on the rollers 222 so that it can be removed
from the main frame 214 of the storage unit 202. The size of each
storage module 204 is determined by the practical limits of the
size of the silo banks 224 and the manageable size of a module 204
that can be removed from the system 200.
[0062] The interior of the silo or passage banks 224 consist almost
entirely of extruded corrugated sheets 226 (see FIG. 13). The
corrugated sheets 226 are interlocked together forming a honeycomb
bank of silos 228 in which tubes 54 are inserted (see FIG. 14).
Each silo 228 can hold thirty matrix tubes 54. Each silo bank 224
formed by the corrugated sheets 226 are stacked into a rectangular
shape to create a number of silos 228. The size of a silo bank or
array 224 will be determined by the practical limits of tolerance
stack up, etc. Each silo 228 is one of the vertical slots that
holds a particular type of product.
[0063] With reference to FIGS. 15A and 15B, flexible bar levers 230
are shown inserted into a corrugated sheet 226 at each silo
position 228 to prevent tubes 54 from falling out of the silos 228
when the silo bank or array 224 is loaded into the unit framework
220. The levers 230 may be snap-fitted or pressure fitted into the
array 224 or retained in any other manner. To release a tube 54
from a silo 228, the retrieval robot 206 moves a trigger device 232
underneath the correct silo 228 and activates a trigger 234 upward,
pushing the silo lever 230 aside and allowing the tubes 54 to fall
(see FIG. 16A). The tubes 54 gravity-fall through a funnel 236
until the first tube 54 hits a stop 238 in the trigger device 232
(see FIG. 16B). The trigger 234 is then retracted, permitting the
lever 230 to spring back and hold the remaining tubes 54 in place,
while the stop 238 is also retracted, dropping the first tube 54
into a rack well below (see FIG. 16C).
[0064] The retrieval robot 206 moves the trigger device 232 and
well plate pallet 240 (see FIG. 20) to a particular silo 228,
aligns a particular well 242 of a well plate 244 to receive a tube
54, and triggers the release of that tube 54 into the well 242, as
shown in FIGS. 17 and 18. The retrieval robot 206 includes a robot
head 246 and a set of linear slides 248/250 and 252/254 that move
the robot head 246 in a horizontal plane underneath the matrix
storage system 200, allowing it to access any silo 228 in the
storage unit 202 (see FIG. 17). On the robot head 246 is the
trigger device 232, the pallet 240 holding six 96 well plates 244
(see FIG. 20), and the two small slides 252 and 254 to move the
pallet 240 in the horizontal plane relative to the trigger device
232. The small slides 252 and 254 can move any well 242 in the six
well plates 244 underneath the trigger device 232. The four slides
(two large 248 and 250, two small 252 and 254) can operate
simultaneously. For example, the large slides 248 and 250 can be
moving the head 246 underneath a particular silo 228, while the two
small slides 252 and 254 are moving a particular empty well 242
from one of the well plates 244 underneath the trigger device 232.
The robot head 246 moves back and forth from one end of the storage
unit 202 to another end until all six well plates 244 are full of
tubes 54.
[0065] A camera 256 on the robot head 246 calibrates alignment of
the retrieval robot 206 relative to an alignment spot on the
storage unit 202. The camera 256 may either reference special
targets placed at the corners of the storage modules 204 or else
they could perform a pattern recognition routine on a silo 228
positioned adjacent to the target silo 228.
[0066] A laser sensor 258, mounted on the trigger device 232,
counts the number of tubes 54 released from a silo 228 during
retrieval (see FIG. 16). If a number other than one is counted, an
error message stops the robot 206 and notifies maintenance
personnel. The sensor 258 may be is a laser or fiber optic device,
positioned such that its beam 260 passes through the opening of the
funnel 236 to illuminate a photodiode 262. When a tube 54 blocks
the beam 260, the diode's electrical outputs stops, indicating the
presence of a tube 54.
[0067] The rack pallet stacker 210, as shown in FIGS. 10 and 19,
extracts a rack pallet 240 from the retrieval robot 206 when all
six well plates 244 are full and replaces it with another rack
pallet 240 holding six empty well plates or racks 244. The rack
pallet stacker 210 is a device that removes and replaces the rack
pallets 240 from the retrieval robot 206 and stacks the pallets 240
so that the system 200 can run unattended for several hours. An
operator 260 manually places individual empty well plates 244 into
and takes full well plates 244 out of the pallets 240.
Subsequently, the operator 260 places the full well plates 244 one
at a time over a matrix scanner that can read the identifying or 2D
bar code on each of the ninety-six (96) tubes 54. The bar-code data
is compared to the order database. If the bar code data does not
match the expected data for any of the orders in the queue, then
the operator 260 is notified that an error has occurred. If the
data matches one of the orders in the queue, then a bar code is
printed and attached to the well plate 244. A label print and apply
device is placed next to the scanner so that this operation can
occur automatically. The system prints out customer and shipping
information for the well plate 244. The rack pallet stacker 210 can
store up to twelve full rack pallets 240, which generally consists
of an overnight run of the matrix storage system 200 (see FIG. 19).
The stacked pallets 240 are accessible from outside the cold room
218 through a window 262.
[0068] Referring now to FIG. 21, the tube gun 212 extracts a tube
54 from a well plate 244, and turns the tube 54 around, and feeds
it through a hose 264 to the reload robot head 266 (see FIG. 22).
The well plates 244 full of replacement tubes 54 are loaded onto a
conveyor belt 268 rotating into the tube gun 212. The tube gun 212
removes tubes 54 from a well plate 244 in order to add them to the
inventory of the storage unit 202. When a well plate 244 is inside
the gun 212, an actuator pushes and blows the tube 54 into a
revolving holder 270. The revolving holder 270 turns the tube 54
around 180.degree., such that it can be shot (blown or sucked) into
the hose 264, bar code first. The hose 264 extends over the storage
unit 202 and down into the head 266 of the reload robot 208.
[0069] The racks or well plates 244 of tubes 54 are placed into the
tube gun 212 by a robot that is part of a system located adjacent
the matrix storage system 200. The system 200 sends a signal to
this external robot that is ready to process another well plate
244. The external system that is providing the well plates 244
transfers information to the storage and retrieval system 200 about
the identity of the tubes 54 and the well plate 244. A well plate
244 of tubes 54 to be added to the system 200 may have eight (8) or
fewer different types of products so that tubes 54 are added at
least twelve (12) at a time or any other combination to fill a 96
well plate 244. All product added to the system 200 will be frozen
beforehand to prevent spillage of liquid inside the machine.
[0070] As shown in FIGS. 10, 17, and 22, the reload robot 208 add
tubes 54 to the inventory by aligning the hose 264 to a silo or
passage 228 and releasing up to twenty-four replacement tubes 54
into an empty silo 228. The reload robot 208 is constructed the
same as the retrieval robot 206, except that it operates on top of
the storage unit 202 and has a different head 266. The head 266 of
the reload robot 208 has several continuously rotating belts 272
that slows down incoming tubes 54, reducing the possibility of tube
54 damage, while increasing loading accuracy (see FIG. 22). The
belt mechanism 274 is contained within a sealed box 276. While
vacuum or air pressure is being applied to transfer tubes 54, the
box 276 is vented outside of the cold room 218 to maintain the
temperature of the cold room. After several tubes 54 have been sent
through the entry tube 264, the pressure is equalized by the
venting and a door 278 opens to allow the belts 272 to feed the
tubes 54 out of the box 276 and into the top of a silo 228. A fiber
optic sensor 280, mounted on the reload head 266, counts the number
of tubes 54 released into a silo 228 during reload. If a number
other than expected is counted, an error message stops the robot
208 and notifies maintenance personnel.
[0071] During operation, the central storage computer orders
replacement tubes 54 when the number of tubes 54 in a particular
silo or passage 228 depletes below a specified number, e.g., six
tubes. The replacement order initiates synthesis of the product,
and ultimately the arrival of a lot of replacement tubes 54 at the
matrix storage site. As explained previously, a lot of replacement
tube 54 may be any number of tubes 54 that is commercially
desirable. For example, the lot may be eighteen (18) tubes for the
Alpha modules and twenty-four (24) tubes for the Bravo modules, the
difference being the dilution or practical division of the DNA
products between each lot after synthesis. The replacement lot is a
batch of tubes 54 with the same product that will be entered into
the storage system 200 at one time. The type of synthesis (Alpha or
Bravo), is one more category of information to maintain in the
inventory database.
[0072] A camera 282 mounted on the reload robot 208 will check the
position of the robot 208 relative to silos 228 in the same fashion
as the camera 256 on the retrieval robot 206.
[0073] In order to provide for jam recovery, in the same carriage
that holds the reload robot 206, a device is provided that removes
jammed or frozen tubes 54 from a silo 228. The jam recovery device
includes one end of an optical sensor that works with a sensor
mounted on the retrieval robot 206 to check if a silo 228 is empty.
If the tube 54 fails to drop into the retrieval robot 206, the
sensor will check to see if anything is in the silo 228. If the
silo 228 is not empty, a flexible rod from the device is extended
into the silo 228 until the tube 54 is dislodged.
[0074] The central computer of the system 200 controls the
database, robots, and sensors. The computer minimizes robot travel
by optimizing ordering of tube retrieval and reloading. The
computer also maintains information on each product type (i.e., the
contents in each silo 228), including the number of tubes 54 and
contents in each tube 54 to include synthesis description, date and
operator.
[0075] The average retrieval time for a tube 54 within the matrix
storage system 200 is calculated at less than about two (2) seconds
(see below). The strategy employed is to divide up the total area
of the storage device 202 into narrow columns. The system 200
operates as if the storage array 202 has an area that is 111 meters
long and 0.42 meters wide. The retrieval robot 206 will travel back
and forth across the length of the system 200 several times and end
up back at the same end. The width of the column is set so that the
average travel between pick or delivery points will be the same in
the "X" and "Y" directions. During each complete sweep of the
storage system 200, 576 tubes will be placed into a total of six
well plates 244. The system 200 will reorder the pick list so that
the first tube 54 picked is the first one that occurs in the map of
the storage device, rather than the first one in the destination
rack or well plate.
1 MOTOR TRAVEL TIME Length (L) of storage unit 18.5 m Width (W) of
storage unit 2.5 m Number of wells to fill per loading 576 (6 racks
with 96 wells each) L sweeps made by retrieval robot during 6
loading Width of L sweeps 0.42 m Total distance in all L sweeps
(18.5*6) 111 m Average L travel per well filled (111/576) 0.19 m
Average W travel per well filled (0.42/2) 0.21 m Max speed of
motors (ball screw servo) 1 m/sec Time to travel 50% L distance at
max 0.1 sec speed Time to accelerate to max speed 0.25 sec Time to
decelerate to a stop 0.25 sec Average time to access tube (L travel
as 0.6 sec limit) TRIGGER TIME Trigger engages lever 0.35 sec Tube
drops into trigger device 0.45 sec Trigger releases lever 0.35 sec
Average time to retrieve a tube from a 1.15 sec silo UNLOAD AND
LOAD RACK PLATES Full rack plate unloaded from retrieval 30 sec
robot Empty rack plate loaded into retrieval 30 sec robot Average
time to unload/load plates per 0.1 sec tube (60/576) SENSING TIME
Position alignment compensation 0.15 sec TOTAL TIME TO RETRIEVE A
TUBE 2.0 SEC (AVG)
[0076] Again, the matrix storage system 200 is housed at a
substantially constant -20.degree. C. temperature. The room 218 is
provided with a dual refrigeration system, so that one can take
over automatically if the other fails. The system 200 is also
constructed so that it can be disassembled and rolled through a
standard double door seven feet tall and five feet wide. Completed
system 200, including the exterior freezer walls are about ten (10)
feet tall. The system 200 is also capable of loading any
combination of tubes 54 into a matrix rack or well plate 244 at an
average rate of four seconds per tube 54 (384 seconds per rack).
This time includes time required to remove filled well plates 244,
add empty well plates 244, and sense position alignment.
Furthermore, this system 200 is capable of replacing tubes 54 into
the system 200 at a rate comparable to the dispensing rate, such
that rarely is one or more DNA sets not available. Rarely is
generally defined as an average of eight (8) or less hours per week
for one depleted assay set, and an average of one or less hours per
week for one depleted set.
[0077] The system 200 can retrieve 960 tubes from storage 202 to
fill ten well plates 244 as randomly specified in software without
mechanical jamming or retrieving the wrong tube 54. The system 200
can load ten (10) lots of tubes 54, twenty-four (24) tubes per lot
into the system 200 as randomly specified in software without
jamming or loading into the wrong location. The system 200 can also
provide accurate information on inventory to include timely
rendering of the correct tubes 54.
[0078] The system 200 is provided with electrical power at 110 VAC
one phase; and 208 VAC, three phase; and clean, and dry compressed
air for the robots and delivery tube. In case of an emergency, such
as a fire, earthquake, or refrigerator break down, the system 200
is designed so that all tubes 54 can be moved out of the building
in less than one hour. This is accomplished by easily detaching
sections of the storage system 202 from the main frame 214 and
service robots and wheel the modules away. In this regard, storage
modules 204 are mounted on rollers 222. These rollers 222 move
along the main frame 214 of the storage system 200. Each module 204
can be rolled to one end of the main frame 214 and then placed on
the ground.
[0079] The system 200 also meets applicable codes for fire safety,
electrical construction and structural integrity. The refrigerated
room 218 also includes sprinklers. Moving mechanisms, such as
robots, may have guards to limit access to the moving mechanisms.
Any guards that can be removed without tools and doors may have
interlock switches. The interlock switches will be connected
through safety related relays to devices, which may turn off the
main air supply and turn off the power through servomotors to cease
movement of the robots.
[0080] The description of the various embodiments of the invention
is merely exemplary in nature and, thus, variations that do not
depart from the gist of the invention are intended to be within the
scope of the invention. For example, The inventory of tubes stored
by the matrix storage system is divided into the unique DNA sets
with capability to store a number of tubes containing the same DNA
set. For example, the matrix storage system 10 may contain 100,000
unique DNA sets with 30 tubes containing the same DNA set. The
system also replaces tubes at a rate comparable to the expenditure
of tubes. It should also be pointed out that the matrix storage
system may also store various other size tubes containing other
substances, as well as store various numbers of tubes with the
above values being merely exemplary parameters. Such variations are
not to be regarded as a departure from the spirit and scope of the
invention.
* * * * *