U.S. patent application number 11/304108 was filed with the patent office on 2007-09-27 for specimen carrier transfer apparatus.
Invention is credited to Douglas Barry, Thomas L. Bybee, Adrian Chan, John Fuller, Ray Puseman, Greg Rothman, Don R. Simms, Michael Turner, Jay Woods, Inna M. Zevakina.
Application Number | 20070225857 11/304108 |
Document ID | / |
Family ID | 31495731 |
Filed Date | 2007-09-27 |
United States Patent
Application |
20070225857 |
Kind Code |
A1 |
Barry; Douglas ; et
al. |
September 27, 2007 |
Specimen carrier transfer apparatus
Abstract
A transfer apparatus includes a shuttle depending from an
overhead support with a pair of arms for receiving and shifting a
specimen carrier from one conveyor to a second conveyor of a
dual-conveyor track. The shuttle is operable to retain a specimen
carrier along either the first or second conveyor and to release a
specimen carrier along either the first or second conveyor. Sensors
are located to detect the presence of a specimen carrier at each of
the retention locations, and to confirm the release of a specimen
carrier from the shuttle along each of the conveyors. A drive motor
for moving the shuttle between the retention and release positions
is electrically connected to a command module with a processor, for
receiving instructions as to the position of the shuttle. The
sensors are also connected to the processor to transmit detection
data to the processor. A queue is positioned upstream of the
shuttle and is electrically connected to the processor. The queue
includes retractable shafts, sensors and scanners for selectively
retaining, detecting and scanning identification data from a
specimen carrier on either conveyor upstream of the shuttle, and
transmitting the information to the processor.
Inventors: |
Barry; Douglas; (Lincoln,
NE) ; Bybee; Thomas L.; (Omaha, NE) ; Chan;
Adrian; (Richmond Hill, CA) ; Fuller; John;
(Omaha, NE) ; Puseman; Ray; (Bellevue, NE)
; Rothman; Greg; (Omaha, NE) ; Simms; Don R.;
(Council Bluffs, IA) ; Turner; Michael; (Bellevue,
NE) ; Woods; Jay; (Omaha, NE) ; Zevakina; Inna
M.; (Omaha, NE) |
Correspondence
Address: |
GEORGE R. NIMMER
PO Box 252
OMAHA
NE
68101-0252
US
|
Family ID: |
31495731 |
Appl. No.: |
11/304108 |
Filed: |
December 15, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10626466 |
Jul 24, 2003 |
6999847 |
|
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11304108 |
Dec 15, 2006 |
|
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60398893 |
Jul 26, 2002 |
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Current U.S.
Class: |
700/213 ;
198/348 |
Current CPC
Class: |
B65G 2201/0261 20130101;
B65G 47/914 20130101; G01N 2035/0467 20130101; G01N 35/0099
20130101; G01N 2035/047 20130101; G01N 2035/0484 20130101; B65G
37/005 20130101; B65G 21/22 20130101; B65G 47/52 20130101; B65G
47/902 20130101; B65G 37/02 20130101; B65G 47/763 20130101; B65G
23/30 20130101; G01N 2035/0465 20130101; B25J 18/04 20130101; G01N
2035/0406 20130101; Y10T 436/113332 20150115; G01N 2035/0462
20130101; B65G 23/08 20130101; G01N 35/04 20130101 |
Class at
Publication: |
700/213 ;
198/348 |
International
Class: |
G06F 7/00 20060101
G06F007/00 |
Claims
1. In combination: a dual conveyor track having first and second
parallel, spaced apart conveyors with upper surfaces within a
single plane, the conveyors operable in the same longitudinal
direction; a plurality of specimen carriers carried on said first
and second conveyors of said track; and a transfer apparatus
located between the first and second conveyors, with downstream
portions extending past the transfer apparatus to carry specimen
carriers to separate, predetermined locations, the transfer
apparatus comprising: a frame connected to the track for supporting
an operable shuttle; a shuttle operably connected to the frame for
transverse movement between the conveyors generally perpendicular
to the movement the specimen carriers on the conveyors; a first
stop member on said frame, projecting partially over the first
conveyor; a second stop member on said frame, projecting partially
over the second conveyor; said shuttle having a pair of parallel
arms spaced apart a distance to receive a specimen carrier
therebetween; said shuttle operable to a first "hold" position with
the shuttle arms located such that a specimen carrier therebetween
is in contact with the first stop member, to thereby prevent
downstream movement of a carrier on the first conveyor; said
shuttle operable to a first "release" position with the shuttle
arms located such that a specimen carrier therebetween bypasses the
first stop member and moves downstream through the shuttle arms on
the first conveyor; said shuttle operable to a second "release"
position with the shuttle arms located such that a specimen carrier
therebetween bypasses the second stop member and moves downstream
through the shuttle arms on the second conveyor; and a drive
assembly on the frame for selectively moving the shuttle among the
first "hold" position, the first "release" position and the second
"release" position.
2. The combination of claim 1, wherein said shuttle is operable to
a second "hold" position with the shuttle arms located such that a
specimen carrier located therebetween contacts the second stop
member to thereby prevent downstream movement the carrier on the
second conveyor, and wherein said drive assembly additionally
selectively moves the shuttle to the second "hold" position.
3. The combination of claim 1, wherein said frame further includes
a platform thereon extending between the conveyors, the platform
coplanar with the conveyors such that movement of the shuttle
between the conveyors moves a specimen carrier located within the
arms of the shuttle across the platform to the opposing conveyor.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This is a Continuation of Ser. No. 10/626,466, filed Jul.
24, 2003, which claims the benefit of U.S. Provisional Application
Ser. No. 60/398,893, filed Jul. 26, 2002.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED
RESEARCH AND DEVELOPMENT
[0002] (Not applicable)
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT
DISC
[0003] (Not applicable)
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to track utilized in
an automated clinical laboratory conveyor system, and more
particularly to an improved specimen carrier transfer apparatus for
transferring specimen carriers from one track loop to another in a
dual track system.
[0006] 2. Description of Related Art Including Information
Disclosed under 37 CFR 1.97, 1.98
[0007] Clinical laboratory testing has changed and improved
remarkably over the past 80 years. Initially, tests or assays were
performed manually and generally utilized large quantities of
serum, blood or other materials and/or body fluids. As mechanical
technology developed in the industrial work place, similar
technology was introduced into the clinical laboratory. With the
introduction of new technology, methodologies were also improved in
an effort to improve the quality of the results produced by the
individual instruments, and to minimize the amount of physical
specimen required to perform a particular test.
[0008] Instruments have been developed to increase the efficiency
of testing procedures by reducing turnaround time and decreasing
the volumes necessary to perform various assays. Robotic
engineering has evolved to such a degree that various types of
robots have been applied in the clinical laboratory setting.
[0009] The main focus of prior art laboratory automation relied on
the implementation of conveyor systems to connect areas of a
clinical laboratory. Known conveyor systems in the laboratory
setting utilize separate conveyor segments to move specimens from a
processing station to a specific laboratory work station. In order
to obtain cost savings, one typical scenario called for specimens
to be sorted manually and grouped together in a carrier rack to be
conveyed to a specific location. In this way, a carrier would move
a group of 5-20 specimens from the processing location to the
specific work station for the performance of a single test on each
of the specimens within the carrier rack.
[0010] With the development of new and improved automatic conveyor
systems for laboratories and other environments, it is possible to
select, track, and convey individual specimens throughout a
laboratory for a variety of different testing, while maintaining a
priority system for certain types of testing or special urgent
requests for a time-specific response. These new automated conveyor
systems are of various types and design, but the inventors herein
have found that a dual conveyor system, using a pair of parallel
conveyor tracks circulating throughout a laboratory, provides the
greatest flexibility and versatility. The integration of various
track devices with software directing the operation of the conveyor
system and the various automated testing stations, has improved
both the speed and capability of automated conveyor systems in
recent years.
[0011] Track devices form the physical interface between the
specimen samples in carriers being directed throughout the system,
while the Laboratory Automation System (LAS) database provides
direction for the system through its command and control features.
The LAS and the various track devices work in combination to
direct, manage and track all specimens throughout the system.
[0012] The dual-lane conveyors used in the present invention
utilize table top chain to transport specimen carriers about a
closed loop among various stations. Typically, the inside lane of
the dual lane conveyor acts as a highway to rapidly transport
specimens to their proper destination. The outside lane accepts
specimens diverted to it from the inside lane, and queues them for
processing at one of the automation system modules or laboratory
instruments. The continuous loop dual lane design means that
specimens will quickly circulate back to any module or instrument
on the system without operator intervention. Rules based processing
guidelines determine all specimen actions, including routing
changes for additional testing or modified processing.
[0013] In order to effectively manage, track and route specimens
throughout a clinical laboratory, it is necessary to maintain
constant "awareness" of the location of every specimen throughout
the system, and be able to direct each specimen to the appropriate
location at the most appropriate time for storage, testing or other
processing. This in turn is accomplished, in part, by one or more
transfer apparatus for selectively shifting a specimen carrier
between the inside and outside lanes of the dual lane conveyor.
BRIEF SUMMARY OF THE INVENTION
[0014] It is therefore a general object of the present invention to
provide an improved transfer apparatus for selectively moving
specimen carriers between the lanes of a dual lane, closed loop
conveyor in an automated conveyor system.
[0015] These and other objects will be apparent to those skilled in
the art.
[0016] The transfer apparatus of the present invention includes a
shuttle depending from an overhead support with a pair of arms for
receiving and shifting a specimen carrier from one conveyor to a
second conveyor of a dual-conveyor track. The shuttle is operable
to retain a specimen carrier along either the first or second
conveyor and to release a specimen carrier along either the first
or second conveyor. Sensors are located to detect the presence of a
specimen carrier at each of the retention locations, and to confirm
the release of a specimen carrier from the shuttle along each of
the conveyors. A drive motor for moving the shuttle between the
retention and release positions is electrically connected to a
command module with a processor, for receiving instructions as to
the position of the shuttle. The sensors are also connected to the
processor to transmit detection data to the processor. A queue is
positioned upstream of the shuttle and is electrically connected to
the processor. The queue includes retractable shafts, sensors and
scanners for selectively retaining, detecting and scanning
identification data from a specimen carrier on either of the
conveyors, upstream of the shuttle, and transmitting the
information to the processor.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0017] The preferred embodiment of the invention is illustrated in
the accompanying drawings, in which similar or corresponding parts
are identified with the same reference numeral throughout the
several views, and in which:
[0018] FIG. 1 is a perspective view of a transfer apparatus of the
present invention installed along a dual lane conveyor track;
[0019] FIG. 2 is a top plan view of the transfer apparatus module,
showing various possible positions of a specimen carrier as the
transfer apparatus operates;
[0020] FIG. 3 is a front elevational view of the transfer
apparatus;
[0021] FIG. 4 is a side elevational view of the transfer
apparatus;
[0022] FIG. 5 is a bottom view of the drive assembly of the
transfer apparatus;
[0023] FIG. 6 is a front elevational view of the transfer apparatus
showing the shuttle in a first position;
[0024] FIG. 7 is a front elevational view of the transfer apparatus
showing the shuttle in a second position; and
[0025] FIG. 8 is a front elevational view of the transfer apparatus
showing the shuttle in a third position.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to the drawings, in which similar or
corresponding parts are identified with the same reference numeral,
and more particularly to FIG. 1, the transfer apparatus of the
present invention is designated generally at 10, and is shown
installed between two conveyors 12 and 14 of a dual lane automated
conveyor transport track 16, to selectively transfer a specimen
carrier 18 between conveyors 12 and 14. Transfer apparatus 10
includes three general components: a queue 20, a lane changer 22
and a command module 24. Queue 20 serves to stop each specimen
carrier 18 that travels by the queue, identify the carrier 18 and
then release the carrier at a time determined by the command module
24. Lane changer 22 is operated by the command module 24 to receive
and shift a specimen carrier 18 from one of conveyors 12 or 14, to
the other. The command module 24 serves as the "brain" of the
transfer apparatus 10 and interacts with the Laboratory Automation
System (LAS) to identify, track and direct specimen carriers 18
through the transfer apparatus 10.
[0027] Referring now to FIG. 2, conveyors 12 and 14 use a table top
chain known in the art to transport specimen carriers 18. Each
table top chain includes a plurality of plates 26, each having a
flat upper surface or "table top" for moving carriers 18. Plates 26
are interconnected by links, which permit plates 26 to pivot about
the links within a horizontal plane. The links are engaged by a
drive mechanism to pull the chain along track 16 and thereby move
carriers 18 supported on the track. The upper surfaces of plates 26
form a flat planar surface identified throughout this specification
as a drive plane.
[0028] A pair of elongated guide rails 28 and 30 are disposed along
the lengths of each conveyor 12 and 14 on opposing sides of plates
26 to guide specimen carriers 18 therebetween. One embodiment of
specimen carriers 18 is disclosed throughout this specification,
but it should be understood that many other sizes and shapes of
carriers for specimens could be utilized with the present
invention. Each specimen carrier 18 includes a generally
rectangular body with a forward wall and a top surface. A plurality
of openings are formed in the top surface and extend into the
interior of the body for receiving and supporting a specimen tube,
slide, or other specimen container in an upright position.
[0029] Conveyors 12 and 14 operate in the same direction,
designated generally by arrow 32, although they may be operated at
different speeds. Queue 20 includes a housing 34 positioned between
conveyors 12 and 14 and located upstream of lane changer 22. A pair
of forward and rearward retractable shafts 36 and 38 extend
transversely outwardly from a first side 20a of queue 20, and
project over conveyor 12 to restrain a specimen carrier 18 from
passing by shaft 36 or 38. Forward and rearward sensors 40 and 42
are positioned adjacent each shaft 36 and 38, respectively, to
detect the presence of a specimen carrier 18 at the associated
shaft.
[0030] A second pair of forward and rearward retractable shafts 44
and 46 extend transversely outwardly from the opposing second side
20b of queue 20, and project over conveyor 14 to restrain a
specimen carrier 18 from passing by shaft 44 or 46. Forward and
rearward sensors 48 and 50 are positioned adjacent each shaft 44
and 46, respectively, to detect the presence of a specimen carrier
18 at the associated shaft.
[0031] In the preferred embodiment of the invention, forward shafts
36 and 44 are the projecting ends of a single shaft. In this way,
only one carrier 18 is permitted to continue downstream at a time,
since the retraction of one end of the shaft would cause the other
end to project farther over the opposing track. Similarly, rearward
shafts 38 and 46 are preferably the projecting ends of a second
single shaft. Again, only one carrier is permitted to advance
downstream from queue 20 along the conveyors 12 and 14.
[0032] The inward guide rails 30 of conveyors 12 and 14 are removed
from between the downstream end of queue 20 and lane changer 22,
and a platform 52 is installed with its top surface coplanar with
the drive plane of conveyors 12 and 14. Thus, carriers 18 may be
moved off of one conveyor and onto the other by sliding the carrier
across platform 52.
[0033] As shown in FIGS. 3 and 4, lane changer 22 includes a lower
housing 54 mounted between conveyors 12 and 14 and depending below
the drive plane "P". A rigid upright back 56 is connected at its
lower end to housing 54 and projects upwardly between conveyors 12
and 14. A support plate 58 projects forwardly and transversely
outwardly from the top of back 56, and serves as the frame for
supporting the shuttle 60, the shuttle drive assembly 62 and
sensors 64 and 66, all of which are described in more detail
hereinbelow.
[0034] Shuttle 60 serves to receive a specimen carrier 18 between a
pair of arms 68 and 70 and transversely move carrier 18 between
conveyors 12 and 14, and includes a base plate 72 connecting the
upper ends of arms 68 and 70 to form an inverted U-shaped
structure. Base plate 72 is mounted to the bottom of a slide 74
which in turn is slidably connected to a linear rail 76 on the
bottom of support plate 58. As shown in FIG. 3, linear rail 76
extends transversely over both conveyors 12 and 14, thereby
permitting movement of shuttle 60 over both conveyors. An
encoder-monitored DC stepper motor 78 selectively drives a drive
belt 80 connected to slide 74 to precisely position shuttle 60
where desired along rail 76.
[0035] The lower ends of arms 68 and 70 on shuttle 60 each have a
guide blade 82 and 84, respectively, mounted thereon. Blades 82 and
84 diverge outwardly as they project forwardly from the arms 68 and
70, to thereby shift a specimen carrier 18 transversely into
alignment between the arms 68 and 70. Blades 82 and 84 are
preferably formed of a resilient and flexible material so that
shuttle 60 can shift fully against the outside guide rails 28 (see
FIG. 2) to release a carrier 18 onto either conveyor 12 or 14.
[0036] A presence sensor 86 is positioned adjacent each outward
extent of shuttle 60 to detect the presence of a carrier 18 within
shuttle 60 on either conveyor 12 or 14. An exit sensor 88 is
positioned downstream of shuttle 60 along each conveyor 12 and 14,
to detect the presence of a carrier that has exited the shuttle
along either conveyor.
[0037] A pair of carrier stop arms 90 and 92 project transversely
outwardly from back 56 and extend partially over conveyors 12 and
14, respectively. However, stop arms 90 and 92 do not project far
enough to prevent a carrier 18 from passing between the stop arm
and the associated outside guide rail 28, if aligned with the
opening therebetween by carrier shuttle 60.
[0038] Referring once again to FIG. 2, the operation of transfer
apparatus 10 is as follows. While specimen carriers 18 travel along
both conveyors 12 and 14 during operation the description of the
operation of the transfer apparatus will assume that a carrier 18
first reaches queue 20 along conveyor 12. The rest position of all
four shafts 36, 38, 44 and 46 of queue 20 are in an extended
position, so that a carrier 18 is prevented from advancing beyond
the associated shaft until the particular shaft is retracted. Thus,
carrier 18, on conveyor 12 will first contact extended shaft 36 and
stop in position "A". Sensor 40 detects the presence of carrier 18,
and retracts shaft 36 to permit the carrier to proceed downstream.
Carrier 18 is then stopped by extended shaft 38. When rearward
sensor 42 detects the presence of carrier 18 at position "B", a
barcode scanner 94 is turned on to scan the barcode label on the
side of carrier 18. This data is then transmitted to the command
module 24, which will determine the appropriate action to take,
based upon priority rules and guidelines set up by the LAS.
[0039] Once the command module has determined the action to be
taken, shaft 42 is retracted, and carrier 18 proceeds to a "hold"
position "C" on conveyor 12. As shown in FIG. 6, the "hold"
position locates shuttle 60 slightly inwardly from the lane of
conveyor 12, so that blade 82 directs the carrier between arms 68
and 70, and into contact with stop 90. If carrier 18 is to be
diverted to conveyor 14, then command module 24 will instruct lane
changer 22 to move shuttle 60 across platform 52, as shown in FIG.
7, to the "release" position "D" on conveyor 14. The release
position "D" locates carrier 18 on conveyor 14 so that it bypasses
stop 92, to permit the carrier to proceed downstream, as shown in
FIG. 8. As the carrier leaves lane changer 22 it will pass exit
sensor 88 at position "E", which will confirm that the desired
action has occurred.
[0040] In the alternative, if carrier 18 is to be released along
conveyor 12 rather than diverted to conveyor 14, then shuttle 60
will be instructed to move outwardly from the "hold" position to
the "release" position. This movement will cause carrier 18 to be
moved outwardly beyond the end of stop 90, permitting the carrier
to proceed downstream on conveyor 12. As the carrier leaves lane
changer 22, it will pass exit sensor 88 at position "F", which will
confirm that the desired action has been taken.
[0041] This same sequence of actions occurs with a carrier 18 that
approaches queue 20 along conveyor 14, with the same options of
releasing the carrier on the same conveyor, or diverting the
carrier to conveyor 12.
[0042] Whereas the invention has been shown and described in
connection with the preferred embodiment thereof, many
modifications, substitutions and additions may be made which are
within the intended broad scope of the appended claims.
* * * * *