U.S. patent application number 11/555619 was filed with the patent office on 2007-03-15 for automated sample processing system.
This patent application is currently assigned to Beckman Coulter, Inc.. Invention is credited to Santiago F. Allen, Mark Gross, Wing S. Pang, G. Andrea Pedrazzini, Ruediger F. Rauskolb, Hendra Tanumihardja.
Application Number | 20070059209 11/555619 |
Document ID | / |
Family ID | 37449877 |
Filed Date | 2007-03-15 |
United States Patent
Application |
20070059209 |
Kind Code |
A1 |
Pang; Wing S. ; et
al. |
March 15, 2007 |
AUTOMATED SAMPLE PROCESSING SYSTEM
Abstract
A system for a clinical lab that is capable of automatically
processing, including sorting, of multiple specimen containers. The
system comprises a central controller, a workstation, one or more
analyzers, and an automated centrifuge. The workstation has
automatic detectors for detecting the presence of a holder holding
specimen containers. The workstation has a bar code reader for
reading bar codes on the containers. The system has a transport
subsystem, preferably a workstation robotic arm and an analyzer
robotic arm for transporting the specimen containers, moving them
to and from the workstation, to and from the analyzers, and to and
from the centrifuge. The centrifuge is loaded with buckets
containing specimen containers. The workstation can be provided
with a balance system for balancing the weight of the buckets used.
The workstation can also have a decapper for automatically removing
caps from the specimen containers.
Inventors: |
Pang; Wing S.; (Hacienda
Heights, CA) ; Gross; Mark; (Mission Viejo, CA)
; Tanumihardja; Hendra; (West Covina, CA) ;
Rauskolb; Ruediger F.; (Palo Alto, CA) ; Pedrazzini;
G. Andrea; (Segrate, IT) ; Allen; Santiago F.;
(Yorba Linda, CA) |
Correspondence
Address: |
HOGAN & HARTSON L.L.P.
1999 AVENUE OF THE STARS
SUITE 1400
LOS ANGELES
CA
90067
US
|
Assignee: |
Beckman Coulter, Inc.
Fullerton
CA
|
Family ID: |
37449877 |
Appl. No.: |
11/555619 |
Filed: |
November 1, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09561627 |
May 2, 2000 |
7141213 |
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11555619 |
Nov 1, 2006 |
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08887601 |
Jul 3, 1997 |
6060022 |
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09561627 |
May 2, 2000 |
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08675901 |
Jul 5, 1996 |
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08887601 |
Jul 3, 1997 |
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Current U.S.
Class: |
422/72 |
Current CPC
Class: |
G01N 2035/00495
20130101; Y10T 436/113332 20150115; G01N 2035/0405 20130101; G01N
35/0099 20130101; G01N 2035/047 20130101; Y10T 436/11 20150115;
G01N 35/0095 20130101; Y10T 436/115831 20150115; B04B 2011/046
20130101; Y10T 436/114165 20150115; G01N 2035/0465 20130101 |
Class at
Publication: |
422/072 |
International
Class: |
G01N 9/30 20060101
G01N009/30 |
Claims
1-20. (canceled)
21. A workstation for automatic preparation of multiple containers
containing specimens for analysis, the workstation operating in
cooperation with a centrifuge and a controller, the centrifuge
being capable of centrifuging multiple receptacles containing
containers, at least some of the containers having a cap, each of
the containers having container identification indicia thereon, the
workstation comprising: (a) a table; (b) holders on the table for
holding the containers in predetermined locations; (c) receptacle
positioners on the table for positioning receptacles; (d) an
indicia reader for reading the container identification indicia,
the reader having an output element for providing the container
identification indicia to the controller; (e) a receptacle balance
system on the table for balancing the weight of receptacles
containing containers for the centrifuge; (f) a decapper on the
table for selectively decapping centrifuged containers; (g) an
analyzer delivery site on the table for receiving centrifuged,
decapped containers for analysis by the analyzer and an analyzer
receiving site on the table for receiving analyzed samples from the
analyzer; and (h) a transport system on the table for (i)
transporting containers to and from the centrifuge receptacles, the
analyzer delivery and receiving sites, and the decapper, (ii)
sorting containers for processing, and (iii) transporting
receptacles to and from the receptacle balance system and the
centrifuge, the transport mechanism having an input element in
communication with the controller so that the controller can
control the transport system.
22-25. (canceled)
26. A workstation for automatic preparation of multiple containers
containing specimens for analysis, the workstation operating in
cooperation with a controller and at least one analyzer, the
containers having container identification indicia thereon, the
containers being held in holders, the workstation comprising: (a) a
table; (b) detectors for detecting the presence of a holder on the
table at the predetermined locations, the detectors having an
output element for signaling the presence of a holder to the
controller; (c) an indicia reader for reading the container
identification indicia, the reader having an output element for
providing the container identification indicia to the controller;
(d) an analyzer delivery site on the table for placement of holders
for analysis by the analyzer and an analyzer receiving site on the
table for receiving analyzed samples from the analyzer; and (e) a
transport system on the table for (i) transporting containers to
and from the analyzer delivery and receiving sites, and (ii)
sorting containers for processing, the transport mechanism having
an input element in communication with the controller so that the
controller can control the transport system.
27. The workstation of claim 26, wherein the transport system
comprises a robotic arm on a longitudinal track, and the table
includes a base, the base comprising: (a) a plurality of rigid
bulkheads; (b) a pair of longitudinal beams connecting respective
opposite sides of the bulkheads; and (c) a longitudinal rail
connecting respective column extremities of the bulkheads in
vertically spaced relation between the beams, the track being
supported on the rail.
28. The workstation of claim 27, wherein the workstation further
comprises a pneumatic subsystem for the transport system, the rail
forming a reservoir of the pneumatic subsystem.
29. (canceled)
30. A workstation for automatic preparation of multiple containers
containing specimens for analysis, the workstation operating in
cooperation with a centrifuge and a controller, the centrifuge
being capable of centrifuging multiple receptacles containing
containers, at least some of the containers having a cap, each of
the containers having container identification indicia thereon, the
containers being held in holders, the workstation comprising: (a) a
table; (b) detectors for detecting the presence of a holder on the
table, the detectors having an output element for signaling the
presence of a holder to the controller; (c) an indicia reader for
reading the container identification indicia, the reader having an
output element for providing the container identification indicia
to the controller; (d) a receptacle balance system on the table for
balancing the weight of receptacles containing containers for the
centrifuge; and (e) a transport system on the table for (i)
transporting containers to and from the centrifuge receptacles,
(ii) sorting containers for processing, and (iii) transporting
receptacles to and from the receptacle balance system and the
centrifuge, the transport mechanism having an input element in
communication with the controller so that the controller can
control the transport system.
31. The workstation of claim 30, comprising a decapper on the table
for selectively decapping centrifuged containers, and wherein the
transport system transports containers to and from the
decapper.
32. A system for automated analysis of specimens in containers
comprising: (a) a workstation for preparation of specimens for
analysis, the workstation having a front, a rear, and opposed
sides; (b) a first analyzer for analysis of specimens prepared by
the workstation, the analyzer having opposed sides, a front, a top,
and a back, the top having analytical equipment thereon and being
accessible from the front by a user; and (c) a transport mechanism
for automated transport of specimens from the workstation to the
analyzer, wherein the workstation is proximate to one of the sides
of the analyzer without any obstruction of the front of the
analyzer.
33. The system of claim 32, comprising a centrifuge, wherein the
rear of the workstation is proximate to the analyzer, the transport
mechanism transports specimens from the workstation to the
centrifuge and from the centrifuge to the workstation, and the
centrifuge is proximate to one of the sides of the workstation.
34. The system of claim 33, wherein the centrifuge abuts against
said side of the workstation.
35. The system of claim 32, wherein the workstation abuts against
said side of the analyzer.
36. The system of claim 32, comprising a second analyzer, the two
analyzers having their backs proximate to each other, the transport
mechanism transporting specimens to both analyzers, and the rear of
the workstation is proximate to one of the sides of each
analyzer.
37. The system of claim 36, comprising a centrifuge, the transport
mechanism transports specimens from the workstation to and from the
centrifuge, and the centrifuge is proximate to one of the sides of
the workstation.
38. The system of claim 37, wherein the transport mechanism
comprises a robotic arm on the workstation, and a robotic arm on
each of the analyzers.
39. The system of claim 33, wherein the transport mechanism
comprises a robotic arm on the workstation and a robotic arm on the
analyzer.
40. The system of claim 32, wherein the transport mechanism
comprises a robotic arm on the analyzer.
41. A system for automated analysis of specimens in containers
comprising: (a) a workstation for preparation of specimens for
analysis, the workstation having a top, the top having a delivery
site for placement of containers for analysis by the analyzer and a
receiving site for receiving analyzed samples from the analyzer;
(b) an analyzer for analysis of specimens prepared by the
workstation; and (c) a robotic arm on the analyzer for automated
transport of specimens from the workstation to the analyzer.
42. The system of claim 41, wherein the delivery site and the
receiving site are the same.
43. The system of claim 42, wherein the workstation has an
adjustment mechanism for aligning the delivery and receiving site
with the robotic arm without moving either the analyzer or the
workstation.
44. The system of claim 41, wherein the delivery site and the
receiving site are different sites.
45. The system of claim 44, wherein the workstation has an
adjustment mechanism for independently aligning the delivery site
and the receiving site with the robotic arm without moving either
the analyzer or the workstation.
46. An analyzer for automated analysis of specimens in containers
comprising: (a) a base having opposed sides, a front, a top, and a
back, the top having analytical equipment thereon and being
accessible from the front by a user; (b) a pedestal on the top of
the base, the pedestal having a front work area and a roof; and (c)
a transport mechanism for automated transport of specimens from the
workstation to the analyzer, the transport mechanism being on top
of the roof.
47. The analyzer of claim 46, wherein the transport mechanism has a
rest position that does not obstruct the top of the base or the
front work area of the pedestal.
48. The analyzer of claim 46, wherein the transport mechanism
comprises a robotic arm, a path along the entire width of the roof,
and a drive for moving the robotic arm along the path.
49. The analyzer of claim 46, wherein the robotic arm comprises a
track engaging element, an extension arm extending from the track
engaging element in the same direction the path extends, and
grippers connected to the extension arm, the extension arm being
sufficiently long that when the track engaging element is at the
end of the path, the robotic arm does not obstruct the top of the
base or the front work area of the pedestal.
50. A decapper system for removing pressed-in caps from specimen
containers, comprising: (a) a receiver for clampingly holding a
container; (b) a yoke member movably mounted relative to the
receiver and having means for holding a cap seated in the
container; and (c) a translator for laterally moving the yoke
member between open and closed positions thereof; and (d) an
elevator for raising the yoke member, in the closed position
thereof, relative to the receiver to thereby remove the cap.
51. The decapper system of claim 50, further comprising: (a) a
collector for receiving caps from the yoke member; and (b) an
unloader for transferring removed caps from the yoke member to the
collector.
52. The decapper system of claim 51, for use with each cap having a
shoulder surface extending outwardly from opposite sides an
adjacent container portion, wherein the holding means comprises the
yoke having an upwardly facing ledge portion for engaging the
shoulder surface of a cap seated in the container, the ledge
portion extending under the shoulder surface of the cap in the
closed position.
53. The decapper system of claim 51, wherein the unloader comprises
a post fixedly located relative to the receiver, in combination
with the translator and the elevator being programmed for lowering
the yoke member for engagement of the cap with the post, thereby
stripping the cap from the yoke member.
54. The decapper system of claim 51, further comprising a guide for
directing the stripped caps into the receiver.
55. The decapper system of claim 51, further comprising a cap
sensor for sensing and signaling passage of removed caps into the
collector.
56. The decapper system of claim 50, further comprising a drive for
rotating the receiver, for removal of threaded caps from the
container.
57. The decapper system of claim 56, wherein the receiver comprises
a bladder member for enclosing a portion of the container, the
bladder member being confined by a rigid member and fluid-connected
through a control valve to a pressure source for selectively
gripping the container.
58. The decapper system of claim 56, wherein the receiver
comprises: (a) a flexible sleeve within a rigid member for
enclosing a bottom portion of the container, the sleeve having a
closed end; (b) a jaw member extending between the rigid member and
the flexible sleeve; and (c) an actuator for moving the jaw member
forcibly against the sleeve, thereby the clamp the container
relative to the rigid member.
59-68. (canceled)
Description
RELATED APPLICATION
[0001] This application is a continuation-in-part of application
Ser. No. 08/675,901 that was filed on Jul. 5, 1996, being
incorporated herein by this reference.
BACKGROUND
[0002] The present invention relates generally to systems for the
automation of laboratory tests, and particularly testing of
biological specimens.
[0003] Laboratory testing has changed and improved remarkably over
the past 70 years. Initially, tests or assays were performed
manually, and generally utilized large quantities of serum, blood,
or other biological fluids. However, as mechanical technology
developed in the industrial workplace, similar technology was
introduced into the clinical laboratory. With the introduction of
new technology, methodologies were also improved resulting in
improved quality of the results produced by the individual
instruments, and a decrease in the amount of specimen required to
perform each test.
[0004] Instruments have been developed to increase the efficiency
of testing procedures by reducing turnaround time and decreasing
the volumes necessary to perform various assays. Exemplary of such
instruments are the Synchron.TM. line of automated analyzers
available from Beckman Instruments of Fullerton, Calif. Such
instruments are capable of automatically analyzing a large number
of blood specimens and a large number of analytes, providing
reliable, accurate, and fast analysis of specimens.
[0005] There remains room for improvement in the operations of
clinical laboratories, in spite of the advances that have been
made. For example, significant labor is still required for sample
preparation. Sample preparation can include the sorting of
specimens for processing, centrifugation, and removal of the caps
of containers containing the specimens. Centrifugation requires
loading multiple specimen containers, which are typically test
tubes, into centrifuge buckets, balancing the weight of the buckets
so the centrifuge is balanced, loading the buckets into the
centrifuge, closing the centrifuge lid, centrifuging, opening the
lid, removing the buckets, and then removing the test tubes from
the buckets. All these operations are labor intensive, increasing
the cost of laboratory analysis. Moreover, these labor intensive
steps can lead to operator error. Also, human involvement always
involves the risk of contamination of specimens by the operator,
and exposure of the operator to dangerous biological
substances.
[0006] There have been attempts to improve automation include the
use of conveyor systems for conveying specimens to analyzers, such
as those described in U.S. Pat. Nos. 5,178,834 and 5,209,903. A
difficulty with using conveyor systems is that they generally are
part of a total integrated system, which system includes special
analyzers and other handling equipment. Thus a clinical laboratory
that wishes to switch to a conveyor system may need to replace its
entire existing system, with attendant high capital investment and
significant training expense for the operators.
[0007] Another common problem in clinical laboratory systems is how
to deal with "STAT" specimens. These are specimens that need
immediate attention. For example, specimens from patients in the
emergency room often require "STAT" analysis so attending
physicians can determine the cause of the medical emergency.
Present clinical systems currently depend on operator intervention
to interrupt the normal flow of work to be certain that the STAT
samples get immediate attention. However, in the hustle and bustle
of a clinical laboratory these STAT samples and specimens do not
always get the immediate attention they need.
[0008] Laboratory centrifuges of the prior art typically have a
high-speed motor-driven spindle, a plurality of holders for
test-tubes, test-tube racks and/or vials being provided at
respective angularly spaced stations of a head assembly of the
spindle, the head assembly being located within a tub-shaped cavity
and surrounded by a safety ring, the centrifuge also having a
safety-latched door for covering the cavity during operation of the
spindle. The spindle is driven at a selected speed which can be as
high as from about 3600 RPM up to about 100,000 RPM.
[0009] A number of challenges are associated with automation of
centrifugation. For example:
[0010] 1. It is desired to bypass centrifuging in some cases;
[0011] 2. Access to the centrifuge is impeded by the presence of a
protective cover, which typically swings vertically between open
and closed positions,
[0012] 3. Inordinate expense is associated with automating the
cover and protecting against persons being injured during movement
thereof;
[0013] 4. It is necessary to have the centrifuge balanced within
approximately 10 grams before high-speed operation can commence;
and
[0014] 5. Many processes are inordinately burdened by the time
required for spinning the samples, particularly when lengthy
periods are needed for loading and unloading the centrifuge, for
programming spin cycles, and for accelerating and decelerating the
centrifuge.
[0015] In some centrifuges of the prior art, a spindle head can be
indexed to one of a plurality of rest positions for facilitating
loading and unloading at corresponding angularly spaced receptacle
stations of the spindle head assembly. However, these centrifuges
are undesirably complex and expensive to provide in that separate
motors and controls are used for the indexing and for high-speed
operation; a further consequence being degraded high-speed
performance resulting from added inertia that is associated with
the indexing motor.
[0016] Accordingly, there is a need for a system that can automate
the sample handling and sample preparation process, including the
centrifugation for analytical procedures, including in particular,
clinical laboratories. It is desirable that the system can be used
with existing equipment, i.e., existing equipment does not need to
be replaced, and can be used with a wide variety of existing
analytical equipment. Further, system throughput should be only
minimally affected by specimens requiring centrifugation. Moreover,
it is desirable that the system recognize and expeditiously handle
STAT samples, minimize the health risks associated with contacting
biological samples, and minimize the chance that specimens will be
inadvertently contaminated by operator error.
SUMMARY
[0017] The present invention provides a system that meets these
needs. The present system is based upon a modular workstation that
can automatically prepare biological specimens for further
processing by a large variety of analytical equipment, without
having to replace existing analytical equipment. The system can
sort incoming samples, and prioritize STAT samples. As needed,
incoming samples can be automatically centrifuged, decapped, and
transported to selected analytical equipment. The system can be
automatically controlled through the use of a central controller.
The system provides efficient, high throughput and fast turnaround
analytical results, with decreased chance for operator error and
decreased exposure of operators to biological substances.
[0018] Typically, specimens to be automatically processed are in
multiple containers, such as test tubes, which can be capped. Each
of the containers is provided with container identification
indicia, such as a bar code. The containers are in one or more
holders such as sectors and/or racks that can have identification
indicia thereon.
[0019] In accordance with one aspect of the present invention, a
processing system includes (i) the central controller, (ii) a
workstation having subsystems for sorting, preparing, and
transporting the containers, (iii) a centrifugation system for
centrifugation of selected specimens, and (iv) at least one
analyzer for selectively analyzing specimens. Not only is this
overall system believed to be novel and inventive, it is also
believed that the subsystems of the overall system, as well as
particular mechanical components of the system, are novel and
inventive.
Central Controller
[0020] The central controller, which can be provided as part of the
workstation, comprises memory storage and a data input element for
inputting processing instructions into the memory storage for the
processing of each container according to the container
identification indicia. Based on instructions in the central
controller, each container can preferably be processed as
follows:
[0021] (a) Sorting only, i.e., the workstation is used only for
sorting containers for further processing;
[0022] (b) Sorting and centrifugation;
[0023] (c) Sorting, centrifugation, and decapping;
[0024] (d) Sorting, centrifugation, decapping and analysis;
[0025] (e) Sorting, decapping and analysis (for samples not
requiring centrifugation); and
[0026] (f) Sorting and analysis (for samples not requiring
centrifugation and automated decapping).
[0027] The central controller can be provided with a process
supervisor having a programmed detect input step for determining
introduction of containers at an input location on the workstation,
a container select step in which detected containers are selected
for processing, an identification step for defining process
components for each selected container according to the container
identification indicia, and a process select step for initiating
the defined process components being one or more of sorting,
centrifugation, decapping, and analysis.
Workstation
[0028] The workstation is provided with detectors for detecting the
presence of a holder in the system. The detectors have an output
element for signaling the presence of a holder to the central
controller. The workstation has an indicia reader, such as a bar
code reader, for reading the container identification indicia. The
indicia reader is provided with an output element for providing
container identification indicia to the central controller.
Preferably the indicia reader is also effective for signaling
holder identification indicia to the central controller.
[0029] The workstation also includes a container sorting subsystem
which has a data input element in communication with the central
controller for receiving instructions from the central controller
for sorting containers for selective processing according to the
processing instructions stored in the central controller memory
storage. The container sorting system also includes a plurality of
sort sites for placement of containers according to their
processing instructions.
[0030] Typically the workstation includes multiple input locations
for initial placement of the containers by an operator, each of the
input locations having one of the detectors. Preferably at least
one of the locations is selected for priority containers, i.e.,
STAT specimens, so that the central processor, when signaled by the
detector output element about the presence of a priority container,
provides instructions for priority processing of priority
containers.
[0031] The workstation typically comprises a table with
positioners, such as posts, for positioning the holders and
centrifuge receptacles in predetermined locations. The table can be
provided with below surface detectors, such as reed switches, for
detecting the presence of a holder on the table. A workstation
robotic arm is supported on the table, and is generally provided
with the indicia reader, which can be a bar code reader. The table
has an analyzer delivery site for placement of holders for analysis
by the analyzer, and an analyzer receiving site for receiving
analyzed samples from the analyzer. Preferably the workstation is
provided with a shield system for selectively blocking operator
access such as would interfere with system operation. The shield
system can include a partition that encloses the top of the
workstation and having openings for passage of the analyzer robotic
arms, an enlargement for passage of receptacles to the centrifuge,
and an interlocked access door. The access door can be a sash door
having an actuator being responsive to the central controller, and
an operator input device for signaling access requests to the
central controller, the controller being operative for
appropriately inhibiting operation of the workstation robotic arm
and then activating the actuator for opening the door. Preferably a
base of the table has a modular plurality of bulkheads that are
connected by a pair of beams and a rail of the robotic arm track.
Preferably the rail provides a high capacity air reservoir for the
system.
[0032] Two different types of holders can be used, and different
types of positioners for the different types of holders can be
used. For example, a first holder, such as a sector, can be used
for containers to undergo processing, wherein the first holders are
transported by the transport system. Second holders, such as racks,
can be used where the containers of the second holder are
transported by the transport system individually for sorting. It is
preferred that the holder positioners for the second holders are
closer to the transport system than are the holder positioners for
the first holders for minimal movement of the transport system.
[0033] Typically the table is located proximate to one of the
analyzers. Preferably the section of the table closest to the
analyzer is used for holding containers for delivery to the
analyzer. The table can have an input side for receiving containers
for processing, the input side being opposed from the analyzer
side, with a transport path for the workstation robotic arm located
between the input side and the analyzer side.
Centrifugation System
[0034] The centrifugation system includes an automated centrifuge
which is loaded with multiple receptacles, also known as baskets or
buckets, each bucket receiving multiple containers. The centrifuge
includes a motor coupled to a spindle that receives the buckets, a
controller, and optionally, a lid, and a lid drive. The centrifuge
controller indexes or stops the spindle at selected positions for
automated placement and removal of the buckets in response to
signals from the central controller. The lid has a closed position
and an open position, and the lid drive opens and closes in
response to instructions from the centrifuge controller.
[0035] Before the loaded receptacles are placed in the centrifuge,
preferably they are balanced in a balance system. The balance
system, which can be an included part of the workstation, comprises
a scale having sites for receiving and holding a plurality of
container receptacles, and a balance controller for selectively
depositing containers in cavities of the receptacles while
correlating incremental weight changes with the locations of each
deposit for equalizing weight in pairs of the receptacles. The
balance controller can be implemented as a balance program within
the central controller, the balance program maintaining a database
of container locations and associated weights, and directing the
robotic arm for depositing the containers. Preferably the balance
system also includes a supply of dummy loads, i.e., dummy test
tubes, the balance controller being operative for selectively
depositing selected dummy loads in receptacles for limiting weight
variations between receptacles. Preferably the dummy loads are
weighted for limiting the weight variations to not greater than 10
grams between members of each pair of receptacles.
[0036] A preferred centrifuge according to the present invention
includes a base; a spindle head supported relative to the base for
supporting and spinning an angularly spaced plurality of fluid
receptacles about a vertical axis; a spindle motor coupled to the
spindle head; a rotary encoder associated with the motor for
producing an index signal and a plurality of position signals for
each revolution of the spindle shaft; a driver for powering the
spindle motor in response to an external signal; an enclosure
supported by the base for enclosing the head means during the
spinning, an upper portion of the enclosure having an openable
access lid therein for accessing the fluid samples; a positioner
coupled to the access lid for horizontal translation thereof
between open and closed positions; a lid position sensor for
signaling the closed position of the lid; and a controller for
signaling the driver and the door positioner in response to the
encoder, the door position sensor, and external signals.
Centrifuge Controller
[0037] Preferably the centrifuge controller is operative for (a)
receiving an storing a centrifuge spin profile including a rotor
spindle speed and duration; (b) indexing the rotor for advancing a
selected one of the sample stations into an access position; (c)
spinning the rotor in accordance with the cycle profile; and (d)
stopping the rotor with a predetermined sample station at the
access position. Preferably the same spindle motor is operative for
both indexing and spinning the rotor for avoiding deleterious
addition of inertia to the spindle head. Preferably the controller
is further operative for implementing programmed acceleration and
velocity of the spin profile together with a distance of rotation,
the distance of rotation including a first distance corresponding
to spin rate and duration, and a second distance corresponding to
acceleration to the spin rate and deceleration to rest. Preferably
the distance of rotation further includes a distance interval from
the indexed position to the predetermined sample station for smooth
deceleration from the spin rate to rest with the sample station at
the access position.
[0038] Preferably the lid positioner is frictionally coupled to the
lid for preventing injury in case if inadvertent contact with the
lid during movement thereof. The lid positioner can include a drive
wheel biasingly contacting the lid for movement thereof while
limiting application of driving force thereto,
Decapper System
[0039] Before centrifuged containers are analyzed, they can be
decapped in the decapper system, which can also be an included part
of the workstation. The decapper system includes a receiver for
clampingly holding a container, a yoke member movably mounted
relative to the receiver and having means for holding a cap seated
in the container, a translator for laterally moving the yoke member
between open and closed positions thereof, and an elevator for
raising the yoke member, in the closed position thereof, relative
to the receiver to thereby remove the cap.
[0040] Preferably the decapper system also includes a collector for
receiving caps from the yoke member, and an unloader for
transferring removed caps from the yoke member to the collector.
The means for holding the cap can include an upwardly facing ledge
portion of the yoke for engaging an outwardly extending shoulder
surface of the cap, the ledge portion extending under the cap in
the closed position. The unloader can be implemented by a post
fixedly located relative to the receiver, in combination with
programmed operation of the translator and the elevator for
locating the yoke member in the open position thereof with the
removed cap aligned above the post, and lowering the yoke member
for engagement of the cap with the post, thereby stripping the cap
from the yoke member. In a preferred alternative to the ledge
portion, the yoke member has a powered clamp mechanism for gripping
the cap, and the unloader can be a plunger biasingly supported on
the yoke, in combination with programmed operation of the
translator for loading the plunger by the cap prior to activation
of the gripping mechanism, the cap being ejected by the plunger
upon release of the clamping mechanism.
[0041] Preferably, the decapper further includes a guide for
directing the stripped caps into the receiver. Also, the decapper
further includes a cap sensor for detecting and signaling the
passage of caps into the receiver for verifying proper
decapping.
[0042] Preferably the receiver is controllably rotatable for
removal of threaded caps. The receiver can include an inflatable
bladder within a rigid member and fluid-connected through a control
valve to a pressure source for selectively gripping the container.
In a preferred alternative, a flexible sleeve having a closed
bottom encloses a portion of the container within a rigid member, a
jaw mechanism in the rigid member selectively clamping the
container through the sleeve, the sleeve advantageously preventing
spillage in case of a broken container.
[0043] The system of the present invention is useful with a wide
variety of specimens, and generally is used with biological
specimens such as human blood samples. However, it can also be used
for non-biological specimens.
Analyzer
[0044] Typically the system comprises two analyzers, i.e., a single
workstation centrifuge can serve two analyzers. However, the system
can be used with one analyzer or more than two analyzers. Typically
each analyzer comprises a mechanism for selectively performing at
least two different analyses on a specimen, and an analyzer
controller in communication with the central controller, so the
central controller can instruct the analyzer controller as to what
analysis to perform for each specimen. Each analyzer also includes
an output system for providing analysis results to memory of the
central controller. Typically each analyzer output system has an
output element for providing analyzer availability information to
the central controller, and the central controller has means for
selectively determining which analyzer each specimen that is to
undergo analysis is analyzed by.
[0045] A typical analyzer has opposed sides, a front, a top, and a
back, the top having analytical equipment thereon and being
accessible from the front by a user. Preferably the workstation is
proximate to one of the sides of the analyzer without any
obstruction of the front of the analyzer. The workstation has a
front, a back, and opposed sides, and preferably the back of the
workstation is proximate to the side of the analyzer. When a
centrifuge is used, preferably it is proximate to one of the sides
of the workstation. When two analyzers are used, preferably they
are back-to-back, the back of the workstation being proximate to
one of the sides of each analyzer.
[0046] In a typical analyzer, the analyzer has a base, and a
pedestal sitting on the base, the pedestal having a roof Preferably
the analyzer robotic arm is on top of the roof so that it is out of
the way when it is in a rest position. There can be a robotic path
along the roof, and a drive for moving the robotic arm along the
path, the robotic arm having a track engaging element. An extension
arm can extend from the track engaging element in the same
direction the path extends, with container grippers being connected
to the extension arm. Preferably the extension arm is sufficiently
long that when the track engaging element is at the end of the
path, the robotic arm does not obstruct the top of the base of the
front work area of the pedestal.
[0047] Preferably the grippers of the analyzer robotic arm are
adapted for engaging container holders for lifting and transporting
the holders between the analyzer receiving site and the analyzer.
The holders can be sectors having a spaced pair of gripper openings
in an upwardly facing wall portion thereof, the grippers having
oppositely extending hook extremities for engaging a bottom surface
of the wall portion through respective ones of the gripper
openings. In a preferred alternative, the holders have an
upstanding handle portion including a resilient member and having a
cylindrical shape for facilitating effective gripping by the
grippers over a range of vertical positions of the grippers
relative to the holders. As used herein, "cylindrical" means having
a surface that is generated by a straight line that moves parallel
to a reference axis.
Transport System
[0048] The transport system (i) transports containers to and from
the centrifuge receptacles, the analyzers and the decapper system;
(ii) transports receptacles to and from the balance system and the
centrifugation system; and (iii) transports containers in the
sorting system. The transport system has a controller in
communication with the central controller so the central controller
can direct the transport system.
[0049] In a preferred system, the transport system includes at
least two robotic arms. Each analyzer has a robotic arm for
transporting the containers to and from the analyzer, and the
workstation has a robotic arm for the other transport
functions.
[0050] Preferably the workstation robotic arm comprises (i) a
longitudinal track on the workstation, (ii) a base carriage
positionable along the workstation track, the track extending
proximately between opposite ends of the workstation and
approximately centered laterally, (iii) a panning head controllably
rotatably supported, (iv) an upper arm controllably rotatably
supported on the panning head, (v) a lower arm controllably
rotatably supported on an extremity of the upper arm, (vi) a wrist
head controllably rotatably supported on an extremity of the lower
arm, and (vii) a gripper head controllably rotatably supported
therefrom on a gripper axis. The gripper head has a pair of gripper
fingers extending therefrom, being controllably movable with
tactile feedback toward and away from opposite sides of the gripper
axis for selectively grasping and transporting containers, and
holders thereof. Preferably the gripper head also includes an
optical head sensor for sensing objects located proximate the
gripper fingers. The head sensor can include a light source portion
and a light receiver portion, and having respective source and
receiver axes converging proximate the gripper axis, preferably in
approximate orthogonal relation to the gripper fingers relative to
the gripper axis for sensing entry of a container portion or holder
extremity between the gripper fingers.
[0051] Preferably the robotic arm is provided with an indicia
scanner for reading indicia of the containers and of holders of the
containers, for identification of same. The indicia scanner is
operative relative to a scan axis thereof, the scanner being
preferably mounted to the upper arm of the robotic arm with the
scan axis oriented downwardly and outwardly from proximate an upper
portion of the pan head for reading indicia being both horizontally
and vertically oriented when the gripper fingers are near the
indicia.
[0052] Preferably the pan head is movable about the pan axis
throughout an angle of greater than 180?, and the base carriage is
movable to proximate opposite ends of the work station for
facilitating transport of containers and holders substantially
anywhere on the workstation. Further, the gripper head is
preferably locatable in overhanging relation to the workstation for
accessing an external process station.
[0053] It is desirable that the central controller track containers
by the holders in which they are located. Accordingly, preferably
the indicia reader can read the holder identification indicia, the
reader output element providing holder identification indicia to
the central controller for tracking containers according to the
respective holders.
[0054] In other aspects of the invention, a centrifuge system
includes the plurality of receptacles; the centrifuge having the
spindle, centrifuge controller that indexes the spindle for
automatic loading and unloading of the receptacles, and the powered
lid; the balance system; and the transport system for transporting
the containers and the receptacles between the balance system and
the centrifuge.
[0055] A preferred balance system for the centrifuge receptacles
comprises the above-identified balance system wherein the locations
of containers in receptacles are correlated with weights thereof
for symmetrical loading of each receptacle.
[0056] A preferred decapper according to the present invention
comprises the above-identified decapper systems, including the
capability of unscrewing the caps.
[0057] Test tubes containing specimens to be analyzed come in
different heights and different diameters. Accordingly, the holders
and centrifuge receptacles are preferably provided with spring
fingers.
[0058] During use of the workstation, it is possible that the
workstation becomes misaligned with the analyzer so that the
analyzer robotic arm does not adequately grip holders containing
containers for analysis, and/or improperly delivers holders
containing analyzed specimens to the workstation. Accordingly,
preferably the sites at which holders are maintained by the
workstation for delivery to the analyzer or for receipt by the
analyzer are provided with an adjustment mechanism for
independently aligning the sites, without moving either the
analyzer or the workstation. The adjustment mechanism includes a
rotatable and translatable platform having at least one holder site
thereon, and a clamp activator for selectively holding the platform
in a fixed position on the workstation.
Method of Using the System
[0059] A method according to the present invention makes uses of
this system. In the method of the present invention, instructions
for the processing of each container according to the container
identification indicia are stored in the memory of the central
controller. The presence of a holder in the system is detected and
signaled to the central controller. Container identification
indicia are read and also signaled to the central controller. The
containers are transported with the robotic arm to a plurality of
sort sites according to the processing instructions that are in the
memory storage. Selected specimens are sorted, and optionally
centrifuged, decapped, and analyzed.
[0060] For centrifugation of selected specimens, containers
containing the selected specimens are transported to the centrifuge
receptacles and loaded into a selected receptacle with the
workstation robotic arm according to processing instructions. The
loaded receptacles are then balanced, such as by loading pairs of
the receptacles using symmetrical loading patterns having equal
numbers of loaded positions, and/or putting in "dummy" test tubes
in the receptacles that need extra weight. The balanced receptacles
are placed in the centrifuge, and containers are centrifuged for a
time and rate according to instructions from the central
controller. The centrifuge is unloaded by stopping the centrifuge,
indexing the centrifuge to selected unloading positions, and
removing the receptacles from the centrifuge with the robotic arm
in response to signals from the central controller.
[0061] In the analysis operation, each analyzer provides analyzer
availability information to the central controller, and the central
controller determines which analyzer each specimen that is to
undergo analysis is analyzed by.
[0062] Accordingly, in the system and method of the present
invention, sample preparation for analysis of specimens is
automated. Moreover, the system can be used with existing
equipment, i.e., existing analyzers can be utilized by retrofitting
them with a robotic arm and data communication with a central
controller. Moreover, the system can recognize and expeditiously
handle STAT samples. Further, the system minimizes human handling
of specimens. This reduces health risks associated with contacting
biological samples and the risk of contaminating specimens.
DRAWINGS
[0063] These and other features, aspects and advantages of the
present invention will become better understood from the following
description, appended claims, and accompanying drawings where:
[0064] FIG. 1 is a perspective view of a system according to the
present invention, comprising a workstation, a centrifuge, and two
analyzers;
[0065] FIGS. 2A-2C are flow charts of the steps of processing
containers using the system of FIG. 1, FIG. 2A being for a process
supervisor; FIG. 2B being for a centrifugation subsystem of the
supervisor of FIG. 2A; and FIG. 2C being for an analysis subsystem
of the supervisor of FIG. 2A;
[0066] FIG. 2D schematically shows how the process controller of
the system of FIG. 2A controls the workstation, analyzer, and
centrifuge;
[0067] FIGS. 3A-3E are plan views of different layouts of a
workstation, analyzers, and a centrifuge;
[0068] FIG. 3F is a plan view of a workstation and centrifuge
according to the present invention, being used with a conveyor
system;
[0069] FIG. 3G is a plan view of an analyzer according to the
present invention being used with a conveyor system;
[0070] FIG. 4 is a schematic plan view of the workstation of FIG.
1;
[0071] FIG. 5 is a view of the workstation of FIG. 1, similar to
that of FIG. 4, showing the location of positioning pins used for
locating holders, and the location of detectors for detecting
holders;
[0072] FIGS. 6A-6C show different types of positioning pins used
with the workstation of FIG. 5;
[0073] FIG. 7 is a partial sectional view of the workstation of
FIG. 5, showing a detector for detecting the presence of a
holder;
[0074] FIG. 8A is a perspective view of a sector for use with the
system, and showing how positioning pins of the workstation
interface with the sector;
[0075] FIGS. 8B and 8C are top and bottom plan views of the sector
of FIG. 8A;
[0076] FIG. 8D is a partial perspective view showing an alternative
configuration of the sector of FIG. 8A;
[0077] FIGS. 9A and 9B are a top plan view and a side elevation
view, respectively of a rack for use in the system of the present
invention;
[0078] FIGS. 9C and 9D are exploded perspective and fragmentary
side sectional views of an insert portion of the rack of FIGS. 9A
and 9B;
[0079] FIG. 10A is a top plan view of a bucket seated in a spindle
head cradle of the centrifuge of the system of the present
invention;
[0080] FIG. 10B is a side elevational view of the bucket of FIG.
10A;
[0081] FIG. 10C is a bottom elevational perspective view of the
bucket of FIG. 10A, and showing an alternative configuration of the
centrifuge cradle;
[0082] FIGS. 11A-11D show different loading patterns for the
centrifuge buckets according to the present invention;
[0083] FIG. 12A is a top plan view of a delivery site adjustment
mechanism of the workstation of FIG. 1;
[0084] FIG. 12B is a sectional view of the adjustment mechanism,
taken on line 12B-12B of FIG. 12A;
[0085] FIGS. 13A-13D show details of the robotic arm of the
workstation of FIG. 1, FIG. 13A being a perspective view; FIG. 13B
being a schematic plan view showing a range of movement of the
robotic arm relative to the workstation of FIG. 1; FIG. 13C being a
perspective view, partly exploded, of a gripper head and an optical
head sensor of the robotic arm; and FIG. 13D being a perspective
view as in FIG. 13C, showing an alternative configuration of the
optical sensor;
[0086] FIGS. 14A and 14B are front and side elevational views of
one of the analyzers of the system of FIG. 1, FIG. 14B being taken
on line 14B-14B in FIG. 14A;
[0087] FIGS. 15A-15G show details of a gripper portion of the
robotic arm of the analyzer of FIG. 14A, FIGS. 15A and 15B being
front and right side elevational views; FIG. 15C being a right side
view as in FIG. 15B, with the gripper portion lowered into
engagement with a sector; FIGS. 15D and 15E being sectional views
on line 15D-15D of FIG. 15A, FIG. 15E showing engagement with a
sector; and FIG. 15G is a perspective view showing an alternative
configuration of the gripper portion;
[0088] FIG. 16A is a fragmentary front elevational perspective view
of a centrifuge unit of the system of FIG. 1;
[0089] FIG. 16B is a fragmentary detail rear perspective view
showing an alternative configuration of an access door portion of
the centrifuge unit of FIG. 16A;
[0090] FIG. 16C is a detail perspective elevational view showing a
drive mechanism for the access door of FIG. 16B;
[0091] FIGS. 16D and 16E are a pictorial block diagram and a
circuit block diagram of the centrifuge unit of FIG. 16B;
[0092] FIG. 16F is a simplified circuit diagram of a circuit
interface module of the centrifuge unit of FIG. 16B;
[0093] FIG. 16G is a flow chart for a computer program of the
centrifuge unit of FIG. 16B;
[0094] FIGS. 17A and 17B are a top plan view and a side elevational
view, respectively, of the balance subsystem of the system of FIG.
1;
[0095] FIG. 18A is a perspective view of the decapper subsystem of
the system of FIG. 1;
[0096] FIG. 18B is a schematic view showing the decapper system of
FIG. 18A on the workstation;
[0097] FIG. 18C is a perspective view showing an alternative
configuration of a portion of the decapper system of FIG. 18A;
[0098] FIGS. 18D and 18E are side sectional elevational and bottom
views of the decapper system portion of FIG. 18C;
[0099] FIG. 18F is a fragmentary side elevational view of an
alternative receiver portion of the decapper system portion of FIG.
18A
[0100] FIG. 19 is a diagram of a pneumatic subsystem of the system
of FIG. 1;
[0101] FIGS. 20A and 20B are exploded perspective and side
elevational views of a workstation table of the system of FIG. 1;
and
[0102] FIG. 21 is a fragmentary sectional elevational view of a
door portion of a protective shield of the workstation.
DESCRIPTION
System Overview
[0103] With reference to FIGS. 1, 2, 4, 8A, 9A, and 10A, a system
10 according to the present invention comprises, as its main
components, a workstation 100, a centrifuge unit 1000, and at least
one analyzer 2000, and typically two analyzers, designated 2000A
and 2000B. The workstation 100 is loaded with containers 12, such
as test tubes 102 (see FIG. 8A) by an operator. The test tube 102
is provided with identification indicia, namely a bar code 104 and
a cap 103. Typically the containers are held in a holder 14, such
as a sector 300 (FIG. 8A) or a test tube rack 600 (FIG. 9A). For
centrifugation, the containers 12 are typically transferred to
receptacles or buckets 1200 (FIG. 10A).
[0104] As shown in FIG. 2A, a process supervisor 200 of the system
10 includes a detect input step 202 for detecting presence of
containers 12 at an input location 16 (FIG. 4) of the workstation
100. In a container select step 204, detected containers 12 are
then selected for processing. Processing is on a first-in,
first-out basis, except for containers that need priority or "STAT"
treatment. Those containers 12 are placed by the operator within a
priority region 18 on the workstation 100 for priority
processing.
[0105] After a container 12 is selected for processing, the
container ID, i.e., the bar code 104, is read in a container ID
read step 206, and main process components are defined in a process
select step 208, based on processing specified for the container
12. The container is then processed in one or more of a
centrifugation step 210, a decapping step 212, an analysis step
214, and an output sorting step 216.
[0106] For a specimen that is to undergo complete processing, the
container is sent by the centrifugation step 210 to the
centrifugation subsystem for centrifuging in the centrifuge unit
1000 (FIGS. 16A-16G). The centrifuged container is then processed
in the decapping step 212 by a decapping subsystem 900 (FIGS. 18A
and 18B). Decapped samples are then transported in the analysis
step 214 for analysis on any available analyzer. Substantially any
type of analysis that is effective for biological materials can be
done, including analysis of urine, blood, and cerebrospinal fluid.
Moreover, the system 10 of the present invention can be used for
industrial analysis, and thus is not limited to biological
substances.
[0107] After analysis on one or both analyzers 2000, the containers
are returned to the workstation 100, and then subjected to output
sorting in the output sorting step 216, wherein each container 12
is put into a specified holder 14. Some of the holders 14 are for
containers that will undergo further analysis or processing; other
holders being for containers whose processing is completed.
[0108] As further shown by FIG. 2A, containers 12 need not go
through all of the processing steps 210, 212, 214, and 216. For
example, the workstation 100 can be used just for output sorting.
Alternatively, it can be used for containers that do not need
centrifugation and/or decapping, the supervisor 200 using the
results of the process select step 208 for determining subsequent
ones of the processing steps. For example, appropriate ones of the
containers 12 can be sent straight to analysis and then output
sorting.
[0109] The centrifuge unit 1000, which is described in detail
below, is designed for centrifuging containers that are loaded in
receptacles or buckets 1200 (FIG. 10A). Each bucket 1200 holds
multiple containers to be centrifuged, and the centrifuge 1000 is
adapted for centrifuging multiple buckets 1200, typically four. It
is important for the proper operation of the centrifuge and to
avoid damage to the centrifuge, that buckets loaded across from
each other in the centrifuge have substantially the same weight,
within typically about 10 grams.
[0110] The centrifugation step 210 supervises the centrifugation
subsystem generally as shown in FIG. 2B. In the centrifugation
subsystem, the buckets 1200 are loaded in selected locations, and
the location for each container in each bucket is stored in memory.
The buckets are loaded in a predetermined order to be approximately
balanced as well as reasonably permitted by the specific complement
of containers 12 requiring centrifugation. Preferably the loading
is monitored by a balance system 800 (FIGS. 17A, 17B) and the
buckets 1200 are further balanced to comply with a predetermined
tolerance. The balanced buckets are then loaded into the centrifuge
1000, centrifuged, and then unloaded. The individual containers 12
are then unloaded from the buckets 1200 for further processing.
[0111] The analysis step 214 supervises the analysis subsystem
generally as shown in FIG. 2C, the containers 12 (typically the
test tubes 102) being placed in sectors 300, and data corresponding
to the particular sector in which the container is located is
stored in the memory of a process controller 500. As shown in FIG.
1, a loaded sector 300 is placed at a delivery site 106 of the
workstation 100 by a robotic arm 700 of the workstation 100, there
being a delivery site 106 for each of the analyzers. An analyzer
robotic arm 2002 picks up the sector from the delivery site 106 and
delivers it to an analyzer transfer site 2004. The analyzer 2000
then proceeds to analyze the specimen according to processing
instructions from the process controller, and stores the results of
the analysis in the memory of the process controller 500. Then the
analyzer robotic arm 2002 picks up the sector 300 containing
analyzed specimens from the analyzer transfer site 2004 and returns
them to a workstation receiving site 110. The sector 300 at the
workstation receiving site 110 is then picked up by the workstation
robotic arm 700 for sorting.
[0112] FIG. 2D shows the data and operating instruction information
flow between the various components of the system 10. The system
includes the central process controller 500, which can be typically
a computer system. Exemplary of the computer systems that can be
used are industrial counterparts of commonly available 32-bit
personal computers having read-write memory in the several megabyte
range. The controller 500 is provided a suitable input device such
as a keyboard, touch screen, card reader, or another computer, for
inputting processing instructions into memory for processing each
of the containers 12 according to container identification
indicia.
[0113] The process controller 500 provides instructions for
mechanical control of the workstation 100, using feedback in the
form of station status and sample identification data. The
analyzers 2000 are provided with respective controllers 2008A and
2008B as well as a separate controllers 2010A and 2010B for the
robotic arms 2002. The analyzer controllers 2008A and 2008B can be
commercially available industrial microcomputers, or counterparts
of the process controller 500. Each of the analyzer controllers
2008A and 2008B has an output interface for providing the central
controller 500 information from each analyzer about availability,
whether the analyzer can perform a particular test, and test
results. In return, the process controller 500 provides test
requests to each analyzer 2000 for each specimen, as well as
operating instructions through an input interface of the
corresponding controller 2008A or 2008B. Similarly, the process
controller 500 provides to each of the analyzer robotic arm
controllers 2010A and 2010B various load and unload instructions.
Suitable devices for the analyzer robotic arm controllers 2010A and
2010B are available from a variety of industrial robot
suppliers.
[0114] Based on the analyzer availability information provided by
each analyzer output to the central controller 500, the central
controller selectively determines which analyzer to use for each
specimen. This can be effected by software loaded in the controller
memory, where the software compares analyzer availability data
against the tests required by the specimen. The analyzer
availability data includes what tests each analyzer is capable of
performing, and analyzer status information, such as whether
reagents are loaded for particular tests and analyzer backlog.
[0115] The process controller 500 also provides mechanical control
instructions to the centrifuge unit 1000, and receives status
information from the centrifuge unit.
[0116] Optionally, the entire system can be interfaced with a host
computer 502. The host computer 502 can be interfaced with multiple
systems, each system containing a workstation, a centrifuge, and
one or more analyzers. The host computer can be used for inputting
instructions for each specimen to the process controller 500, and
the test results can be reported by the central process controller
500 to the host computer 502.
[0117] The interfaces between the components of the system, i.e.,
output elements, output system elements, and input system, can be
conventional data connections, such as RS 232 connectors with
interconnecting cables, buses, and data transport mechanisms such
as IR transfer or direct hard wiring.
Layout of System Components
[0118] As shown in FIG. 1, the workstation 100 comprises a table
112 having a table top 114. The workstation has a front or input
section 116, a rear or analyzer section 118, and two opposed sides
120. The front has placement locations for placement of holders 14
for holding containers 12 that are to be processed, containers
whose processing has been completed, and containers which have been
partially processed. Down the middle of the table is a track 704
for the robotic arm 700.
[0119] The system is adapted to be used with many configurations of
holders 14. For example, it can be used for sectors 300 as shown in
FIGS. 8A, 8B, and 8C, which hold a small number of test tubes 102.
Sectors 300 are particularly useful for containers which need to
undergo identical processing. As detailed below, the workstation
robotic arm 700 has grippers 726 adapted to grip not only
individual containers 12 but also the sectors 300, so that a group
of containers 12 can be transported for various processing steps
simultaneously. The workstation 100 can also be used with racks
600, as shown in FIG. 9, which are capable of holding multiple
containers. The containers 12, which typically are test tubes 102,
are removed one by one from the rack 600 for processing. Preferably
the racks 600 are placed closer to the robotic arm track 704 than
the sectors 300, to help speed up and increase the throughput of
the system. On the analyzer section 118 of the workstation 100,
there are located sectors 300 containing containers for delivery to
and to be received from the analyzers 2000.
[0120] As shown in FIG. 1, the workstation robotic arm 700 is
preferably centrally located on the table 112 for easy access both
to the front input section 116 and the analyzer section 118 of the
table. Also, the centrifuge 1000 is preferably positioned at one of
the sides 120 of the workstation 100, for permitting operator
access to the full length of the front or input section 116 of the
table 112, the rear or analyzer section 118 being reserved for
access by the analyzers 2000.
[0121] In the layout of FIG. 1, the analyzers 2000 are positioned
with their sides proximate to, and preferably abutting, the
workstation 100, with the two analyzers 2000 being back-to-back. In
the configuration of FIG. 1, the workstation 100 does not interfere
with operation of either analyzer, and neither analyzer interferes
with operation of the workstation. Moreover, the centrifuge 1000,
being located at one of the ends of the workstation, is likewise
out of the way of the analyzers and the workstation. The analyzers
are substantially identical, differing in that one (2000A) is
"right armed" with its robotic arm 2002A positioned to reach to the
right to the workstation 100, and second analyzer 2000B is "left
armed" with its robotic arm 2002B positioned to reach to the left
to the workstation 100.
[0122] FIG. 3A is a top plan view of the layout of the system shown
in FIG. 1. Alternative layouts are possible, such as shown in FIGS.
3B-3F. The layout of FIG. 3B is the same as that of FIG. 3A, except
that the centrifuge 1000 is placed in a U-shaped space formed by
the workstation 100 and the two analyzers 2000, up against the back
2020 of the base 2012 of both workstations.
[0123] In the version of the invention shown in FIG. 3C, the layout
is the same as that shown in FIG. 3B, except that the second
analyzer 2000B is placed against the end of the workstation 100
that is distal from the first analyzer.
[0124] In the layout of FIG. 3D, the two analyzers 2000 are placed
on opposite sides of the workstation 100, thereby forming a
"cross," with the right hand analyzer 2000A up against the rear 118
of the workstation and the left hand analyzer 2000B against the
front 116 of the workstation 100. The centrifuge 1000 is at one of
the ends of the workstation, as in the layout of FIG. 3A.
[0125] The layout of FIG. 3E is similar to that of FIG. 3D, except
the two analyzers 2000 are positioned at the centrifuge end of the
workstation 100 rather than in the middle of the workstation. The
layout of FIG. 3E is advantageous compared to that of FIG. 3D in
that the workstation input side is not obstructed by either
analyzer.
[0126] As is evident from these various layouts, it is possible to
position the workstation and centrifuge 1000 so that they do not
obstruct access to either analyzer.
[0127] The workstation and centrifuge of the present invention are
not limited to use in direct conjunction with analyzers as shown in
FIGS. 3A-3E. Instead they can be used with the conveyor system that
includes a conveyor 126, as shown in FIGS. 3F and 3G. In the
version of FIG. 3E, the robotic arm 700 of the workstation picks up
containers, generally in sectors, from the conveyor 126, processes
the containers, and optionally the containers are centrifuged. Then
processed containers are returned to the conveyor 126.
[0128] In the version of FIG. 3G the conveyor cooperates with the
analyzer 2000 whose robotic arm 2002 picks up and delivers
containers, and/or sectors, to the conveyor 126.
Analyzers
[0129] The analyzers 2000 shown in FIG. 1 are Synchron CX analyzer
units available from Beckman Instruments of Fullerton, Calif.,
being modified or retrofitted to incorporate the robotic arms 2002
as described herein. As also shown in FIGS. 14A and 14B, each
analyzer 2000 has a base 2012 having opposed sides 2014, a front
2016, a top 2018 and a back 2020. The top 2018 has the analyzer
transfer site 2004 and analytical equipment thereon and is
accessible from the front by a user. A pedestal 2022 is provided on
the back portion of the top 2018 of the base 2012, the pedestal
2022 having a front work area 2024 and a roof 2026. On top of the
roof 2026 is a transport mechanism including the robotic arm 2002,
for automated transport of specimens from the workstation 100 to
the analyzer 2000, and for transport of the analyzed specimens from
the analyzer 2000 to the workstation 100. A path or track 2028
having a drive 2030 therein extends across the roof 2026 for moving
the robotic arm 2002 along the path 2028. The robotic arm 2002 has
a track engaging element 2032, and an extension arm 2034 extending
from the track engaging element 2032 in the same direction the path
2028 extends. From the end of the extension arm 2034, there is a
forwardly extending arm 2036, with a downwardly depending arm 2038
at the end of the forwardly extending arm 2036. At the bottom of
the forwardly extending arm are grippers 2040.
[0130] Because of the extension arm 2034, the grippers 2040 can
reach sectors 300 on top of the workbench 100. Moreover, in a
"rest" position, the robotic arm 2002A of the first analyzer 2000A
is out of the way with regard to the top 2018 of the base 2012 and
the front work area of the pedestal, and thereby does not interfere
with processing and operator access to the analyzers.
[0131] As further shown in FIGS. 15A-15F the grippers 2040 of each
analyzer robotic arm 2002 are supported from a gripper actuator
2041, the actuator 2041 being mounted on a bracket 2042 that is
rigidly attached to an elevator member 2043 of the robotic arm
2002. A crank member 2044 is movable about a vertical axis 2045 of
the actuator 2041 between first and second positions through an
angle of approximately 180? for selective opposite orientational
placement and recovery of sectors 300 at the analyzer transfer site
2004 and at the workstation delivery site 106. A robotic clamp 2046
is mounted to an end extremity of the crank member 2044 for movably
supporting an outwardly facing pair of hook-shaped gripper members
2048, each of the gripper members 2048 being insertable through a
respective top wall slot 322 of the sector 300, the sectors 300
being described below in connection with FIGS. 8A-8C. After such
insertion, hook-shaped end extremities 2049 of the gripper members
2048 engage the underside of a top wall 306 (having the slots 322
formed therein) upon activation of the clamp 2046 for separating
the gripper members 2048. Also, each gripper member 2046 has an
extractor member 2050 vertically slidably engaged therewith, a
vertically oriented compression spring 2052 being interposed above
the extractor member for biasingly contacting the top wall 306
between the slots 322 when the gripper members 2048 extend into the
slots 322. One purpose of the extractor members 2050 is for
insuring that the sector 300 remains in place undisturbed when
being deposited at a site, the extractors holding the sector down
during withdrawal of the gripper members 2048 during raising of the
elevator member 2043. Another purpose of the extractor members 2050
is for stabilizing the sector 300 on the gripper members 2048
during manipulation by the analyzer gripper 2040.
[0132] A device suitable for the actuator 2042 is available as
Model NCRB/BW30-180S rotary actuator, from SMC of Tustin, Calif. A
device suitable for use as the robotic clamp 2046 is Model HGP-10-A
gripper, available from Festo, of Hauppauge, N.Y. Devices suitable
for use as the analyzer track 2028 and drive 2030 are available as
Model IS-MX-20-200-400 robotic positioning system with Model SA-A
vertical moving feature, from Intelligent Actuator of Torrance,
Calif.
[0133] With further reference to FIG. 13G, a preferred alternative
configuration of the gripper members 2048 for use with the sectors
300' includes one gripper member, designated 2048', for engaging
the resilient block 334, and a complementary gripper member,
designated 2048'', for clamping against the back wall 305 of the
sector 300'.
Workstation
[0134] A layout of a preferred workstation 100 or bench is shown in
FIG. 4. This layout is particularly adapted for having the
centrifuge 1000 on the right side of the workstation 100 as shown
in FIGS. 1 and 4. On the input section 116 of the table 112, there
are provided fifteen sort sites 128 labeled from left to right, as
A-O, for sectors 300, and corresponding fifteen sort sites 130 A-O
for racks for holding test tubes. The track 704 for the robotic arm
700 extends down the middle of the table, extending from end to
end, dividing up the table into the input sections 116 and the
analyzer section 118. The racks are closer to the track 704 than
are the sectors, because there is more travel of the robotic arm
associated with the racks, where the containers need to be loaded
and unloaded one by one.
[0135] In a typical assignment of the sector and rack sites, the
input locations 16 include rack sites 128 and sector sites 130
labeled A-J, where new containers to be processed are located
(including the priority region 18 at site A, for "STAT" specimens),
the output locations 17 include sites N and O, where sectors and
racks having completed processing and awaiting removal from the
workstation 100 are located; and the auxiliary region 19 include
sites K-M, where sectors and racks having specimens ready for
analysis are located, such as for a first analysis by one of the
analyzers, or for specimens having already been analyzed by one
analyzer and are ready for a second analysis process on a second
analyzer. It will be understood that the particular division of
functions for the locations on the input section 116 can vary
depending on the throughput rates of the analyzers, the number of
analyzers available, and other factors, and the assignments can
differ as between the rack sites 128 and the sector sites 130.
[0136] The racks 600, which can be provided with a bar code
identification 601, are used for storing and/or sorting test tubes,
and as a way of removing and placing large quantities of test tubes
on the workstation. The sectors 300, although having smaller
capacity, can be picked up by the robotic arms 700 and 2002, being
used not only for processing but also for sorting multiple test
tubes simultaneously, thereby adding to the efficiency of the
workstation 100.
[0137] The workbench of FIG. 4 is adapted for use with at least two
analyzers. Thus, a "launch pad" 105 at each end of the analyzer
section 118 has the delivery site 106 for pickup of sectors by the
analyzer robotic arm 2002, and the receiving site 110 for delivery
of sectors containing analyzed samples from the robotic arm 2002.
Surrounding the launch pads are a plurality of sector locations 134
being used for empty sectors, or for locating loaded sectors at
peak processing times when the input section is full.
[0138] In the middle of the analyzer side are buckets or
receptacles 1200, and a scale 802 and an auxiliary rack site 804 of
the balance system 800. FIG. 4 shows four buckets or receptacles
1200 on the scale 802 for balancing, the auxiliary site 804 having
a rack 600 for dummy test tubes 806 that are used for balancing out
the weight of the loaded buckets. To the right of the auxiliary
rack site 804 is the decapping system 900, followed by four buckets
1200 either being unloaded after centrifuging, or being loaded with
new test tubes for centrifuging.
[0139] With further reference to FIGS. 20A and 20B, a preferred
configuration of the table 112 includes a base 20 having a
parallel-spaced pair of beam members 22 that connect a spaced
plurality of bulkheads 24, the bulkheads 24 having respective
column portions 25 that support a rail member 26.of the track 704.
Each of the bulkheads 24 also anchors a pair of column members 28
on the beam members 22 the input and analyzer sections 116 and 118
of the table 114 being separately fastened on top of respective
rows of the column members 28. By this construction, the table 112
can be conveniently stored and transported as one compact package
including the beam members 22, the rail member 26, and the sections
116 and 118, and another compact package including the bulkheads 24
having the column members 28 fastened thereto. There are five of
the bulkheads 24, the spaces therebetween defining four bays for
accommodating various power distribution and electronic components
of the system 10 in a conventional manner. Under each end bulkhead
24 is mounted a pair of swivel casters 130 for rollably supporting
the workstation 100, and an adjustable foot assembly 132 is spaced
inwardly from each end and mounted under each beam member 22 for
leveling and anchoring the table 112 in a conventional manner.
[0140] A typical workstation has a length of about 2.83 meters, and
an overall width of about 980 mm, with the input section being
about 540 mm wide, a track width of about 145 mm, and the
analytical section being about 440 mm side.
[0141] As further shown in FIG. 1, the workstation 100 is
preferably provided with a protective shield system 40 for blocking
operator intrusion within space above the table top 114. The shield
system 40 has a frame 42 on which are mounted a plurality of
transparent panel members 44, being vertically oriented proximate
the perimeter of the table top 114, the shield system 40 being
interrupted along the rear section 118 for clearing the respective
analyzer robotic arms 2002A and 2002B. The panel member proximate
the centrifuge unit 1000, designated 44A, has a bubble extension 46
formed therein for inclusion of a path to the centrifuge unit 1000
within the shield system 40. Also, and with further reference to
FIG. 21, the panel member along the front section 116, designated
44B, extends down only partway from the top of the frame 42, three
transparent door panels 48 being supported for vertical movement in
overlapping relation with respective portions of the panel 44B.
Each of the door panels 48 is coupled to a piston rod 50 of a
pneumatic actuator 52 by a handle clamp assembly 54, the actuator
52 being mounted to a top portion of the frame 42. A solenoid latch
56 is located within the table 114 in association with each door
panel 48 for locking same in a closed position thereof In an
exemplary configuration as shown in FIG. 21, the solenoid latches
56 when deactivated engage discontinuities or slots 58 that are
formed in lower extremities of the piston rods 50; activation of
the latches 56 releases the rods 50. The door panels 48 are
reinforced against excessive inward force by the handle clamp
assemblies 54 having depending projections 60 thereon that extend
proximately against an edge extremity of the table top 114 in the
closed positions of the panels 48. A door button 62 is located
under each handle clamp assembly 54 for signaling an associated
door open request to the process controller 500. Subject to
appropriate interlocks and process suspension, the corresponding
latch 58 is activated, followed by activation of the corresponding
pneumatic actuator 52, whereupon the door panel 48 is raised for
operator access to the input section 116 of the workstation 100.
The workstation 100 is preferably provided with two emergency stops
64, one proximate each end of the input section 116, for use by an
operator.
[0142] With reference to FIG. 5, there are provided two sector
registration posts or pins 142 for each sector 300. Similarly, two
rack positioning pins 146 are provided for locating each rack 600
that is on the workstation 100. A table magnet 145 is mounted flush
with the table top 114 in predetermined relationship with pairs of
the pins 142 and 146 for attracting respective holder magnets 330
of the sectors 300 and the racks 600 as further described below.
Also, there are two bucket locator pins 144 on the workstation 100
for each receptacle or bucket 1200 used for the centrifuge. FIGS.
6A-6C show a typical sector pin 142, rack pin 146, and bucket pin
144, respectively. The particular shape of the pins is selected so
they cooperate with the respective devices they serve to locate. As
shown in these figures, the three types of pins are different, to
inhibit operators from mislocating the devices on the workstation.
As further shown in FIGS. 6A-6C, the pins 142, 144, and 146 on the
table 114 are located in shallow wells 156 for confining any
inadvertent spillage from the containers 12. Counterparts of the
wells 156 are also provided on the scale 802. Further, a perimeter
trough 158 is formed in each of the front and rear sections 116 and
118 of the table 114 and surrounding the various sites for the
holders 14, as shown in FIG. 6A.
[0143] The cooperation between the sector pin 142 and a sector 300
is shown in FIG. 8A; the cooperation between the rack a 600 and the
rack locating pins 144 is shown in FIGS. 9A and 9B, and the
relationship between a centrifuge bucket 1200 and the bucket
location pins 146 is shown in FIG. 10C, which shows the pins 146 in
an alternative configuration of the centrifuge 1000.
[0144] The workstation is provided with a detection system for
detecting the presence of sectors and racks on the workstation. In
a preferred version of the invention shown in FIG. 7, there is used
a sensor or reed switch 150, which is recessed slightly below the
top surface of the workstation. Each reed switch 150 is retained by
a flush-fitting plug member 152 that is removable for facilitating
servicing and/or replacement of the reed switch 150. Preferably,
electrical circuits of the reed switches 150 are provided with
suitable connectors (not shown) for facilitating replacement of the
switches 150 without requiring access below the table top 114. The
locations of the reed switches 150 are shown in FIG. 5. The reed
switches can be activated by providing the sectors, racks, and
buckets with magnets strong enough to activate the reed switch.
Also, other detection systems can be used, including weight systems
where the detector detects the presence of a sector or the like by
its weight; or a detector system that relies on an electrical
current, where the presence of a sector or rack closes a circuit so
electrical current can be detected; or an optical interrupter,
where the device interrupts a light path.
[0145] An exemplary sector 300 as shown in FIGS. 8A, 8B, and 8C
includes a base 301 having a convex front wall 302, a concave back
wall 304, a bottom wall 308, and side walls 310. A top 315 snap
fits onto the base 301 and includes a top wall 306 that extends
rearwardly and outwardly from portions of the side walls 310 of the
base (the side walls 310 being staggered for clearing the sector
positioning pins 142 of the workstation 100, thereby forming an
overhang 318, which has two holes 320 therein for the pins 142.
Along the front wall 302 are tubular cavities 314 for test tubes
102, and in the version shown in the figures, there are seven such
cavities. They extend from the top wall 306 and can drain through
the bottom wall 308. Each cavity 314 has a slot 316 in the front so
that a bar code reader can read the bar codes 104 on the front of
the test tube 102. In the top wall 306 are two slots 322 which can
be engaged by the gripper members or jaws 2048 of the analyzer
robotic arm 2002 (FIGS. 15A-15F). The slots 316 extend partially in
the base 301 and partially in the top 315.
[0146] Extending upwardly from the top wall 306 of the sector 300
is a counterpart of the back wall, designated 305, from which
projects a T-shaped handle 324, the combination of the back wall
305 and the handle 324 being engageable by the gripper element 726
of the workstation robotic arm 700 (FIG. 13C).
[0147] The front wall 302 of the sector 300 is provided with a bar
code 326 to identify, and allow the central controller 500 to track
the sector and the test tubes therein. The base 301 is also
provided with an internal bar code strip 327 which is visible when
a test tube slot 316 is empty, but blocked when a test tube is in
the slot. Thus a bar code scanner 724 (FIG. 13A) can signal the
central processor 500 with the number and location of test tubes in
each sector. A holder magnet 330 is mounted flush with the bottom
wall 308 for stabilizing the sector 300 and holding the sector in
place on the workstation 100 during removal of test tubes 102. The
holder magnet 330 is located and oriented for attraction by
respective ones of the table magnets 145 of the workstation 100. A
sensor magnet 332 is likewise mounted flush with the bottom wall
308, for activation of respective reed switch sensors 150 of the
workstation 100.
[0148] With further reference to FIG. 8D, an alternative and
preferred configuration of the sector, designated 300', has the
back wall 305 (and the handle 324) extended somewhat from the top
wall 306 and having a rearwardly projecting lip portion 305', a
triangularly shaped resilient block 334 being retained on the
handle 324 proximately against the underside of the lip portion
305'. The resilient block 334 advantageously facilitates reliable
engagement of the sector 300' by the gripper members 2048' and
2048'' of the analyser robotic arms 2002 in the configuration of
FIG. 13G, by permitting increased vertical (and horizontal)
alignment tolerance as compared with the engagement configuration
of FIG. 15E. The resilient block 334 also facilitates more
effective gripping by the gripper members 726 of the workstation
robotic arm 700 in the configuration of FIG. 13D, by resilient
conformity of the block 334 with one of the gripper members 726,
and by the combination of the block 334 and the back wall 305
having a non-circularly cylindrical shape, the engagement producing
a centered and vertically aligned relationship between the sector
300' and the gripper axis 715 regardless of slight variations in
vertical positioning of the gripper members.
[0149] Because laboratories typically process specimens from
different sources, such as different hospitals, testing labs, and
doctors' offices, the containers or test tubes 102 often have
different diameters and different heights. To accommodate
variations in diameters, the top 315 has four depending fingers 328
for each test tube slot 314, the fingers being biased radially
inwardly. The sector 300' shown in the FIG. 8D is available from
Beckman Instruments with the Synchron CX machine.
[0150] With reference to FIGS. 9A-9D, a test tube rack 600 suitable
for use in the system 10 includes a frame 602 having the bar code
identifier 601 applied thereto, and defining a 5 by 10 array of
vertical cavities 603. The frame includes holes 604 for the
positioning pins 146, and has counterparts of the holder and sensor
magnets 330 and 332. Each of the cavities 603 is provided with an
insert member 606 having spring fingers 607 to hold different size
test tubes in the rack, the fingers being formed for retaining a
resilient O-ring member 609 that augments frictional engagement of
containers 12 being test tubes 102 by the fingers 607. Thus each
rack 600 forms a holder 14 for the containers 12, the cavities 603
being typically spaced at a pitch of approximately 20 mm, the
inserts 606 being sized for biasingly centering the containers 12
up to approximately 16 mm in diameter, the combination of the
finger members 607 and the O-ring 609 being sufficiently resilient
for effectively centering containers not larger than approximately
13 mm in diameter.
[0151] Although the present invention is described with regard to
bar code and bar code readers for tracking test tubes and other
components of the system, other detection systems can be used. For
example, magnetic ink labels can be placed on test tubes and other
components, to be read by a magnetic ink reader.
[0152] With reference to FIGS. 10A, 10B and 10C, the buckets or
receptacles 1200 each have an array of cavities 1203 corresponding
to the openings 603 of the racks 600, the cavities 1203
symmetrically surrounding a stem member 1204. An upper portion of
the stem member 1204 is square in cross-section for engagement by
the gripper members 726 (FIG. 13C) of the robotic arm 700 in any of
four discrete orthogonal orientations, a spaced pair of resilient
O-rings 1206 being retained on the stem member for augmenting
frictional engagement by the gripper members 726. As shown in FIG.
10A, there are 16 of the cavities 1203 in each receptacle 1200,
each cavity 1203 being defined by a counterpart of the insert 606
and having counterparts of the finger members 607. The receptacles
1200 are adapted for placement in respective cradles 1008 of the
centrifuge unit 1000, having a pair of notches 1208 formed in
opposite sides thereof for registration with respective bearing
caps 1009 of each cradle 1008 as shown in FIG. 10A.
[0153] As shown in FIG. 10C, each receptacle 1200 is formed with a
pair of holes 1210 for registration on corresponding bucket
positioning pins 144, and a counterpart of the sensor magnet 330
for activation of the associated reed switch sensor 150 of the
workstation table 114 (FIG. 5). Optionally and a further shown in
FIG. 10C, a counterpart of the sensor 150 can be located in or
under the cradle 1008 for sensing a seated condition of the
receptacle 1200 in the centrifuge head 1006, and/or counterparts of
the positioning pins 144 can be mounted on the cradle 1008 as an
alternative to registration of the receptacle 1200 by the bearing
caps 1009.
[0154] When loading buckets with test tubes for use in the
centrifuge, it is important they be loaded in a systematic way to
provide balance. FIGS. 11A-11D provide a top plan view of
receptacles 1200 loaded into the centrifuge, showing satisfactory
loading patterns. Empty test tube cavities 1203 are represented by
unfilled circles, blackened circles representing cavities loaded
with test tubes 102. The buckets are loaded to provide even weight
on opposite sides of the center point of the centrifuge, as well as
maintain each receptacle approximately balanced relative to the
respective stem member 1004. Other suitable loading patterns are
known to those of ordinary skill in the art.
[0155] With particular reference to FIGS. 13A, 13B, and 13C, an
exemplary configuration of the robotic arm 700 includes a base
carriage 702 that is positionable along the workstation track 704.
The track 704 extends proximately between opposite ends of the
workstation 600 approximately centered between opposite sides
thereof, and having protective accordion covers 705. A panning head
706 is controllably rotatably supported on a vertical pan axis 707
of the base carriage 702, an upper arm 708 being likewise
controllably rotatably supported on a horizontal shoulder axis 709
of the panning head 706. A lower arm 710 is likewise controllably
rotatably supported on an elbow axis 711 of the upper arm 708, the
elbow axis 711 being parallel-spaced from the shoulder axis 709 at
an outer extremity of the upper arm 708. Similarly, a wrist head
712 is controllably rotatably supported on a wrist axis 713 of the
lower arm 710, and having a gripper head 714 controllably rotatably
supported therefrom on a gripper axis 715. The axes 713 and 715 are
orthogonal, the wrist axis 713 being parallel-spaced from the elbow
axis 711 at an outer extremity of the lower arm 710. The gripper
head 714 has a gripper body 716, pair of gripper armatures 717
being controllably movable with tactile feedback toward and away
from opposite sides of the gripper axis 715. The gripper head 714
also includes an optical head sensor 718 fixably supported relative
to the gripper body 716, the head sensor 718 including a light
source 719 having a source axis 720, and a light portion 721 having
a receiver axis 722, the axes 720 and 722 converging proximate the
gripper axis 715 from opposite sides thereof in spaced relation to
the gripper body 716 and the gripper armatures 717. The robotic arm
700 also includes a robot control system (not shown) having
suitable provisions for manipulating the gripper head 714 relative
to the workstation track 704 for grasping and transporting objects
in a manner known to those having skill in robotics. As so far
described, the exemplary robotic arm 700 is a commercial device,
available as Model 255 from CRS Robotics of Ontario, Canada.
[0156] As further shown in the drawings, the robotic arm 700 is
provided with an indicia scanner 724, sometimes referred to herein
as bar-code scanner 724, the scanner 724 having a scan axis 725 and
being fixedly located on the upper arm 708 such that the scan axis
normally intersects the gripper axis 715 distally from the
intersection of the source and receiver axes 720 and 722. Thus the
scanner 724 is advantageously oriented on the upper arm 708 for
permitting effective scanning of both vertically and horizontally
oriented indicia. Particularly, the container indicia 104 are
normally vertically oriented, while the various indicia of the
racks 600, receptacles 1200, and sectors 300 are normally
horizontally oriented. Moreover, the gripper head 714 is provided
with a pair of gripper members 726, the gripper members 726 being
mountable on respective ones of the gripper armatures and being
adapted for grasping containers, receptacles, and sectors as
described herein, for transport thereof. Further, the head sensor
718, in combination with programmed movement of the gripper head
714, permits determinations of the heights of the containers 12 for
effective engagement by the gripper members 726.
[0157] As further shown in FIG. 13B, the robotic arm 700 is movable
about the pan axis 707 within an angle ? that is symmetrical on
opposite sides of the workstation track 704 and greater than 180?,
being approximately 315?. This range of angular orientations about
the pan axis 707, in combination with the base carriage being
movable to proximate each end of the workstation 600, facilitates
transport of containers 12, sectors 300, and other holders to
virtually any location within the table 114, often without
requiring movement of the base carnage 702 along the workstation
track 704. Also, the gripper head 714 is advantageously locatable
in overhanging relation to the table panel 114 for accessing the
centrifuge unit 1000.
[0158] With further reference to FIG. 13D, an alternative
configuration of the gripper head 714 has the head sensor 718 on
one side only of the gripper body 716, a laser source 719' being
substituted for the emitter 719 and mounted adjacent the light
receiver 721. Thus the source and receiver axes 720 and 722
converge from the same side of the gripper axis 715; however, the
laser source 719' more than compensates for any loss of
effectiveness of the sensor 718 that would be attributable to the
axes 720 and 722 being asymmetrical relative to the gripper axis
715.
Site Adjusters
[0159] The workstation delivery site 106 and receiving site
preferably are provided with a site adjustment mechanism 961 for
each of the analyzers 2000, each adjustment mechanism 961
facilitating exchanges of holders 300 between the workstation 100
and the corresponding analyzer 1200. As shown in FIGS. 12A and 12B,
the delivery site adjuster 961 includes a platform member 962 and a
clamp member 964 that are movably coupled on opposite sides of the
table panel 112 of the workstation 100 by a plurality of threaded
fasteners 965, the fasteners 965 and a boss portion 966 of the
platform member 962 extending through a clearance opening 967 that
is formed in the table 112. Each of the fasteners 965 carries a
compression spring 968 for biasing the platform member 962 and the
clamp member 964 into clamping engagement with the table panel 112,
the platform member 962 also having an O-ring 969 partially
recessed therein for frictionally gripping the table during the
clamping. A pneumatic cylinder 970 is coupled between the clamp
member 964 and the boss portion 966 of the platform member 962 for
releasing the clamping in response to selective application of
pressurized gas to a gas port 971 of the pneumatic cylinder 970 by
a gas pressure system 850 (FIG. 19). Thus the platform member 962
is freely rotatable and laterally translatable while the pneumatic
cylinder 970 is activated. The platform member 962 has two pairs of
the locating pins 142 mounted thereon for locating and holding
corresponding sectors 300 thereon, the sectors 300 being accessible
by either the workstation robotic arm 700 or the corresponding
analyzer robotic arm 2002. Also, the platform member 962 has
sensors 150 imbedded therein for sensing corresponding sectors 300
being registered on the associated pair of pins 142, each sensor
150 being typically implemented as a conventional magnetic reed
switch and coupled for signaling with the process controller
500.
[0160] Once each analyzer 2000 is set up in proximate alignment
with the workstation 100, the associated alignment mechanism 961 is
adjusted by first activating the pneumatic cylinder 970 for
releasing the clamping, then manually positioning and orienting the
platform member 962 for alignment of the sectors 300 with the
analyzer gripper 2040 in corresponding workstation transfer
positions of the analyzer robotic arm 2002. The pneumatic cylinder
970 is then released for clamping the platform member 962 in the
aligned position, thereby effecting the adjustment. Finally, the
position and orientation of the platform plate 962 is stored in
memory of the process controller 500 by any suitable means, such as
by scanning the sectors 300 in seated positions thereof on the
platform member 962 using the optical head sensor 718 of the
workstation robotic arm 700.
Balance System
[0161] As indicated above, and with particular reference to FIGS.
4, 17A, and 17B, the processing system 10 includes a balance system
800 for balancing containers 12 in receptacles or buckets 1200
prior to centrifugation, the balance system including the scale 802
and the auxiliary rack site 804 on the rear section 118 of the
workstation 100. The scale 802 can be a conventional electronic
platform scale to which is added counterparts of the bucket
positioning pins 144 for locating the receptacles 1200. Buckets are
moved between the scale 802, the centrifuge unit 1000, and other
locations on the rear section 118 by the workstation robotic arm
700, which also transfers containers 12 to buckets 1200 on the
scale 802 from a rack 600 at the auxiliary site 804 as well as from
other locations on the workstation 100. The balance system 800 also
includes a balance controller for selectively depositing containers
in cavities of the receptacles while correlating incremental weight
changes with the locations of each deposit for equalizing weight in
pairs of the receptacles. The balance controller can be implemented
as a balance program 808 within the central process controller 500,
the balance program 808 maintaining a database 810 of container
locations and associated weights, and directing the robotic arm 700
for depositing the containers 12 into the receptacles 1200 in
response to weights measured by the scale platform 802, the weights
being signaled in any suitable manner to the process controller
500.
[0162] Preferably the balance system also includes a supply of
dummy loads 806 (which can be test tubes 102 that are loaded with
predetermined weights) to be selectively deposited into the
receptacles 1200. Accordingly, the balance controller is operative
for moving dummy loads 806 to appropriate locations in particular
receptacles 1200 for limiting weight variations between
receptacles. Preferably the dummy loads 806 are progressively
weighted for limiting the weight variations in pairs of the
receptacles 1200 to not greater than 10 grams. The auxiliary rack
site 804 is provided on the workstation 100 proximate the scale 802
for facilitating temporary storage of the dummy loads 806, the rack
600 at the site 804 also providing additional temporary storage for
containers 12 to be further processed and/or sorted.
[0163] In the balance program 808, the scale database 810 is
initially loaded in a select specimens step 812 with counterparts
of container indicia 104, and with data for a common spin cycle
1002 associated therewith, the corresponding containers 12 being in
a quantity appropriate for simultaneous centrifugation by the
centrifuge unit 1000. Next, in a tare step 814, an appropriate
complement of receptacles 1200 for holding the containers 12 is
identified, and seated if necessary, at respective sites on the
scale platform 802. A total load on the scale 802 is measured
fallowing the depositing of each item on the scale 802, a
difference between successive measurements representing each
particular added load. Following the tare step 814 is a load step
816, wherein the containers 12 to be centrifuged are sequentially
placed in respective ones of the receptacles 1200 according to an
appropriate one of the patterns of FIGS. 11A-11D, depending on the
number of the containers 12 to be centrifuged. The balance program
808 continues monitoring the loads added to the scale 802 during
the load step 816. Thus the balance program 808 is operative for
monitoring the total weight associated with each of the receptacles
1200. After the load step 818, appropriate ones of the dummy loads
806 are added in a correction step 820 as required to bring members
of each pair of the receptacles 1200 to within the predetermined
allowable variation.
Decapper System
[0164] With particular reference to FIGS. 18A and 18B, the decapper
system 900 includes a receiver 902 for clampingly holding a
container or test tube 102 having a cap 103 frictionally engaging
the test tube 102 and extending laterally from opposite sides of a
top portion of the test tube 102. The receiver 902 is mounted in
depending relation to a decapper deck insert 903 of the workstation
100 as further described below. An important aspect of the present
invention is that the decapper system 900 is operative with both
threadingly engaged caps as described below, and with caps having
frictional engagement only with the container 12 as described
herein. A yoke member 904 having a cap slot 905 formed therein is
movably mounted on an elevator 906 that projects above the deck
insert 903, being supported thereby. The elevator 906 includes an
actuator 908 and an elevator column 909 that is rigidly connected
to the yoke member, the actuator 908 being coupled to a translation
motor 910 through a translation belt 911 for rotational translation
of the yoke member 104 concentric with the elevator column 909
between open and closed positions thereof The elevator 906 is also
coupled to an elevator motor 912 through an elevator belt 913 for
raising and lowering the elevator column together with the yoke
member 904. The yoke member 904 has an upwardly facing ledge
portion 916 formed within the cap slot 905 for engaging the
underside of an outwardly extending shoulder surface 917 of the cap
103 when the cap 103 is seated in the test tube 102, the tube 102
being held in the receiver 902, in the closed position of the yoke
member 904.
[0165] With the ledge portion 916 extending under the shoulder
surface 917 in the closed position of the yoke member 904, the
elevator 906 is operative for raising the yoke member 904 relative
to the receiver 902 to thereby remove the cap 103. The receiver 902
includes a bladder cage 920 for rigidly supporting a bladder 921,
the bladder 921 having a gas port 922 for selective inflation from
a suitable pressure source, described below, thereby to grip a test
tube 102 being seated therein. Thus the receiver 902 is operative
for holding the container 12 against axial forces exerted by the
yoke member 904 as the cap 103 is being pulled from the container
12.
[0166] As mentioned above, a further important capability of the
decapper system 900 is removal of threadingly engaged caps 103.
Accordingly, the bladder cage 920 is rotatably mounted to the deck
insert 903, being coupled to a rotation motor 924 through a
rotation belt 925 for controllably turning the bladder 921
concentrically with the container 102, thereby to unscrew the
container 12 from the cap 103. The cap 103 is prevented from
rotation within the yoke member 904, being formed with a
non-circular outer contour having an enlargement 927 formed
thereon, the enlargement 927 of the cap 103 bearing against a
portion of the cap slot 905 when torque is applied to the container
12 by the retainer 902. The gas port 922 is preferably configured
to provide a rotary connection to the bladder 921, the port 922
being connected to a three-way control valve 928 through a cage
line 929 for selective pressure activation in response to the
central controller 500 to effect the above-described holding of the
containers 12.
[0167] With further reference to FIG. 15F, a preferred alternative
of the bladder cage, designated clamp cage 920', includes a
resilient sleeve 921' in place of the bladder 921, the sleeve 921'
having three outwardly projecting ears 926 that engage respective
ear slots 929 of the cage 920' to insure rotational integrity of
the sleeve 921' with the cage 920'. Three vertically oriented jaws
913 are spaced between the ears 926 together with corresponding cam
bars 914, the bars 914 resting on a disk plate 915. An air cylinder
918 that is coupled by the fitting 922 to the control valve 928
through the cage line 929 drives the disk plate 915 and the bars
914 upwardly. The bars 914 have a spaced pair of cam slots 914A
that engage corresponding pins 914A that project from the jaws 913,
thereby driving the jaws 913 inwardly in response to the upward
movement of the bars 914 for compressing the sleeve 921' against
the test tube 102. The sleeve 921' is closed at the bottom for
confining debris in case a test tube 102 is fractured therein.
Also, the sleeve 921' has ribs 923 formed therein for contacting
the test tube 102, including three full-length clamp ribs 923A that
are aligned with the jaws 913 and three foreshortened holder ribs
923B. Spaces between the ribs 923 contribute flexibility to the
sleeve 921' for enhanced effectiveness of the jaws 913 in gripping
the test tubes 102. Test tubes 102 that are 100 mm in length
normally extend to proximate the bottom of the sleeve 921', while
test tubes 102 having a length of 75 mm are normally inserted only
partway into the sleeve 921' as indicated by broken lines in FIG.
15F, the holder ribs 923B being configured for retention of the
shorter test tubes 102 partially inserted, without adding
unnecessarily to the axial forces required for full insertion and
withdrawal of the 100 mm test tubes 102.
[0168] Preferably the decapper system also includes a collector 930
for receiving caps 103 from the yoke member, and an unloader 932
for transferring removed caps from the yoke member 904 to the
collector 930. An exemplary implementation of the unloader includes
an upstanding unloader post 934 fixedly mounted to the deck insert
903 proximate the collector 930, in alignment with the cap slot 905
in the open position of the yoke member. A decapper program portion
of the central controller 500 is operative for moving the yoke
member 904, having a removed cap 103 therein, until the post 934
strips the cap 103 from the yoke member. Preferably, the collector
930 further includes a tube member 936 for directing the stripped
caps 103 into the collector 930.
[0169] With further reference to FIGS. 18C-18E, an alternative and
preferred configuration of the decapper system, designated 900',
includes a yoke housing 938 having a bottom cover 939 as a
counterpart of the yoke member 904, a clamp mechanism 940 being
operative within the housing 938 for positively gripping the caps
103. As shown in FIG. 18E, the clamp mechanism 940 has an opposed
pair of pivotally mounted jaws 942 that are operated by a pneumatic
cylinder 944 having a wedge-shaped cam actuator 946 that extends
from the cylinder 944 in response to applied gas pressure. The jaws
942 are each formed having a plurality of projections 943 therein
for gripping opposite sides of the caps 103 when same are
positioned within the cap slot 905. The yoke housing 938 is formed
having a passage 948 therein from the cylinder 944 to a fitting 949
that projects below the cover 939 for connecting a flexible line
950, the line 950 extending below the deck insert 903 to a
three-way valve 952. The valve 952, being connected by a decapper
line 870 to the pneumatic system 850 (FIG. 19) as is the valve 928
described above, is operative for activating the pneumatic cylinder
944 in response to the central controller 500 to effect gripping of
the caps 103. Thus the caps 103 are not required to have
enlargements 927 or to otherwise have a rotationally interfering
fit with the cap slot 905. Further, the caps 103 are not required
to have the outwardly projecting shoulder surface 917 (FIG. 18A) in
the preferred decapper 900'.
[0170] As further shown in FIGS. 18C and 18D, the decapper system
900' includes a counterpart of the unloader 932 on the yoke housing
938, in the form of a plunger assembly 954. The plunger assembly
954 includes a shouldered plunger 955 that is guided within an
ejector support 956, the plunger 955 having an upwardly projecting
stem 957 that slidingly engages the support 956, an ejector spring
958 being interposed on the stem 957 for downwardly biasing the
plunger 955 against the yoke housing 938. A cap 103 being released
from the jaws 942 by deactivation of the valve 952 is forcefully
extracted from the cap slot 905 by axial movement of the plunger
955 into engagement with the yoke housing 948. Thus caps 103 are
prevented from sticking to the projections 943 of the jaws 942 when
the clamp mechanism 940 is opened, for reliable unloading into the
collector 930.
[0171] The controller 500 is programmed for driving the elevator
906 sufficiently high for the plunger 955 to clear the cap 103 as
the cap slot 905 is rotated into position over the cap 103, then
lowering the yoke housing 938, thereby compressing the ejector
spring 958 as the jaws 942 are lowered into a desired alignment
with the cap 103, the cap 103 supporting the plunger 955. Next, the
clamp mechanism 940 is closed by activation of the valve 952, the
jaws 942 gripping the cap 103, and operation of the decapper 900'
continues as described above in connection with the decapper system
900 of FIGS. 18A and 18B.
[0172] As further shown in FIG. 18B, the tube member 936 is
provided with a cap detector 959 for signaling the controller 500
upon each passage of a cap 103 into the collector 930. Thus
appropriate corrective action can be taken in the event that
processing a capped container 12 by the decapper system 900' fails
to result in detected passage of the cap 103 into the collector
930.
[0173] As shown in FIG. 19, the workstation 100 is provided with a
pneumatic circuit or gas pressure system 850 having a plug
connection 851 to a suitable source 852 of pressurized gas, the gas
being fed through an inlet filter 853 to an accumulator reservoir
854 of approximately 22 liters capacity, a one-way inlet valve 855
being provided for maintaining pressure when the source 852 is
inactive. A main solenoid valve 858 and a pressure transducer 859
are series-connected between the inlet filter 853 and the inlet
valve 855, the transducer 859 signaling the normal presence of gas
pressure at approximately 5 atmospheres. The rail 26 of the track
704 is utilized as the reservoir 854, the rail 26 advantageously
providing large capacity and extending substantially the full
length of the workstation 100 for enabling relatively short
pneumatic connections.
[0174] A distribution manifold 860 is connected to the reservoir
854 for feeding pneumatic elements of the workstation 100 as
described herein. In a bearing branch 861 from the manifold conduit
860, a moisture filter 862, a pressure regulator 863 having an oil
filter 864 and a pressure indicator 865, and a pressure transducer
866 are series-connected for feeding air bearings of the track 704
of the workstation robot arm 700, the transducer 866 signaling a
normal pressure of approximately 4.5 atmospheres. A brake branch
867 from the manifold 860 has a solenoid brake valve 868 connected
therein for activating a track brake of the track 704. A
counterpart of the pressure regulator, designated 869, is connected
in a decapper branch 870 from the manifold conduit 860 for feeding
the decapper system 900. A shield branch 871 from the manifold 860
having another regulator, designated 872, feeds a trio of door
valves 873 for controlling the pneumatic actuators 52 of the shield
system 40. A pair of adjuster valves 874 being mounted to the rail
26 of the track 704 for fluid connection to the reservoir 854 for
selectively releasing the delivery site adjusters 961, the valves
874 being connected by respective adjuster lines 875 to
corresponding gas ports 971 of the adjusters 961. Finally, a pair
of side loader branches 876 of the manifold conduit 960 have
corresponding counterparts of the valves 874, designated manually
activated valves 878, therein for feeding pneumatic components of
the analyzers 2000, including the analyzer robotic arms 2002.
Centrifuge Unit
[0175] As described above, the centrifuge unit 1000 receives the
specimens in containers 120 that have been loaded into receptacles
1200, subjecting the specimens to a specified spin cycle 1002 prior
to further processing in the analyzer 2000. With particular
reference to FIG. 16A, the centrifuge unit 1000 provides a
plurality of load stations 1004 on respective cradles 1008 of a
rotatably driven spindle head 1006 for receiving a balanced
complement of the receptacles 1200 within a spin chamber 1010 of
the centrifuge unit 1000. As used herein, "receptacle" includes
buckets 1200, but broadly means a device for holding a fluid
specimen within a centrifuge and during transport of the specimen
into and out of the centrifuge. Thus "receptacle" can stand for (1)
a single test tube, vial or other container when the container is
loadable directly into a centrifuge head cavity; or (2) a rack,
sector, or other holder for one or more containers when the
containers are in such holders during centrifugation.
[0176] An exemplary embodiment of the centrifuge unit 1000 includes
a cabinet 1012 having a chamber opening 1014 for accessing the spin
chamber 1010, a spindle unit 1016 being supported within the
cabinet 1012 under the opening 1014 for driving the spindle head
1006, the cradles 1008 being pivotally mounted to the spindle head
1006 as indicated by pairs of bearing caps 1009. The cabinet 1012
includes a wheeled base frame 1018 having a base plate 1020
fastened thereon, a plurality of body panels including respective
pairs of side panels 1022 and end panels 1024 surrounding the frame
1018 and extending upwardly from the base plate 1020, and a deck
panel 1026, the deck panel 1026 extending between upper extremities
of the body panels 1024 and 1026. A chamber bezel 1028 having the
chamber opening 1014 formed therein covers a portion of the deck
panel 1026, an access panel 1030 also covering a portion of the
deck panel 1026, the deck panel 1026 having an opening (not shown)
that corresponds to the chamber opening 1014, and another opening
(not shown) under the access panel 1030 for service access to
interior portions of the cabinet 1012.
[0177] According to the present invention, the centrifuge unit 1000
includes a horizontally oriented door member 1032 that is laterally
movable under the chamber bezel 1028 between an open position as
shown by solid lines in FIG. 16A, and a closed position as
indicated by dashed lines. The open position of the door member
1032 provides access to the spin chamber 1010, the closed position
blocking such access for protecting against accidental contact with
the spindle head 1006 and contents thereof during operation of the
centrifuge unit 1000. The door member is supported within a door
frame 1034, the frame 1034 being rigidly spaced above the base
plate 1020 on a plurality of column members 1036. The door member
1032 is driven between the open and closed positions by a
frictionally coupled door actuator 1038 as further described below,
the actuator 1038 advantageously protecting personnel from being
injured in case of inadvertently reaching through the cavity
opening 1014 while the door member 1032 is moving to the closed
position, by limiting the application of actuating force to the
door member 1032. As further shown in FIG. 16A, the centrifuge unit
1000 can include an input keyboard 1040 and a CRT display 1042 for
interfacing with an operator of the unit 1000.
[0178] With further reference to FIGS. 16B-16E, a preferred
alternative configuration of the centrifuge unit 1000 has a smaller
counterpart of the cabinet (not shown) with counterparts of the
door member, designated 1032?, and the door frame, designated
1034?, whereby access through the chamber opening 1014 to the spin
chamber 1010 is normally through a reduced-size access opening 1044
for facilitating rapid opening and closing of the door member
1032?. As shown in FIG. 16B, the door panel 1032? is supported
within a removable door module 1046 between an upper or outer tray
member 1048 and a lower or inner tray member 1050, vertically
aligned counterparts of the opening 1044 being formed in each of
the tray members 1048 and 1050. The access opening 1044 is
sufficiently large for passing one of the receptacles 1200
vertically therethrough into seating engagement with one of the
load stations 1004 when that load station 1004 is indexed to a
loading position as described below. More particularly, the tray
members 1048 and 1050 of the door module 1046 are fastened to
opposite sides of respective spacers 1052, a handle 1054 being
mounted on one of the spacers 1052 for horizontally withdrawing the
door module 1046 from the frame 1034?, thereby to fully expose the
spin chamber 1010 through the chamber opening 1014. It will be
understood that access to the door module 1046 can be provided by
any suitable means, such as removal of the associated end panel
1024.
[0179] As further shown in FIG. 16B, the door frame 1034? includes
a support plate 1056 that extends between upper extremities of the
column members 1036, a spaced pair of side rails 1058 being rigidly
fastened along opposite sides of the support plate 1056 for
laterally locating the door module 1046. As shown in FIG. 16C, the
door actuator 1038 includes a friction drive wheel 1060 that is
rotatably supported by a drive housing 1062, a stepper motor 1064
being coupled thereto. The drive wheel 1060 has a resilient ring
member 1066 formed thereon for biasingly contacting an edge surface
1068 of the door member 1032? thereby to translate the door member
1032? between the open and closed positions thereof.
[0180] An important feature of the door actuator 1038 is that the
drive wheel 1060 is not positively coupled to the door member
1032?, making sliding contact therewith in case movement of the
door member 1032? is blocked, for example, by laboratory personnel
reaching into the spin chamber 1010 as the door member 1032? is
being driven toward the closed position. The door member 1032? is
movably supported within the door module 1046 by a plurality of
guide rollers 1070 that engage a pair of tracks, designated primary
track 1072 and secondary track 1073, the tracks 1072 and 1073 being
fastened to the inner tray member 1050.
[0181] As further shown in FIG. 16C, the door member 1032? is
supported both vertically and horizontally relative to the primary
track 1072, horizontally oriented ones of the rollers 1070 being
mounted by respective threaded fasteners 1070A to the door member
1032?, vertically oriented ones of the rollers 1070 being supported
on respective rods 1070B that are clamped to the door panel 1032?
by corresponding retainer plates 1070C. The housing 1062 is
adjustably mounted to the door frame 1034? by suitable fasteners
1074 for providing a desired degree of coupling between the drive
wheel 1060 and the edge surface 1068.
[0182] As further shown in FIGS. 16B and 16D, a solenoid-operated
latch 1076 is mounted to the door frame 1034? for locking the door
member 1032? in the closed position thereof, the door member 1032?
having an opening 1078 formed therein for engagement by the latch
1076. Also, a slot 1079 is formed in the inner tray member 1050 and
one of the spacers 1052 for permitting withdrawal of the door
module 1046 when the latch 1076 is retracted from the door member
1032?. It will be understood that the door actuator 38 as described
above is suitable for driving the door member 1032 of FIG. 16A as
well as the door member 1032? of FIG. 16B, counterparts of the
guide rollers 1070 also being suitable for supporting of the door
member 1032 of FIG. 16A.
[0183] As shown in FIG. 16D, the centrifuge unit 1000 includes a
control circuit 1080 for operating the spindle unit 1016, the drive
unit 1038, and the latch 1076, a pair of optical position sensors
being located relative to the door frame 1034? for signaling the
open and closed positions of the door member 1032?, a first sensor
1081 signaling the closed position, a second sensor 1082 signaling
the open position of the door member 1032?.
[0184] The spindle unit 1016 includes the spindle head 1006, a
spindle assembly 1084 having a spindle shaft 1085 for rotatably
supporting the spindle head 1006 within the spin chamber 1010, the
spindle assembly 1084 also having a spindle housing 1086 that is
supported from the base plate 1020. A spindle motor 1088 is coupled
to the spindle shaft 1085 in a conventional manner, the motor 1088
being fixedly supported relative to the base plate 1020 by any
suitable means.
[0185] An important feature of the present invention is that the
spindle unit 1016 is capable of indexing each of the load stations
1004 into alignment with the access opening 1044 for receipt and
delivery of the receptacles 1200, the spindle head 1006 coming
directly and rapidly to a halt in a predetermined one of the
indexed positions at the conclusion of any desired spin cycle.
Accordingly, the spindle motor 1088 is provided with a position
encoder 1090 for signaling angular positions of the spindle head
1006. In an exemplary and preferred configuration of the control
circuit 1080 shown in FIGS. 16D and 16E, the spindle motor 1088 is
a four-pole brushless AC servo motor, a motor of this type being
Model SGM-00A3 Servomotor, available from Yaskawa Electric America,
Inc., of Northbrook, Ill. The above-identified motor includes the
encoder 1090 having a quadrature incremental count output 1091 of
2048 pulses/rev., and an index pulse output 1092. As also shown in
FIG. 16D, the control system 1080 also includes a centrifuge
processor 1093, a motion processor 1094, and a motor driver 1095,
the motion processor 1094 being responsive to the encoder 1090 and
position setpoint signals from the centrifuge processor 1093 for
feeding acceleration control signals to the motor driver 1095,
thereby driving the motor ain 1088 from an indexed initial rest
position to a programmed spin velocity, holding that velocity for a
programmed spin duration, then decelerating the motor 1088 to rest
at a predetermined final rest position.
[0186] Suitable devices for use as the centrifuge processor 1093
are commercially available from a variety of sources, one such
being a STD-32 486 CPU Board, available from Ziatech of San Luis
Obispo, Calif. A device suitable for use as the motion processor
1094 is available as Model STD/DSP Motion Controller from Motion
Engineering, Inc. Of Santa Barbara, Calif. This device processes
the quadrature signals of the count output 1091 for feeding a
position register with 8192 counts per revolution of the spindle
motor 1088, the device also having a destination register that is
loaded from the centrifuge processor 1093, and a digital to analog
converter (DAC) that generates an analog output as a function of
the difference between the position register and the destination
register and other variables including maximum velocity and
acceleration. It will be understood that the above-identified motor
and motor driver would not ordinarily be considered suitable for
use as the spindle motor 1088 and the motion processor 1094, in
that the rated allowable load inertia is only 0.189 oz-in-sec.sup.2
(0.836.times.10.sup.-4), being a factor of approximately 250 below
what is practically feasible in the centrifuge unit 1000 of the
present invention. In accordance with the present invention, it has
been discovered that the above-identified motor and motor driver
are suitable for use in the centrifuge 1000, with a suitable
compensating filter 1096 connected between the motion processor
1094 and the filter 1095. Primarily, the compensating filter 1095
provides a "notch" frequency response, the notch being centered at
approximately 75 Hz.
[0187] As further shown in FIG. 16D, the control circuit 1080 also
includes a stepper motor driver 1098 for operating the stepper
motor 1064 of the door actuator 1038 in response to the centrifuge
processor 1093. A device suitable for use as the stepper motor
driver 1098 is available as Model 48312 Microstepping Driver from
Intelligent Motion Systems, Inc. of Taftville, Conn. The centrifuge
processor 1093 also has a system interface 1099 for communication
with the process controller 400. It will be understood that the
keyboard 1040 and the display 1042 in the configuration of FIG. 16A
have conventional interfaces (not shown) with the centrifuge
processor 1093, those components not being required when the
processor 1093 is interfaced with the process controller 400. The
actual connections among the components of the control circuit 1080
are best shown in FIG. 16E, the circuit 1080 further including a
conventional STD-32 cardcage 1100 for the centrifuge processor 1093
and the motion processor 1094, an EMI filter 1102 having means for
connection to an external source of electrical power, a main power
supply 1104 and a stepper power supply 1106 for the stepper motor
controller 1098, the power supplies 1104 and pard fs22 1106 being
powered from the EMI filter 1102, a regeneration unit 1108 for the
motor driver 1096, and an I/O board 1110 that provides principal
interconnections between components of the control circuit 1080.
The regeneration unit 1108 absorbs energy that is recovered from
the spindle motor 1088 during deceleration, for limiting unwanted
power dissipation by the motor drive 1095. A device suitable for
use as the regeneration unit 1108 is available as Model JUSP-RG08
Regenerative unit, from Yaskawa Electric. The I/O board 1110 also
incorporates the compensating filter 1096 and conventional buffer
circuits for the sensors 1081 and 1082, and for the solenoid latch
1076, as shown in FIG. 16F. More particularly, the compensating
filter 1096 includes a twin-T filter 1112, a low-pass operational
amplifier 1114, a two-stage low-pass filter 1116, and a buffer
amplifier 1118, these elements being series-connected between the
previously introduced analog output, designated 1120, of the motion
processor 1094 and a torque command input 1122 of the motor driver
1095.
[0188] FIG. 16G depicts a control program 1130 of the centrifuge
processor 1093, the program 1130 having an initialization procedure
1131 wherein both program and data information is loaded into
memory of the motion processor 1094, serial communications are
established between the processor 1093 and the stepper motor drive
1098, default variable values are stored in variable memory of the
processor 1093, and action flags are reset. The initialization
procedure 1031 is followed by a main loop 1132 having a get command
step 1133 for receiving commands and data from the process
controller 400. In an exemplary implementation of the program 1130,
the executable commands are listed in Table 1, below.
TABLE-US-00001 TABLE 1 Centrifuge Commands Command Code Command
Name IM Index Move SA Set Acceleration SV Set Velocity ST Set Time
BR Begin Run HD Home Door HM Home Motor ER Stop VS Get Velocity
Status RS Get Rotor Status OD Open Door CD Close Door
[0189] In the following description, it will be understood that
many details of the control program 1130 are within the skill of
ordinary process control programmers. For example, the get command
step 1133 appropriately stores data accompanying several of the
commands, the commands being processed only when completely
received, with control being passed from the command step during
execution of time-consuming commands for continuous status
monitoring by the control program 1130. The get command step 1133
is followed by an execute command step 1134 that initiates
execution of the command, and sets appropriate flags and the like.
Execution of the Home Motor command is performed in a spindle
homing procedure 1135 wherein the spindle head 1006 is advanced to
a home index station wherein the load station 1004A is aligned with
the access opening 1044, as determined by activation of the index
output 1092 of the encoder 1090. The spindle homing procedure 1135
includes an advance step 1136 wherein the spindle head 1006 is
advanced at a moderate velocity until the head 1006 passes an index
position at which the index output is activated, a reverse step
1137 wherein the spindle head 1006 is stopped, then reversed at a
small fraction ( 1/25) of the moderate velocity of the advance step
1136; and an offset step 1138 wherein the spindle head 1006 is
again stopped and then advanced beyond the index position by an
offset distance. The index position is intentionally angularly
displaced from the load station 1004A, for activation of the index
output 1092 in the advance step 1133 preferably slightly prior to
alignment of the load station 1004A. Thus the offset distance can
be made advantageously small for rapid completion of the offset
step 1138.
[0190] Execution of the Index Move command is performed by an index
function 1140, wherein the load stations 1004A, 1004B, 1004C, and
1004D are addressed by corresponding digits 1, 2, 3, and 4, and the
spindle head is advanced (algebraicly) by the difference between a
presently indexed position and the addressed station, the
difference being the number of encoder counts between stations
times zero, one, two, or minus one.
[0191] Execution of the Begin Run command is performed in a begin
run procedure 1142, wherein data of the spin cycle 1002 is used to
calculate a destination distance as a sum of an acceleration
distance and a constant velocity distance, the acceleration
distance being the combination of both acceleration and
deceleration distances. More particularly, the constant velocity
distance, D.sub.Vis the product of the velocity V and time T of the
spin cycle 1002, and the acceleration distance is V.sup.2/A, where
A is a predetermined acceleration, A, V, and T having been
previously defined by corresponding ones of the above-identified
commands. These distances are summed, then offset by a distance
corresponding to the presently indexed position relative to the
home position, the result being signalled to the motion board 1094
for activation of the spindle motor 1088. Accordingly, the spindle
head 1006 is accelerated at the commanded acceleration to the
commanded spin velocity, the spin velocity being maintained for the
commanded spin time, the spindle head 1006 being then decelerated
at the commanded acceleration to rest at the home position.
[0192] Execution of the Home Door command is performed in a home
door procedure 1144 having a check home step 1145 and a move home
step 1146. The procedure 1144 is exited from the check home step if
the first sensor is activated, signifying the door being closed;
otherwise, the move home step 1146 is entered for activating the
stepper motor driver 1098 to advance the stepper motor 1064 at a
slow homing velocity (100 steps/sec.) toward the closed
position.
[0193] Execution of the Open Door and Close Door commands is
performed in a door function 1148, in corresponding opening and
closing steps 1149 and 1150. In the closing step 1150, the stepper
motor 1064 is caused to be driven 1200 steps toward the closed
position at 1500 steps/sec., followed by further movement at 50
steps/sec. until the home (closed) position is sensed. In case door
movement is hindered by blockage as described above, damage of the
centrifuge unit 1000 and/or injury to laboratory personnel is
prevented by the drive wheel 1060 slipping against the edge surface
1068 of the door member 1032? as described above. Similarly, the
opening step 1149 operates with opposite activation of the stepper
motor 1064, until the second sensor 1082 signals the open position
of the door member 1032?.
System Software
[0194] A preferred software implementation of the process
supervisor 200 and incorporating a graphical user interface (GUI)
is based on the Lab-View.TM. software development package,
available from National Instrumentation Corp. of Austin, Tex. In
this implementation, maps of the system 10, including the
workstation 100 and the centrifuge 1000, for example, are
displayed, together with various status indicators and controls.
Map displays show the locations of all of the holders 14, and by
clicking on a particular holder, its identification is displayed
and a map of the containers 12 therein is available. Conversely,
the location of a particular container 12 can be searched by
entering its identification. This implementation is available as
AccelNet software from Beckman Instruments.
[0195] Although the present invention has been described in
considerable detail with reference to certain preferred versions
thereof, other versions are possible. For example, as an
alternative to the shield system 40 or in addition thereto, the
workstation 100 can be provided with detectors to detect presence
of an operator in a portion of the workbench which can be dangerous
to the operator, to automatically stop operations, as is typically
used in industrial machinery. This can be a device such as light
beam and a light beam detector, shutdown of the workstation being
triggered by interruption of the light beam. Therefore, the scope
of the appended claims should not be limited to the description of
the preferred versions contained herein.
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