U.S. patent application number 12/211796 was filed with the patent office on 2009-07-16 for integrated robotic sample transfer device.
This patent application is currently assigned to SEQUENOM, INC.. Invention is credited to Richard Capella, Justin Cuzens, Rolf Silbert.
Application Number | 20090180931 12/211796 |
Document ID | / |
Family ID | 40468735 |
Filed Date | 2009-07-16 |
United States Patent
Application |
20090180931 |
Kind Code |
A1 |
Silbert; Rolf ; et
al. |
July 16, 2009 |
INTEGRATED ROBOTIC SAMPLE TRANSFER DEVICE
Abstract
Embodiments include integrated robotic sample transfer devices
and components thereof which are used for reliably and accurately
transferring small samples of material from one registered position
to another registered position. Such transfers of material may be
carried out by a single pin tool or an array of pin tools of a pin
tool head assembly of robotic sample transfer devices. Some
embodiments also include automated cleaning of the pin tools used
to transfer the sample material. Some embodiments are fully
integrated units having internal fluid supply and waste tanks,
vacuum source, fluid pumps, controllers and user interface
devices.
Inventors: |
Silbert; Rolf; (Del Mar,
CA) ; Capella; Richard; (La Jolla, CA) ;
Cuzens; Justin; (San Diego, CA) |
Correspondence
Address: |
GRANT ANDERSON LLP;C/O PORTFOLIOIP
PO BOX 52050
MINNEAPOLIS
MN
55402
US
|
Assignee: |
SEQUENOM, INC.
San Diego
CA
|
Family ID: |
40468735 |
Appl. No.: |
12/211796 |
Filed: |
September 16, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60972879 |
Sep 17, 2007 |
|
|
|
Current U.S.
Class: |
422/63 ; 250/288;
382/103; 422/400; 422/67; 73/1.79; 73/863.01 |
Current CPC
Class: |
B01J 2219/00351
20130101; B01L 2400/025 20130101; B01L 3/0244 20130101; G01N
35/0099 20130101; B01J 2219/00277 20130101; Y10S 901/24 20130101;
B01J 19/0046 20130101; B01L 3/0251 20130101; G01N 2035/1037
20130101 |
Class at
Publication: |
422/63 ; 422/100;
422/67; 73/1.79; 250/288; 73/863.01; 382/103 |
International
Class: |
G01N 35/00 20060101
G01N035/00; B25J 7/00 20060101 B25J007/00; G01N 31/20 20060101
G01N031/20; G01B 21/00 20060101 G01B021/00; H01J 49/26 20060101
H01J049/26; G01N 1/00 20060101 G01N001/00; G06K 9/00 20060101
G06K009/00 |
Claims
1. A robotic sample transfer device, comprising: a substantially
horizontal work surface including a plurality of functional
elements configured for small sample processing; a three axis
robotic positioning assembly having a fixed mount portion secured
in fixed relation with the work surface, a translatable carrier
configured to be translatable in three axes with respect to the
fixed mount portion and working surface and having a stepper motor
corresponding to each axis and at least one linear encoder assembly
configured to generate position data for at least one axis; at
least one pin tool coupled to the translatable carrier; and a
controller in communication with the stepper motors of each of the
three axes of the three axis robotic positioning assembly and the
at least one linear encoder assembly.
2. The sample transfer device of claim 1 further comprising a
housing disposed about the work surface, three axis robotic
positioning assembly and controller.
3. The sample transfer device of claim 2 further comprising a
graphic user interface on an exterior of the housing and
operatively coupled to the controller for providing user input to
the controller.
4. The sample transfer device of claim 1 wherein the three axes of
the three axis robotic positioning assembly are substantially
orthogonal to each other.
5. The sample transfer device of claim 1 wherein the three axis
robotic positioning assembly further comprises a bar code
reader.
6. The sample transfer device of claim 1 wherein the three axis
robotic positioning assembly further comprises an imaging camera
translatable in at least two axes and operatively coupled to an
image processor.
7. The sample transfer device of claim 1 wherein the controller
comprises at least one processor which is disposed within the
housing at a level which is above the level of the work
surface.
8. A robotic sample transfer device, comprising: a housing; a
substantially horizontal work surface disposed within the housing;
a three axis robotic positioning assembly disposed within the
housing having a fixed mount portion secured in fixed relation with
the work surface and a translatable carrier member translatable in
three different axes with respect to the fixed mount portion and
work surface; at least one pin tool coupled to the translatable
carrier having a shaft and a sample reservoir in a distal end of
the shaft; a plurality of functional elements disposed on the work
surface having a nominal upper surface at substantially the same
height; and a controller operatively coupled to the three axis
robotic positioning assembly.
9. The sample transfer system of claim 8 further comprising an
imaging camera movable in at least the x-y plane substantially
parallel to the work surface and having a shallow range of focus
and focused at the nominal upper surface of the functional
elements.
10. The sample transfer device of claim 8 wherein the functional
elements comprise a vacuum drying station, a fluid rinse station, a
microtiter plate having an array or regularly space sample supply
wells and a chip having an array of regularly spaced sample
deposition sites.
11. The sample transfer device of claim 8 further comprising a pin
tool head assembly having an array of regularly spaced pin tools
secured to the translatable carrier and wherein the vacuum drying
station includes a plurality of regularly spaced vacuum drying
ports corresponding to the spacing of the pin tools of the pin tool
head assembly, the fluid rinse station includes individual rinse
tubes corresponding to each of the pin tools of the array of
regularly spaced pin tools of the pin tool head assembly.
12. The sample transfer device of claim 10 further comprising a
self-leveling gravity fed ultrasonic cleaning well and an
ultrasonic cleaning fluid reservoir having a supply port configured
to couple into fluid communication with the ultrasonic cleaning
well when coupled to an inlet port of the ultrasonic cleaning well
and be substantially sealed when the removed from the inlet port of
the ultrasonic cleaning well.
13. The sample transfer device of claim 10 wherein the ultrasonic
cleaning fluid reservoir further comprises a ball valve which is
configured to seal the supply port when the fluid reservoir is
removed from the inlet port of the ultrasonic cleaning well.
14. The sample transfer device of claim 8 wherein the controller
comprises at least one processor which is disposed within the
housing at a level which is above the level of the work
surface.
15. An integrated robotic sample transfer device, comprising: a
housing; a three axis robotic positioning assembly disposed within
the housing having a fixed mount portion, a translatable carrier
translatable in three axes with respect to the fixed mount portion
and working surface and having a stepper motor corresponding to
each axis and at least one linear encoder assembly for generating
position data for at least one axis of the translatable carrier; a
pin tool head assembly secured to the translatable carrier member
having an array of regularly spaced pin tools with sample
reservoirs disposed in the distal ends thereof and configured for
axial displacement relative to a pin head body secured to the
translatable carrier of the three axis robotic positioning
assembly; a substantially horizontal work surface disposed within
the housing and secured in fixed relation to the fixed mount
portion of the three axis positioning assembly and having a fluid
rinse station, a vacuum drying station including a plurality of
regularly spaced vacuum drying ports corresponding to the regular
spacing of the array of pin tools, a self-leveling ultrasonic
cleaning well and a microtiter plate mount block configured to
releasably secure a sample well; a controller including a processor
disposed within the housing at a position which is above the level
of the work surface; a rinse fluid supply tank in fluid
communication with the fluid rinse station and disposed within the
housing; a waste fluid tank in fluid communication with an overflow
basin of the fluid rinse station and disposed within the housing; a
vacuum source in fluid communication with the vacuum drying
station; and an ultrasonic cleaning fluid reservoir in fluid
communication with a self-leveling ultrasonic cleaning well.
16. The sample transfer device of claim 15 wherein in the
ultrasonic cleaning fluid reservoir comprises a gravity feed
reservoir having a supply port configured to couple into fluid
communication with the ultrasonic cleaning well when coupled to an
inlet port of the ultrasonic cleaning well and be substantially
sealed when the removed from the inlet port of the ultrasonic
cleaning well.
17. The sample transfer device of claim 15 further comprising a
rinse fluid supply tank fluid level indicator.
18. The sample transfer device of claim 15 further comprising a
rinse fluid supply pump disposed within the housing, in fluid
communication with the rinse fluid supply tank and fluid rinse
station and configured to pump rinse fluid from the rinse fluid
supply tank to the fluid rinse station.
19. The sample transfer device of claim 15 further comprising a
waste fluid tank fluid level indicator.
20. The sample transfer device of claim 15 further comprising a
vacuum drying supply tank in fluid communication with the vacuum
drying ports of the vacuum drying station.
21. The sample transfer device of claim 20 further comprising a
vacuum pump in fluid communication with the vacuum drying supply
tank.
22. The sample transfer device of claim 15 wherein a nominal upper
surface of the fluid rinse station, nominal upper surface of the
vacuum drying station, nominal upper surface of the ultrasonic
cleaning well, nominal upper surface of a chip disposed in the chip
mount block and microtiter plate/sample well mounted in the sample
well mount blocks all being at substantially the same z-axis
level.
23. The sample transfer device of claim 15 further comprising an
imaging camera and image processing controller.
24. The sample transfer device of claim 15 further comprising a bar
code reader head and bar code reader processor in communication
with the bar code reading head and controller.
25. The sample transfer device of claim 15 wherein the fluid rinse
station comprises an array of regularly spaced individual rinse
tubes having a regular spacing corresponding to the regular spacing
of the pin tools of the pin tool head assembly.
26. The sample transfer device of claim 15 further comprising a
door on the housing covering an opening to a processing chamber
disposed within the housing.
27. The sample transfer device of claim 15 wherein the controller
comprises an assembly of electronics and logic circuits which are
disposed within the housing at a position which is above the level
of the work surface.
28. The sample transfer device of claim 15 further comprising a
universal power supply in communication with the controller that
produces a constant output voltage with varied input voltage to
allow device to operate in varying countries.
29. The sample transfer device of claim 15 wherein the entire dry
weight of the device is less than about 150 pounds.
30. The sample transfer device of claim 15 further comprising a
graphic user interface disposed on an outer surface of the housing
and in communication with the controller.
31. The sample transfer device of claim 15 further comprising a
humidity sensor disposed within the processing chamber of the
device and in communication with the controller which is configured
to sense the humidity within the processing chamber.
32. The sample transfer device of claim 31 further comprising
closed loop feedback from the humidity sensor with the controller
in conjunction with a humidity control device for maintaining a
substantially constant humidity within the processing chamber.
33. The sample transfer device of claim 15 further comprising a
temperature sensor disposed within the processing chamber of the
sample transfer device in communication with the controller which
is configured to sense the temperature within the processing
chamber.
34. The sample transfer device of claim 33 further comprising
closed loop feedback from the temperature sensor with the
controller and a temperature control device for maintaining a
substantially constant temperature within the processing
chamber.
35. A method of registering the position of a pin tool head
assembly of a robotic sample transfer device relative to sample
deposition sites on a chip, comprising: providing a robotic sample
transfer device having a work surface with a plurality of
functional elements with a nominal upper surface at substantially
the same level and a three axis positioning system with a camera
and pin tool head assembly secured to a translatable carrier
thereof; imaging the nominal upper surfaces of functional elements
disposed on work surface with the camera; processing the image data
of the nominal upper surfaces of the functional elements from the
camera to determine the approximate position of the pin tool head
assembly relative to the functional elements; using the approximate
position data to move the camera to a first chip having an array of
regularly spaced sample deposition sites and an array of regularly
spaced fiducial marks disposed between the sample deposition sites;
imaging fiducial marks on the first chip; processing the image data
of fiducial marks on the first chip; obtaining feedback regarding a
position of the pin tool head assembly from linear encoders of
three axes of a three axis robotic positioning system; comparing
encoder feedback with image processing feedback and look up table
data to determine the precise position of the pin tools of the pin
tool head assembly with respect to the sample deposition sites on
the first chip.
36. The method of claim 35 further comprising repeating the process
for multiple chips.
37. The method of claim 35 wherein the precise position of the pin
tools of the pin tool head assembly with respect to the sample
deposition sites on the first chip is determined to within about 1
micron to about 10 microns.
38. A method of dispensing calibration material onto a chip,
comprising: providing a chip having a first array of regularly
spaced sample deposition sites disposed on a substantially flat
working surface thereof and at least one sample deposition site for
receiving calibration material which is also disposed on the flat
working surface of the chip and which is off pitch with respect to
the regular spacing of the first array of regularly spaced sample
deposition sites of the chip; providing a robotic sample transfer
device having a pin tool head assembly with an array of regularly
spaced pin tools having distal ends which are substantially
coplanar in a relaxed state and which have a regular spacing which
is the same as the regular spacing of the first array of sample
deposition sites or an integer multiple thereof and configured to
align with the array of regularly spaced sample deposition sites of
the chip or a subset thereof; loading sample reservoirs of the
array of regularly spaced pin tools of the robotic sample transfer
device with calibration material; dispensing calibration material
from the pin tools of the robotic sample transfer device to the at
least one sample deposition site for receiving calibration material
such that the pin tools which are not aligned with sample
deposition sites for receiving calibration material are off pitch
with respect to the first array of regularly spaced sample
deposition sites of the chip and do not contact any of the
regularly spaced sample deposition sites of the first array.
39. The method of claim 38 wherein the chip comprises a second
array of regularly spaced sample deposition sites for receiving
calibration material sample which are off pitch with respect to the
first array of regularly spaced sample deposition sites and further
comprising dispensing calibration material from pin tools of the
robotic sample transfer device to the second array of sample
deposition sites for receiving calibration material such that the
pin tools which are not aligned with sample deposition sites for
receiving calibration material of the second array are off pitch
with respect to the first array of regularly spaced sample
deposition sites of the chip and do not contact any of the
regularly spaced sample deposition sites of the first array.
40. The method of claim 38 wherein the first array of regularly
spaced sample deposition sites comprises an array of regularly
spaced mass spectrometry sample deposition sites.
41. A pin tool displacement block for selectively displacing at
least one pin tool of a pin tool head assembly of a robotic sample
transfer device in an axial direction, comprising: a block body
having a bottom surface and a plurality of parallel slots formed
into the block body portion substantially perpendicular to the
bottom surface with a predetermined regular spacing configured to
correspond to regular spacing of pin tools of a pin tool head
assembly and having a transverse dimension sized to allow easy
movement of a width of a nominal shaft of the pin tools in the
slots but restrictive of movement of an enlarged portion of the
shaft of the pin tools; and at least one relieved portion in a slot
which has a transverse dimension sized to allow easy downward
movement of the enlarged portion of a pin tool shaft which is
greater than the transverse dimension of the slot and which extends
from a top surface of the block body towards the bottom
surface.
42. The pin tool displacement block of claim 41 wherein the at
least one relieved portion terminates at a stop surface which is
spaced from the bottom surface.
43. The pin tool displacement block of claim 41 wherein the at
least one relieved portion extends completely from the top surface
to the bottom surface and is configured to allow the enlarged
portion of a pin tool shaft to pass completely through the block
body.
44. The pin tool displacement block of claim 41 wherein the
relieved portion is configured to mechanically capture the enlarged
portion of a pin tool disposed therein in a lateral direction.
45. The pin tool displacement block of claim 41 wherein the
enlarged portion of a shaft of a pin tool comprises a collar member
and the stop surface of the at least one relieved portion is
configured to prevent axial movement of the collar member and
mechanically capture a collar disposed therein member to prevent
lateral displacement of the block body when the block is deployed
in a pin tool head assembly.
46. The pin tool displacement block of claim 41 wherein the top
surface and bottom surface of the block body are substantially flat
and substantially parallel to each other.
47. The pin tool displacement block of claim 41 wherein the block
body comprises an inert material.
48. The pin tool displacement block of claim 46 wherein the inert
material comprises Delrin.
49. The pin tool displacement block of claim 41 further comprising
a handle member secured to the block body.
50. The pin tool displacement block of claim 41 having a reversible
configuration wherein when the block is oriented in a first
direction a first pin or set of pins is active and when oriented a
second way a second pin or set of pins is active which is different
from the first set.
51. The pin tool displacement block of claim 50 wherein the first
direction is about 180 degrees from the second direction.
52. A method for selectively displacing at least one pin tool of a
pin tool head assembly of a robotic sample transfer device,
comprising: providing a pin tool displacement block including a
block body having a bottom surface and a plurality of parallel
slots formed into the block body portion substantially
perpendicular to the bottom surface with a predetermined regular
spacing configured to correspond to regular spacing of pin tools of
a pin tool head assembly and having a transverse dimension sized to
allow easy movement of a width of a nominal shaft of the pin tools
in the slots but restrictive of movement of an enlarged portion of
the shaft of the pin tools, and at least one relieved portion in a
slot which has a transverse dimension sized to allow easy downward
movement of the enlarged portion of a pin tool shaft which is
greater than the transverse dimension of the slot and which extends
from a top surface of the block body towards the bottom surface;
displacing an array of pin tools of a pin tool head assembly by
depressing the pin tools against a flat surface; deploying the pin
tool displacement block into the pin tool head assembly such that
the parallel slots of the pin tool displacement block slide over
rows of the array of pin tools of the pin tool head assembly; and
allowing the pin tools to return to a relaxed state by retracting
the pin tool head assembly from the flat surface with at least one
of the pin tools axially displaced in the relaxed state.
53. A method of dispensing calibration material onto a chip,
comprising: providing a chip having an array of regularly spaced
sample deposition sites disposed on a substantially flat working
surface thereof and at least one sample deposition site for
receiving calibration material which is also disposed on the flat
working surface of the chip; providing a robotic sample transfer
device having a pin tool head assembly with an array of regularly
spaced pin tools having distal ends which are substantially
coplanar in a relaxed state and which have a regular spacing which
is the same as the regular spacing of the first array of sample
deposition sites or an integer multiple thereof and configured to
align with the array of regularly spaced sample deposition sites of
the chip or a subset thereof; axially displacing at least one of
the pin tools of the pin tool head assembly with a pin tool
displacement block; loading a sample reservoir of at least one
un-displaced pin tool of the robotic sample transfer device with
calibration material; dispensing calibration material from the at
least one un-displaced pin tool of the robotic sample transfer
device to the at least one sample deposition site for receiving
calibration material such that the pin tools which are displaced by
the pin tool displacement block do not contact the chip.
54. The method of claim 53 wherein the array of regularly spaced
sample deposition sites comprises an array of regularly spaced mass
spectrometry sample deposition sites.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. section
119(e) from U.S. provisional application Ser. No. 60/972,879 filed
Sep. 17, 2007, by R. Silbert et al. titled "Integrated Robotic
Sample Transfer Device" which is incorporated by reference herein
in its entirety.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention generally relate to
robotic sample transfer devices and methods which may be used for
reliably and consistently transferring large numbers of small
samples of material from one registered position to another
registered position. Such transfers of material may be carried out
by a single pin tool or an array of regularly spaced pin tools on a
pin tool head assembly. Some embodiments include automated cleaning
of the pin tools used to transfer the sample material between
sample transfer steps.
BACKGROUND
[0003] In recent years, developments in the field of life sciences
have proceeded at a very rapid pace. Universities, hospitals and
newly formed companies have made groundbreaking scientific
discoveries and advances that promise to reshape the fields of
medicine, agriculture, and environmental science. However, the
success of these efforts depends, in part, on the development of
sophisticated laboratory tools that will automate and expedite the
testing and analysis of biological samples. Only upon the
development of such tools can the benefits of these recent
scientific discoveries be fully achieved.
[0004] At the forefront of these efforts to develop better
analytical tools is an effort to expedite the analysis of complex
biochemical structures. This is particularly true for human genomic
DNA, which is comprised of at least about one hundred thousand
genes located on twenty four chromosomes. Each gene codes for a
specific protein, which fulfills a specific biochemical function
within a living cell. Changes in a DNA sequence are known as
mutations and can result in proteins with altered or in some cases
even lost biochemical activities; this in turn can cause a genetic
disease. More than 3,000 genetic diseases are currently known. In
addition, growing evidence indicates that certain DNA sequences may
predispose an individual to any of a number of genetic diseases,
such as diabetes, arteriosclerosis, obesity, certain autoimmune
diseases and cancer. Accordingly, the analysis of DNA is a
difficult but worthy pursuit that promises to yield information
fundamental to the treatment of many debilitating and life
threatening diseases.
[0005] Analysis of DNA is made particularly cumbersome due to size
and the fact that genomic DNA includes both coding and non-coding
sequences (e.g., exons and introns). As such, traditional
techniques for analyzing chemical structures, such as the manual
pipeting of source material to create samples for analysis, are of
little value. To address the scale of the necessary analysis,
scientists have developed parallel processing protocols for DNA
diagnostics.
[0006] Robotic pin tool devices used for the accurate and efficient
transfer of materials from sample wells to sample test sites have
been used for the processing of materials for a great variety of
applications. Such devices are frequently used for the processing
of fluid DNA samples for mass spectrometry, including MALDI mass
spectrometry, genotyping, quantitative gene expression including
PCR methods, methylation analysis and SNP discovery. For such
processes, a small amount of fluid is taken up by a pin tool from a
pre-determined well of a microtiter plate and mapped and deposited
to a pre-determined location on another surface, such as a mass
spectrometry chip. The control software for the robotics of the
robotic pin tool generally will track the transfer of samples from
each well of the microtiter plate to the corresponding location on
the chip such that a comprehensive mapping of samples is
maintained. Once a set of samples have been transferred, the pins
may undergo a washing process and may then be used to transfer
another set of samples. Such tools and processes greatly enhance
the efficiency and reliability of sample handling and processing
where a large number of small volume samples need to be
processed.
[0007] Current devices that perform these procedures are useful,
but are generally large, heavy and expensive machines that require
the use of large external fluid storage tanks, external computing
devices, including desktop units with corresponding keyboard and
monitor devices, external plumbing to facility utilities and the
like. As a result, a standard pin tool sample transfer machine may
take up a large amount of space within a laboratory in which it is
being used. In addition, standard pin tool sample transfer devices
may be inconvenient to operate and maintain. What has been needed
is a robotic sample transfer machine that is small in size and
weight relative to existing machines and less expensive than the
currently available sample transfer devices. What has also been
needed is a robotic sample transfer device that is user friendly,
easy and reliable to operate and economical to maintain.
SUMMARY
[0008] Some embodiments of robotic sample transfer devices include
a substantially horizontal work surface and a three axis robotic
positioning assembly. The three axis robotic positioning assembly
has a fixed mount portion secured in fixed relation with the work
surface, a translatable carrier configured to be translatable in
three different axes with respect to the fixed mount portion and
working surface. The three axis robotic positioning assembly has a
stepper motor and corresponding linear encoder assembly for at
least one axis. A controller is in communication with the stepper
motor of each of the three axes and linear encoder of the three
axis robotic positioning assembly.
[0009] Some embodiments of a robotic sample transfer device include
a housing, a substantially horizontal work surface disposed within
the housing and a three axis robotic positioning assembly disposed
within the housing having a fixed mount portion secured in fixed
relation with the work surface and a translatable carrier member
translatable in three different axes with respect to the fixed
mount portion and work surface. The robotic sample transfer device
also includes at least one pin tool coupled to the translatable
carrier having a shaft and a sample reservoir in a distal end of
the shaft. A plurality of functional elements may be disposed on
the work surface having a nominal upper surface at substantially
the same z-axis height. The robotic sample transfer assembly may
also include a controller operatively coupled to the three axis
robotic positioning assembly.
[0010] For some embodiments, the functional elements disposed on
the work surface include a vacuum drying station, a fluid rinse
station, a self-leveling ultrasonic cleaning well, a microtiter
plate having an array or regularly space sample supply wells and a
chip having an array of regularly spaced sample deposition sites.
For some embodiments, the controller of the robotic sample transfer
device includes at least one processor which is disposed within the
housing at a level which is above the level of the work
surface.
[0011] Some embodiments of an integrated robotic sample transfer
device include a housing, a substantially horizontal work surface
and a three axis robotic positioning assembly disposed within the
housing. The three axis robotic positioning assembly may include a
fixed mount portion, a translatable carrier which is translatable
in three different axes with respect to the fixed mount portion,
and a stepper motor for each axis. Some embodiments may include a
linear encoder for at least one of the axes. A pin tool head
assembly may be secured to the translatable carrier member and have
an array of regularly spaced pin tools which have sample reservoirs
disposed in the distal ends thereof and which are configured for
axial displacement relative to a pin head body secured to the
translatable carrier of the three axis robotic positioning
assembly. The substantially horizontal work surface is disposed
within the housing and is secured in fixed relation to the fixed
mount portion of the three axis positioning assembly. The work
surface may have a plurality of functional components disposed
thereon which may include a fluid rinse station, a vacuum drying
station including a plurality of regularly spaced vacuum drying
ports corresponding to the regular spacing of the array of pin
tools, a self-filling ultrasonic cleaning well and a microtiter
plate mount block. The microtiter plate mount block is configured
to releasably secure a pre-selected microtiter plate sample well
thereto. A chip mount block may also be disposed on the work
surface and have a nominal upper surface at substantially the same
level as at least one or more of the functional components. A
controller including a processor is disposed within the housing at
a position which is above the level of the work surface. A rinse
fluid supply tank is in fluid communication with the fluid rinse
station and disposed within the housing. A waste water tank is in
fluid communication with an overflow basin of the fluid rinse
station and disposed within the housing. A vacuum source is in
fluid communication with the vacuum drying station and an
ultrasonic cleaning fluid supply reservoir is in fluid
communication with the self-filling ultrasonic cleaning well.
[0012] Some embodiments of a method of registering a position of a
pin tool head assembly of a robotic sample transfer device relative
to sample deposition sites on a chip include providing a robotic
sample transfer device having a work surface with a plurality of
functional elements, at least two of which have a nominal upper
surface at substantially the same level. For some embodiments, a
nominal upper surface of all the functional elements may be at the
same z-axis level. For some embodiments, the functional elements
that require a substantially precise positional alignment of pin
tools being used at the functional element may be at substantially
the same z-axis level. The robotic sample transfer device may also
have a three axis positioning system with a camera secured to a
translatable carrier thereof and the pin tool head assembly secured
to a translatable carrier thereof. The nominal upper surfaces of
functional components disposed on work surface are imaged by the
camera and the image data of the nominal upper surfaces of the
functional elements processed by an image processor to determine
the approximate position of the pin tool head assembly relative to
the functional elements. The approximate position data is then used
to move the field of view of the camera to a first chip having an
array of regularly spaced sample deposition sites and an array of
regularly spaced fiducial marks disposed between the sample
deposition sites. The fiducial marks on the first chip are imaged
by the camera and the image data of fiducial marks on the first
chip processed by an image processor. Feedback may then be obtained
regarding a position of the pin tool head assembly from one or more
linear encoders of three axes of a three axis robotic positioning
system. Linear encoder feedback may then be compared with image
processing feedback and look up table data to determine the precise
position of the pin tools of the pin tool head assembly with
respect to the sample deposition sites on the first chip. For some
embodiments, the process may be repeated for two or more chips to
determine the position of the pin tools of the pin tool head
assembly with respect to sample deposition sites of the two or more
chips.
[0013] Some embodiments of a method of dispensing calibration
material onto a chip include providing a chip having a first array
of regularly spaced sample deposition sites disposed on a
substantially flat working surface thereof and at least one sample
deposition site for receiving calibration material which is also
disposed on the flat working surface of the chip and which is off
pitch with respect to the regular spacing of the array of regularly
spaced sample deposition sites of the chip. A robotic sample
transfer device is provided which has a pin tool head assembly with
an array of regularly spaced pin tools having distal ends which are
substantially coplanar with each other in a relaxed state. The
regular spacing of the pin tools corresponds to the regular spacing
of the first array of sample deposition sites or an integer
multiple thereof and is configured to align with the array of
regularly spaced sample deposition sites of the chip or a subset
thereof. Sample reservoirs of the pin tools of the array of
regularly spaced pin tools of the robotic sample transfer device
are loaded with calibration material. Calibration material is
dispensed from the pin tools of the robotic sample transfer device
to the at least one sample deposition site for receiving
calibration material such that the pin tools which are not aligned
with sample deposition sites for receiving calibration material are
off pitch with respect to the first array of regularly spaced
sample deposition sites of the chip and do not contact any of the
regularly spaced sample deposition sites of the first array. For
some embodiments, the chip may include a second array of regularly
spaced sample deposition sites for receiving calibration material
sample which are off pitch with respect to the first array of
regularly spaced sample deposition sites. For such embodiments,
calibration material from sample reservoirs of the pin tools of the
robotic sample transfer device may be dispensed to the second array
of sample deposition sites for receiving calibration material such
that the pin tools which are not aligned with sample deposition
sites for receiving calibration material of the second array are
off pitch with respect to the first array of regularly spaced
sample deposition sites of the chip and do not contact any of the
regularly spaced sample deposition sites of the first array.
[0014] Some embodiments of a pin tool displacement block for
selectively displacing at least one pin tool of a pin tool head
assembly of a robotic sample transfer device include a block body
portion having a top surface and a bottom surface which is
substantially parallel to the top surface and a plurality of
parallel slots formed into the block body portion. The pin tool
displacement block also includes one or more relieved portions in
the slots corresponding to the location of pins that are to remain
in use when the pin tool displacement block is engaged with the pin
tools of the pin tool head. For some embodiments, the parallel
slots formed into the body portion have a width to allow passage
and movement of a pin tool shafts but not a collar member secured
to the pin tool shaft so as to displace the pin in a retracted
position. Relieved portions in the slots are configured to allow
passage and movement of the collar members so as not to displace
the corresponding pin tools in a retracted position located in
positions corresponding to pin tools which are to remain usable
after deployment of the block in a pin tool head assembly. Some
embodiments of the pin tool displacement block have a reversible
configuration wherein when the block is oriented in a first
direction a first set of pins or pin is active and oriented a
second way a second set of pins or pin is active which is different
from the first set.
[0015] Some embodiments of a method for selectively displacing at
least one pin tool of a pin tool head assembly of a robotic sample
transfer device, include providing a pin tool displacement block
with a block body portion having a top surface and a bottom surface
which is substantially parallel to the top surface, a plurality of
parallel slots formed into the block body portion and one or more
relieved portions in the slots corresponding to the location of
pins that are to remain in use when the pin tool displacement block
is engaged with the pin tools of the pin tool head. An array of pin
tools of a pin tool head assembly are displaced by depressing the
pin tools against a flat surface. The pin tool displacement block
is deployed into the pin tool head assembly such that the parallel
slots of the pin tool displacement block slide over rows of the
array of pin tools of the pin tool head assembly and the pin tools
are allowed to return to a relaxed state by retracting the pin tool
head assembly from the flat surface.
[0016] Some embodiments of a method of dispensing calibration
material onto a chip may include providing a chip having an array
of regularly spaced sample deposition sites disposed on a
substantially flat working surface thereof. The chip may also
haveat least one sample deposition site for receiving calibration
material which is also disposed on the flat working surface of the
chip. A robotic sample transfer device may be provided having a pin
tool head assembly with an array of regularly spaced pin tools
having distal ends which are substantially coplanar in a relaxed
state and which have a regular spacing which is the same as the
regular spacing of the first array of sample deposition sites or an
integer multiple thereof. The pin tools of the pin tool head
assembly may be configured to align with the array of regularly
spaced sample deposition sites of the chip or a subset thereof. At
least one of the pin tools of the pin tool head assembly may be
axially displaced with a pin tool displacement block and a sample
reservoir of at least one un-displaced pin tool of the robotic
sample transfer device loaded with calibration material.
Calibration material may be dispensed from the at least one
un-displaced pin tool of the robotic sample transfer device to the
at least one sample deposition site for receiving calibration
material such that the pin tools which are displaced by the pin
tool displacement block do not contact the chip.
[0017] These features of embodiments will become more apparent from
the following detailed description when taken in conjunction with
the accompanying exemplary drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of an embodiment of a robotic
sample transfer device.
[0019] FIG. 2 is a rear elevation view with a rear panel of the
housing not shown.
[0020] FIG. 3 is a front elevation view of the robotic sample
transfer device of FIG. 1 with the processing chamber cover and
tank chamber front cover not shown.
[0021] FIG. 4 is a perspective view of a three axis positioning
system and work surface of the robotic sample transfer device of
FIG. 1.
[0022] FIG. 5 is a perspective view of an x-axis translation
assembly of the three axis positioning system.
[0023] FIG. 6 is a perspective view of the y-axis carrier and
z-axis carrier of the three axis positioning system.
[0024] FIG. 6A is an enlarged view in partial section of a bottom
plate, pin tool shaft, helical spring clip and washer of a pin tool
head assembly embodiment.
[0025] FIG. 6B is a top view in partial section of a shaft of a pin
tool in sliding engagement with a cover plate.
[0026] FIG. 7 is a perspective view of a work surface and
functional components of the robotic sample transfer device of FIG.
1.
[0027] FIG. 7A is an elevation view in partial section of an
embodiment of a wash fluid reservoir.
[0028] FIG. 7B is a transverse cross section of the wash fluid
reservoir of FIG. 7A taken along lines 7B-7B in FIG. 7A.
[0029] FIG. 7C is a perspective view of an embodiment of a
calibration material supply vessel.
[0030] FIG. 7D is a perspective view of an embodiment of a
calibration material supply vessel.
[0031] FIG. 8 is a top view of a work surface and functional
components of the robotic sample transfer device of FIG. 1.
[0032] FIG. 9 is an exploded view of the work surface and
functional components of the robotic sample transfer device of FIG.
1.
[0033] FIG. 10 is an elevation view of the work surface and
functional components of the robotic sample transfer device of FIG.
1.
[0034] FIG. 11 is an enlarged perspective view of a ultrasound
energy generator of the ultrasonic cleaning well disposed on the
work surface.
[0035] FIG. 11A is a top view of an embodiment of a chip having an
array of sample deposition sites disposed thereon.
[0036] FIG. 11B is a bottom view of the chip of FIG. 11A.
[0037] FIG. 12 is an elevation view of a pump housing with a rear
cover of the housing not shown for clarity of illustration.
[0038] FIG. 13 is a perspective view of a waste fluid tank.
[0039] FIG. 14 is a perspective view of a fluid supply tank.
[0040] FIG. 15 is a perspective view of a pin tool displacement
block for selectively displacing a pin tool of a pin tool head
assembly.
[0041] FIG. 15A is a sectional view of the block of FIG. 15 taken
along lines 15A-15A.
[0042] FIG. 16 is a top view of the pin tool displacement block of
FIG. 15.
[0043] FIG. 17 is an elevation view of a pin tool head assembly
embodiment including two spring loaded pin tools.
[0044] FIG. 17A is a front view of the pin tool head assembly of
FIG. 17.
[0045] FIG. 18 is an elevation view of the pin tool head assembly
of FIG. 17 with the pin tools displaced in a proximal
direction.
[0046] FIG. 19 is an elevation view of the pin tool head assembly
with the pin tool displacement block engaged.
[0047] FIGS. 20A-20D illustrate an embodiment of a pin tool
displacement block, single pin configuration.
[0048] FIGS. 21A-21D illustrate an embodiment of a pin tool
displacement block, six pin configuration.
[0049] FIG. 22 is a perspective view from a first side of a
reversible pin tool displacement block embodiment.
[0050] FIG. 23 is an elevation view of the reversible pin tool
displacement block of FIG. 22.
[0051] FIG. 24 is a view from a second side of the reversible pin
tool displacement block of FIG. 22.
[0052] FIG. 25 is an enlarged perspective view of a portion of a
sample chip showing sample deposition sites and sample reservoirs
of a pin tool head assembly disposed over calibration sites.
[0053] FIGS. 26-34 show screen image representations of a graphic
user interface embodiment for communicating instructions and
information to a controller of a robotic sample transfer
device.
[0054] FIGS. 35A-35D illustrate an embodiment of a pin tool
displacement block, single pin configuration.
[0055] FIGS. 36A-36D illustrate an embodiment of a pin tool
displacement block, six pin configuration.
[0056] FIGS. 37A-37C illustrate an embodiment of a pin protection
block tool assembly.
[0057] FIG. 38A is a top view of an outer collar for use with a
plunger mechanism embodiment.
[0058] FIG. 38B is a cross section view of an outer collar for use
with a plunger mechanism embodiment.
[0059] FIG. 39A is a front view of a plunger handle for use with a
plunger mechanism embodiment.
[0060] FIG. 39B is a cross section view of a plunger handle for use
with a plunger mechanism embodiment.
[0061] FIGS. 40A-40C illustrate an embodiment of a dry station
plate assembly, single in configuration.
[0062] FIGS. 41A-41C illustrate an embodiment of a dry station
plate assembly, six pin configuration.
[0063] FIG. 42 illustrates the functional coupling of components
which enable selective displacement of pin tools in the pin tool
head.
DETAILED DESCRIPTION
[0064] As discussed above, currently available robotic sample
transfer devices are generally large, heavy and expensive machines
that require the use of large external fluid storage tanks,
external computing devices, including desktop units with
corresponding keyboard and monitor devices, external plumbing to
facility utilities and the like. As a result, a standard pin tool
sample transfer machine may take up a large amount of space within
a laboratory in which it is being used. In addition, standard pin
tool sample transfer devices may be inconvenient and expensive to
operate and maintain.
[0065] As such, a robotic sample transfer device that is relatively
small in size and weight may be particularly useful. In addition, a
robotic sample transfer device that is user friendly, easy and
reliable to operate and can be simply maintained may also be
particularly useful. Embodiments of robotic sample transfer devices
described herein may be directed to integrated configurations that
have a relatively small footprint with internal storage tanks,
internal controllers and processors, internal plumbing all disposed
within a housing that encloses a processing chamber. Such
embodiments take up less laboratory space and are easy to use and
maintain.
[0066] A graphic user interface may be disposed on an outer surface
of the housing of some embodiments which allows a user to easily
program and use the robotic sample transfer device while keeping
the processing chamber closed. Embodiments of the graphic user
interface may include touch screen displays allowing intuitive user
input without the need for a computer keyboard or mouse, although
such alternative interface tools may be supported in some
embodiments via USB ports or the like. A substantially horizontal
work surface may include a plurality of functional elements with
two or more of the functional elements having nominal upper
surfaces at approximately the same level which allows an imaging
camera to easily image the functional elements of the work surface
as well as providing a work surface at a consistent level for easy
access and navigation. Such imaging of the functional elements may
be used or otherwise processed in some embodiments to quickly
determine the position of pin tools or pin tool head assemblies
with respect to the functional elements with a high degree of
precision.
[0067] Some robotic sample transfer device embodiments may be used
for the accurate and efficient transfer of materials from one
position to another position may be useful for the processing of
samples and the like for a great variety of applications. Some
embodiments may be used for the processing of fluid DNA samples for
mass spectrometry, including MALDI mass spectrometry, genotyping,
quantitative gene expression including PCR methods, methylation
analysis and SNP discovery. Commonly owned U.S. Pat. No. 6,730,517,
filed Oct. 5, 2000 by Koster et al., issued May 4, 2004, titled
"Automated Process Line", describes automated modular analytical
systems and methods of analysis of samples and is hereby
incorporated by reference herein in its entirety. Some or all of
the robotic sample transfer device embodiments discussed herein may
be configured to perform some or all of the analytical processes
discussed in U.S. Pat. No. 6,730,517. Embodiments of the robotic
sample transfer device may be used to transfer samples that include
liquids, solids, gels and the like, or any combination thereof.
[0068] Some robotic sample transfer device embodiments may include
a substantially horizontal work surface that has a plurality of
functional elements disposed on the work surface. The functional
elements may be configured for the processing of small samples of
material. A three axis robotic positioning assembly may have a
fixed mount portion which is secured in a fixed relation with the
work surface to provide mobility of tools and other devices over
and in contact with the work surface and functional elements
thereof. The three axis robotic positioning assembly may include
one or more translatable carriers, at least one of which may be
configured to be translatable in three different axes with respect
to the fixed mount portion and working surface. For some
embodiments, the three different axes of the translatable carrier
may be substantially orthogonal to each other. Certain tools or
other devices may be secured to the translatable carrier in order
to provide high precision mobility of the tools and other devices
with respect to the work surface and functional elements on the
work surface. Some of the tools and devices that may be coupled to
the translatable carrier include pin tools, pin tool head
assemblies, cameras, bar code readers and the like. For some
embodiments, upper nominal surface or surfaces of the functional
elements may form the work surface.
[0069] While some translatable carrier embodiments may be movable
and be positioned in three axes, the three axis robotic positioning
assembly may include other translatable carrier embodiments, to
which these same tools and devices may be coupled, that are
moveable and may be positioned in only one axis or two axes. The
three axis robotic positioning assembly may include a stepper motor
for imparting motion and a corresponding linear encoder assembly
for providing positional feedback or information for one or more of
the three axes of the three axis robotic positioning assembly. As
discussed above, one of the tools that may be moved in three axes
above the work surface is a pin tool which may be coupled to the
translatable carrier of the three axis robotic positioning
assembly. The pin tool may be coupled to the translatable carrier
such that the pin tool is substantially perpendicular to the work
surface. For embodiments that include a pin tool head assembly,
multiple pin tools of a pin tool head assembly which is coupled to
a translatable carrier may also be oriented substantially
perpendicular to the work surface.
[0070] A controller may be used in communication, such as
electrical or optical communication, with the stepper motor and the
linear encoder assembly of one or more of the axes of the three
axis robotic positioning assembly in order to provide controllable
movement to the one or more pin tools or other devices coupled to
the translatable carrier or carriers. Such a controller may include
one or more processors and data storage units in communication with
the processor or processors. Some controller embodiments may also
include one or more data input ports or terminals which allow a
user to input data or other programming information in order to
have the controller carry out desired instructions or processing
protocols. A graphic user interface on a housing of the device may
be in communication with such a terminals or ports of the
controller. Some embodiments of the robotic sample transfer device
may have the controller and associated components and electronics
of the controller disposed above the vertical level of the work
surface to avoid damage to these components from spillage of
liquids on or around the work surface and associated functional
components.
[0071] The controller may receive position data from the linear
encoder assemblies as well as other sources and provide actuation
signals and power to the stepper motors of the three axes in order
to produce predetermined motion and positioning of the translatable
carrier and tools coupled thereto with respect to the work surface
and functional elements and with a high degree of precision.
Position data generated by one of the linear encoder assemblies may
include the position of a translatable carrier relative to a
corresponding rail member upon which the translatable carrier
moves. For such embodiments, an optical linear encoder strip may be
disposed on the rail member and be positioned to be read by a
linear encoder reader disposed on the corresponding translatable
carrier.
[0072] Sometimes a housing may be disposed about the work surface,
three axis robotic positioning assembly and controller as well as
other components of robotic sample transfer device embodiments.
Embodiments of the housing may include a skin material disposed on
a frame structure. The skin material may be made of suitable
polymers, composites, metals or the like in order to provide an
enclosed controlled processing chamber and to protect the
components of the robotic sample transfer device disposed therein.
As discussed above, a graphic user interface may be disposed on or
otherwise accessible from an exterior of the housing and be
operatively coupled to the controller for providing user input,
instructions, data or the like to the controller.
[0073] Some embodiments of a robotic sample transfer device may
include a housing and a substantially horizontal work surface
disposed within the housing. A three axis robotic positioning
assembly may also be disposed within the housing for such
embodiments and have a fixed mount portion secured in fixed
relation with the work surface. The three axis robotic positioning
assembly may include one or more translatable carrier members,
including a translatable carrier member that is translatable in
three different axes with respect to the fixed mount portion and
work surface. At least one pin tool is coupled to the translatable
carrier. The pin tool has a shaft and a sample reservoir in a
distal end of the shaft. A variety of suitable reservoir
embodiments may be used which may be configured to draw and store
small volume liquid samples, generally in the nanoliter range of
volume, into the reservoir by capillary action or other suitable
mechanisms.
[0074] A plurality of functional elements may be disposed on the
work surface with each functional element having a nominal upper
surface. For some embodiments, an upper nominal surface or surfaces
of the functional elements may form the work surface. For some
embodiments, two or more of the nominal upper surfaces the
functional elements may be disposed at substantially the same
z-axis level or height. Such a configuration may be useful in order
to facilitate imaging of the functional elements and positioning of
the pin tool with respect to the nominal upper surface of each
functional element. This may be particularly true in embodiments
wherein an imaging camera is disposed on one or more of the
translatable carriers of the robotic positioning assembly and is
used for imaging the functional elements disposed on the work
surface.
[0075] For such embodiments, it may be useful to have the imaging
camera disposed on a translatable carrier embodiment that is
translatable only in the X-Y plane, substantially parallel to the
work surface. For such a camera with a fixed Z-axis position, the
distance between the camera lens and the work surface or upper
nominal surfaces of functional elements disposed on the work
surface may be substantially fixed. Thus, camera embodiments having
a fixed focal length and narrow range of focus may be positioned on
the translatable carrier at the appropriate focal distance from the
work surface for consistent focused imaging of the upper nominal
surfaces of the functional elements. In this way, the upper nominal
surfaces of the functional elements disposed at substantially the
same z-axis level will remain in focus and be clearly imaged as the
translatable carrier moves about over the work surface. The pin
tool or other devices coupled to a translatable carrier which may
be positioned in three axes may be moved independently of the
camera in the Z-axis direction.
[0076] For some embodiments, the functional elements disposed on
the work surface may include a vacuum drying station, a fluid rinse
station, a self-leveling gravity fed ultrasonic cleaning well, a
microtiter plate having an array or regularly space sample supply
wells and a chip having an array of regularly spaced sample
deposition sites. A controller may be operatively coupled to the
three axis robotic positioning assembly as well as any of the
functional elements on the work surface or components thereof. Such
a controller may include one or more processors and data storage
units in communication with the processor or processors which are
disposed within the housing at a level which is above the level of
the work surface.
[0077] For some embodiments, the pin tool which is coupled to the
translatable carrier may be part of a pin tool head assembly having
an array of regularly spaced pin tools which is secured or
otherwise coupled to the translatable carrier. For some
embodiments, the vacuum drying station may include a plurality of
regularly spaced vacuum drying ports corresponding to the spacing
of the pin tools of the pin tool head assembly. For some
embodiments, the fluid rinse station may include individual rinse
tubes corresponding to each of the pin tools of the array of
regularly spaced pin tools of the pin tool head assembly.
[0078] For some embodiments, an ultrasonic cleaning fluid reservoir
may be disposed in fluid communication with the ultrasonic cleaning
well. The ultrasonic cleaning fluid reservoir may have an enclosed
and fluid tight interior volume in fluid communication with a
supply port configured to couple in fluid communication to an inlet
port of the ultrasonic cleaning well. For some embodiments of such
a configuration, the supply port of the ultrasonic cleaning fluid
reservoir may be open to fluid flow when coupled into fluid
communication with the inlet port of the ultrasonic cleaning well
and be substantially sealed when the removed from the inlet port of
the ultrasonic cleaning well. Some particular embodiments may
include a ball valve which is configured to seal the supply port
when the fluid reservoir is removed from the inlet port of the
ultrasonic cleaning well.
[0079] Some embodiments of an integrated robotic sample transfer
device may include a housing and a three axis robotic positioning
assembly disposed within the housing having a fixed mount portion
and a translatable carrier which is translatable in three axes with
respect to the fixed mount portion and a substantially horizontal
work surface. A stepper motor and corresponding linear encoder
assembly may be included for one or more of the axes of the three
axis robotic positioning assembly. Each stepper motor may be
configured to provide motion in the direction of each respective
axis and each linear encoder assembly may be used to provide
position data in the direction of each respective axis. A pin tool
head assembly may be secured to the translatable carrier member
which has an array of regularly spaced pin tools with sample
reservoirs disposed in the distal ends thereof. The pin tools may
be configured for axial displacement relative to a pin head body
which is secured to the translatable carrier of the three axis
robotic positioning assembly. Some embodiments of the robotic
sample transfer device may also include a door on the housing which
is configured to cover an opening to a processing chamber disposed
within the housing.
[0080] The substantially horizontal work surface may be disposed
within the housing and secured in fixed relation to the fixed mount
portion of the three axis robotic positioning assembly. The work
surface may have one or more functional elements which may include
a fluid rinse station, a vacuum drying station including a
plurality of regularly spaced vacuum drying ports corresponding to
the regular spacing of the array of pin tools, a self-leveling
ultrasonic cleaning well and a microtiter plate mount block
configured to releasably secure a sample well disposed thereon. For
some embodiments, the upper nominal surfaces of two or more of the
functional elements may form the work surface. For some of these
embodiments, a nominal upper surface of the fluid rinse station,
nominal upper surface of the vacuum drying station, nominal upper
surface of the ultrasonic cleaning well, nominal upper surface of a
chip disposed in the chip mount block and microtiter plate/sample
well mounted in the sample well mount blocks are all disposed at
substantially the same z-axis level. For some embodiments of the
robotic sample transfer device, the entire dry weight of the device
is less than about 150 pounds. For some embodiments, functional
elements such as the ultrasonic cleaning well that do not require
precise alignment in the x-y plane may be disposed at a z-axis
level that differs from the z-axis level of the remaining
functional elements or subset of functional elements having an
upper nominal surface disposed at substantially the same z-axis
level.
[0081] A controller may be disposed within the housing. Such a
controller may include one or more processors and data storage
units in addition to an assembly of other electronics and logic
circuits in communication with the processor or processors which
may be disposed within the housing at a level which is above the
level of the work surface. The controller, electronics associated
with the controller as well as other components of the robotic
sample transfer device may be powered by a universal power supply
in communication with the controller that produces a constant or
substantially constant output voltage with varied input voltages.
Such a universal power supply may allow the robotic sample transfer
device to operate in a variety of countries with little or no
modification.
[0082] Embodiments of the robotic sample transfer device may
include a humidity sensor disposed within the processing chamber of
the device in communication with the controller which is configured
to sense the humidity within the processing chamber. For some of
these embodiments, a closed loop feedback of sensed humidity levels
within the processing chamber may be used in conjunction with a
humidity control device for maintaining a substantially constant
humidity within the processing chamber.
[0083] Embodiments of the robotic sample transfer device may
include a temperature sensor disposed within the processing chamber
of the sample transfer device in communication with the controller
which is configured to sense the temperature within the processing
chamber. For some of these embodiments, a closed loop feedback of
sensed temperature levels within the processing chamber may be used
in conjunction with a temperature control device for maintaining a
substantially constant temperature within the processing
chamber.
[0084] A graphic user interface may be disposed on an outer surface
of the housing or in another convenient location and in
communication with the controller. Some embodiments of the robotic
sample transfer device may include an imaging camera which may be
coupled to an image processing controller, a bar code reader head
and bar code reader processor in communication with the bar code
reading head and controller.
[0085] The fluid rinse station may include an array of regularly
spaced individual rinse tubes having a regular spacing
corresponding to the regular spacing of the pin tools of the pin
tool head assembly. A rinse fluid supply tank may be disposed
within the housing and in fluid communication with the fluid rinse
station. Some embodiments of the sample transfer device may include
a rinse fluid supply pump disposed within the housing, in fluid
communication with the rinse fluid supply tank and fluid rinse
station and configured to pump rinse fluid from the rinse fluid
supply tank to the fluid rinse station. Some embodiments of the
sample transfer device include a rinse fluid supply tank fluid
level indicator. Such an indicator may be used to provide users
with information with regard to the fluid level within the rinse
fluid supply tank so the tank may be refilled prior to running out
of rinse fluid.
[0086] A waste fluid tank may be disposed within the housing in
fluid communication with an overflow basin of the fluid rinse
station. Some embodiments of the sample transfer device may include
a waste fluid tank fluid level indicator. Such an indicator may be
used to provide users with information with regard to the waste
fluid level within the waste fluid supply tank so the tank may be
emptied prior to overflowing with waste fluid.
[0087] An ultrasonic cleaning fluid reservoir may be disposed
within the housing in fluid communication with the self-leveling
ultrasonic cleaning well. For some embodiments, the ultrasonic
cleaning fluid reservoir includes a gravity feed reservoir having a
supply port configured to couple into fluid communication with an
inlet port of the ultrasonic cleaning well. The supply port may be
configured to allow fluid flow when coupled to the inlet port of
the ultrasonic cleaning well and be substantially sealed when the
removed from the inlet port of the ultrasonic cleaning well.
[0088] A vacuum source may be disposed within the housing in fluid
communication with the vacuum drying station. Some embodiments of
the sample transfer device may also include a vacuum drying supply
tank in fluid communication with the vacuum drying ports of the
vacuum drying station. The vacuum drying supply tank may be a gas
tight pressure vessel having an interior volume that may be
partially emptied of air so as to provide a large volume of low
pressure which can be used to draw air through the vacuum tubes of
the vacuum drying station. Some of these embodiments may include a
vacuum pump in fluid communication with the vacuum drying supply
tank.
[0089] FIGS. 1-14 illustrate an embodiment of an integrated robotic
sample transfer device 10 that may have features, dimensions and
materials which are similar to or the same as the features,
dimensions and materials of the robotic sample transfer device
embodiments discussed above. The integrated robotic sample transfer
device 10 may be used for reliably transferring large numbers of
samples from one position on a work surface of the device to second
position on the work surface of the device. The integrated robotic
sample transfer device embodiment 10 shown includes a compact and
user friendly configuration in that it does not require any
external tanks or other major peripheral equipment in order to
operate. The ultrasonic wash station, rinse station and vacuum
drying station are all supplied by tanks that are disposed within
the housing of the transfer device. In addition, any waste fluid
generated by these stations drains to a waste fluid tank also
disposed within the housing. Although the wash fluid and waste
tanks include coupling ports to allow a user to connect the tanks
to larger external tanks if desired, having these primary wash
fluid supply and waste tanks disposed within the housing allows a
user having minimum work space to efficiently and effectively use
the sample transfer device.
[0090] The transfer device 10 includes a housing 12 having an outer
sheathing that provides an enclosed processing chamber 14 that may
be accessed by a hinged lid or door 16. The door may include a
window with transparent sheathing material to allow a user to view
the processes taking place within the processing chamber 14 while
keeping the processing chamber enclosed and substantially isolated
from the outside environment. The transparent sheathing of the
window of the door 16 may include materials such as acrylic, PVC,
polycarbonate and the like and have a thickness of about 0.1 inches
to about 0.4 inches, for some embodiments. Such a configuration may
allow the transparent material of the door 16 to be somewhat
flexible and take on a curved shape or configuration. A safety
interlock device (not shown) may include an interlock switch that
is coupled between the door 16 and the remainder of the housing 12.
The interlock device may be configured to detect when the door 16
is open or closed in order to prevent operation of the device 10,
and particularly a robotic positioning system 18 of the device,
while the door 16 is open. The sheathing or skin of the housing 12
may be formed from multiple panels of thin materials such as
polymers, composites, metals, such as aluminum, and the like and
may be secured to a frame structure of the housing 12. For some
embodiments, the side panels of the housing 12 may be removable in
order to provide greater access to the processing chamber 14 during
the loading and unloading of samples or devices from within the
processing chamber 14. An air port (not shown) may also be disposed
on one or more of the panels, such as the side panels, of the
housing 12 in order to provide an access port into the interior of
the housing 12 and processing chamber 14. Such an air port may be
used to force conditioned air into the processing chamber in order
to control the temperature and humidity within the processing
chamber 14.
[0091] The processing chamber 14 may be sized adequately to house
the three axis robotic positioning system, work surface 22 and
functional elements of the work surface 22. In addition, it may be
desirable to have access by a user to some or all of these
components in order to facilitate loading and unloading of samples,
microtiter plates, chips, cleaning fluids and the like. The outer
shape of the housing 12 is generally rectangular, with a sloping
front surface formed by the door 16 that is hinged across the top
edge of the door 16 which is configured to swing up and down. One
or more pressurized gas damping pistons 24 may pivotally secured
between the door 16 and a portion of the housing 12 beneath the
door. The damping pistons 24 may be configured to offset the weight
of the door 16 and provide damping of movement between the door 16
and the remainder of the housing 12 to prevent rapid movement of
the door 16 and keep the door 16 open until manually closed by a
user. Some embodiments of the housing 12 may have a height of about
12 inches to about 30 inches, more specifically, about 20 inches to
about 26 inches, a width of about 20 inches to about 40 inches,
more specifically, about 25 inches to about 30 inches, and a depth
of about 12 inches to about 30 inches, more specifically, about 20
inches to about 26 inches.
[0092] A graphic user interface 26 that includes a touch screen
user interface is disposed on an outside surface of the housing 12.
The touch screen user interface 26 may be a graphic screen coupled
to a controller 28 which is shown in FIG. 2. The touch screen user
interface 26 allows a user to turn on, program, turn off and
generally interact with the controller 28 and other features of the
device through a menu driven interface that is displayed on the
touch screen. The controller 28 may be used or programmed generally
to control the use, motion or both of the active components of the
sample transfer device 10. In particular, the controller may be
used or otherwise programmed to control the use of the functional
elements and supporting element or components of the functional
elements of the work surface 22. For example, the controller 28 may
be used or otherwise programmed to control the movement of fluids,
such as rinse water supply and waste, pressurized gases, vacuum
sources, such as drying vacuum sources, and the administration of
cleaning energy, such as ultrasonic cleaning energy for cleaning
the pin tools of a pin tool head assembly and the like. The
controller 28 may be used to control the movement of the
translatable carriers of the three axis robotic positioning system
18 and the use and control of imaging devices secured to or
otherwise associated with the translatable carriers, such as
imaging cameras, bar code readers and the like. FIG. 2 is a rear
elevation view of the sample transfer device embodiment 10 with a
rear panel of the housing 12 not shown for purposes of
illustration. With the rear panel of the housing removed, the
controller 28 and some of the associated electronics thereof are
visible.
[0093] The controller 28 may include a processor 32, such as a
computer processor, a memory storage unit and suitable accompanying
circuitry such as logic circuits and the like. Some embodiments
include a universal power supply 34 coupled to the controller 28
and other electrical components of the sample transfer device that
is configured to supply a substantially constant operating voltage
to the controller 28 and other electrical components of the device
for a variety of input voltages. Such a universal power supply 34
allows embodiments of the robotic sample transfer device 10 to be
used with a variety of input power supply voltages without the need
for modification. A customized PCB board 36 that includes signal
routing switches, motor controllers, an amplifier for ultrasonic
energy generation, as well as other components is mounted adjacent
the processor 32. A cooling fan 38 is disposed between the PCB
board 36 and processor 32 for cooling the portion of the housing 12
that houses the controller 28.
[0094] The touch screen feature 26 allows a user to interact and
make menu selections directly on the touch screen 26. For the
embodiment shown, the touch screen user interface 26 is disposed on
a hinged cover or door that is disposed over the front of a lower
storage tank chamber 44 which is shown in FIG. 3. The lower storage
tank chamber 44 is a volume disposed within the housing below a
work surface 22 of the sample transfer device 10. FIG. 3 shows a
front elevation view of the sample transfer device 10 with the
hinged cover 42 of the lower storage tank chamber 44 removed for
purposes of illustration.
[0095] FIG. 4 illustrates an enlarged perspective view of some of
the active processing components disposed within the processing
chamber 14 of the sample transfer device embodiment 10. These
active processing components are shown in an isolated view without
the housing or other components for clarity. Generally, the work
surface 22 and functional elements disposed on the work surface 22
provide locations to secure samples and other materials in a first
registered position so that they can be moved or moved in part to a
second registered position, for example, moving a portion of a
sample fluid from a known well of a microtiter plate to a sample
deposition site of a spectrometry chip with a pin tool. The three
axis robotic positioning system 18 provides the system for
generating precise motion relative to the registered positions of
the work surface 22, such as by providing precise known motion and
positioning of a pin tool relative to the work surface 22 and
functional elements thereof. The work surface 22 and functional
elements may also provide the necessary tools to clean the pin tool
or other transfer devices such that they may be used for many
consecutive transfer cycles.
[0096] FIGS. 5 and 6 illustrate components of the three axis
robotic positioning system 18 in more detail. As shown, the three
axis robotic positioning system 18 is disposed substantially above
the work surface 22 and includes a fixed mount portion 46 which is
secured in a fixed relation with the work surface 22. Both the
fixed mount portion 46 and the horizontal work surface 22 may be
secured in fixed relation to each other on a frame structure 48
which may, in turn, be secured to or otherwise mounted to the
housing 12 or frame structure of the housing 12. For the embodiment
shown, the frame structure 48 of the work surface 22 and three axis
robotic positioning system 18 is mounted to the housing 12 with
vibration isolating rubber mounts 52. Also for the embodiment
shown, a base portion of the x-axis rail 54 serves as the fixed
mount portion 46 of the three axis robotic positioning system
18.
[0097] The three axis robotic positioning system 18 includes a
z-axis translatable carrier 56 which is disposed above the work
surface 22 and which may be controllably positioned in three
different axes relative to the work surface 22. The z-axis
translatable carrier 56 is coupled to the fixed mount portion 46 of
the system or base of the x-axis rail 54 through two other
translatable carriers that provide the x-axis and y-axis components
of the three axis motion. The three axes of translation of the
translatable carrier of the three axis positioning system shown are
substantially orthogonal to each other, however, some embodiments
may use non-orthogonal axes. The z-axis translatable carrier 56 may
be translated in either direction along each of the three axes
independently. The movement of the translatable carrier in either
direction along each axis may be actuated by a stepper motor
actuator which is configured to impart linear motion along the
direction of each respective axis.
[0098] Position information regarding the position of the
translatable carrier along one or more of the three axes may be
measured by a linear encoder assembly, such as an optical linear
encoder assembly, corresponding to one or more of the axes or by
any other suitable method. A linear encoder assembly may include a
linear encoder reader head such as an optical linear encoder reader
head and a linear encoder strip such as an optical linear encoder
strip that are coupled to the controller and may provide position
feedback to the controller. A homing switch system may also be used
to facilitate the determination of position of the translatable
carriers along each of their respective axes. Such a homing switch
may be mounted at or near an end of the length of travel or motion
of a respective translatable carrier such that the homing switch is
activated to open or close an electrical loop, optical loop or the
like as the translatable carrier reaches the end of travel at a
pre-determined and repeatable position. The electrical or optical
loop of the homing switch may be coupled to the controller 28 such
that the controller 28 may be programmed to move a translatable
carrier to the "home" position which mechanically activates the
homing switch at the beginning of a transfer cycle or at any other
desired time. For some embodiments, the controller 28 may home one
or more of the translatable carriers by sending a home command to
one or more motor controllers corresponding to each of the
respective stepper motors. Such motor controllers may be located on
board 36 or in any other suitable location. Once the home position
has been determined, the controller 28 may use the stepper function
of the stepper motor actuator to track the number of motion pulses
in each direction along the axes in order to calculate or otherwise
track the position along each of the axes.
[0099] The x-axis rail 54 of the three axis robotic positioning
system 18 extends across the processing chamber 14 and is coupled
to an x-axis carrier 58 which is coupled to a y-axis carrier 62
which is coupled to the z-axis carrier. The x-axis carrier is
configured to translate on the x-axis rail, the y-axis carrier 62
is configured to translate relative to the x-axis carrier in a
y-axis direction and the z-axis carrier is configured to translate
in a z-axis direction relative to the y-axis carrier 62. All three
of the carriers and corresponding carrier rails upon which the
carriers move may be respectively coupled together by high
precision bearings that are configured to promote low friction
linear movement with high precision. The z-axis carrier 56 may be
positioned in three axes which are substantially orthogonal to each
other for such a configuration. The pin tool head assembly 64 is
secured to the z-axis carrier 56 and may also be positioned in the
three substantially orthogonal axes. Various embodiments of the
rails of the three axis robotic positioning system 18 may include
models SR20, RSR12W and HSR20, manufactured by THK Company,
Japan.
[0100] As discussed above, the z-axis translatable carrier 56 is
translatable in the x, y and z axes and is coupled to the fixed
mount portion 46 (or base of the x-axis rail) through the y-axis
translatable carrier 62 and the x-axis translatable carrier with
each translatable carrier configured to move independently of the
other carriers in its respective direction. The pin tool head
assembly 64 is secured directly to the z-axis translatable carrier
56 which moves up and down on the z-axis rail 66 relative to the
y-axis translatable carrier 62 and horizontal work surface 22. The
y-axis translatable carrier 62 moves in a y-axis direction front to
back on a y-axis track relative to the x-axis translatable carrier
58 and the horizontal work surface 22. The x-axis translatable
carrier 58 moves in an x-axis direction side to side relative to
the fixed mount portion 46 on the x-axis rail 54. The superposition
of movement in each of the x-axis, y-axis and z-axis directions
allows the z-axis translatable carrier 56 and pin tool head
assembly 64 secured directly thereto to be positioned in three
dimensions with respect to the horizontal work surface 22 and
functional components disposed on the work surface 22. There may be
no need for movement in a rotational orientation as the pin tools
68 of the pin tool head assembly 64 are generally applied at a
right angle or perpendicular to nominal upper surfaces of the
functional components of the work surface 22. However, an
additional axis or axes of motion could be added to the robotic
positioning system 18. In addition, although the base portion of
the x-axis rail 54 serves as the fixed mount portion 46 and the
z-axis translatable carrier 56 serves as a three axis translatable
carrier, the various carriers may be mixed and matched as desired
in order to achieve the three axes of movement. For example, a base
portion of a rail of either the x, y or z axis of a robotic
positioning system could serve as the fixed mount portion 46 that
is mounted in fixed relation to the work surface 22. Also, either
the x, y or z translatable carrier may serve as the three axis
translatable carrier of a robotic positioning system 18, so long as
the three axis translatable carrier is coupled to the fixed mount
portion through translatable carriers of the other two axes.
[0101] Referring to FIG. 5, the x-axis rail assembly 70 includes a
frame 72 that includes a bottom portion which is secured in fixed
relation to the frame structure 48 beneath the rail assembly 70.
The work surface 22 is also secured in fixed relation to the same
frame structure 48. As such, the bottom of the x-axis rail assembly
70 serves as the fixed mount portion 46 of the three axis robotic
positioning system 18. The x-axis rail assembly 70 includes a first
x-axis rail 74 upon which bearing cars 76 are slidingly engaged and
free to translate along the x-axis direction. The x-axis rail
assembly 70 includes a second x-axis rail 78 upon which a bearing
car 76 is slidingly engaged and free to translate along the x-axis
direction. The x-axis translatable carrier 58 is secured to the
bearing cars of the x-axis rail assembly 70 and thus the x-axis
translatable carrier 58 is free to move along the x-axis direction
riding on the multiple bearing cars 76. A threaded rod 82 is
secured between end plates 84 and 85 of the x-axis rail assembly
70. X-axis stepper motor 86 has a threaded collar 88 that is in
threaded engagement with the threaded rod 82. The threaded collar
88 is configured to rotate with a rotor of the stepper motor 86 but
remain stable in an axial direction relative to the stepper motor
body. The stepper motor 86 thus moves along and relative to the
threaded rod 82, frame 70 and x-axis when the stepper motor 86
drives the threaded collar 88 which rotates relative to the
threaded rod 82. The x-axis stepper motor 86 is also secured in
fixed relation to the x-axis translatable carrier 58 and thus
drives the x-axis translatable carrier 58 along the x-axis
direction when actuated. For such an arrangement, the threaded
collar 88 of the stepper motor 86 may include an anti-backlash
device in order to maintain high precision linear movement of the
x-axis translatable carrier 58. An linear encoder strip 92 is
disposed on a front surface of the rail assembly 70 as shown in
FIG. 4, which may be read by an encoder head 94 which is secured to
the x-axis translatable carrier as shown in FIG. 3. The linear
encoder strip 92 may include model RGS40S, manufactured by Renishaw
Corporation located in Gloucestershire, England. The linear encoder
reader head 94 may include model RGH41, also manufactured by
Renishaw Corporation. The linear encoder systems may have a
resolution of about 0.5 microns to about 5 microns, more
specifically, about 0.8 microns to about 1.5 microns, for some
embodiments. The various stepper motor embodiments may include
model series 57000, size 23, and model series 43000, size 17,
manufactured by Hayden Switch and Instrument Company, Waterbury,
Conn.
[0102] Referring to FIG. 4, a y-axis rail assembly 96 is secured to
the x-axis translatable carrier 58. The y-axis rail assembly 96
includes a frame 95 y-axis rail 98 upon which a bearing car (not
shown) is slidingly engaged and free to move along the y-axis
direction. The y-axis translatable carrier 62 is secured to the
bearing car of the y-axis rail assembly 96 and thus the y-axis
translatable carrier 62 is free to move along the y-axis direction
riding on the bearing car. A threaded rod 102 is secured between
end plates 104 and 105 of the y-axis rail assembly 96. Y-axis
stepper motor 106 has a threaded collar 108 that is in threaded
engagement with the threaded rod 102. The threaded collar 108 is
configured to rotate with a rotor of the stepper motor 106 but
remain stable in an axial direction relative to the stepper motor
body. The stepper motor 106 thus moves along and relative to the
threaded rod 102, frame 95 and y-axis when the stepper motor drives
the threaded collar 108 which rotates relative to the threaded rod
102. As with the x-axis assembly 70, the threaded collar 108 of the
stepper motor 106 may include an anti-backlash device in order to
maintain high precision linear movement of the y-axis translatable
carrier 62. A y-axis linear encoder strip 112 is disposed along a
top portion of the y-axis rail assembly 96. A y-axis linear encoder
reader head (not shown) may be disposed on the y-axis translatable
carrier 62 and configured to read the y-axis linear encoder strip
112. The encoder strip 112 and reader head may be the same as or
similar to the x-axis encoder strip 92 and reader head 94 discussed
above.
[0103] A z-axis rail assembly 114 is secured to the y-axis
translatable carrier 62 to provide controllable high precision
movement along the z-axis direction in combination with x-axis and
y-axis movement provided by the respective translatable carriers 58
and 56 in those axes. The z-axis rail assembly 114 includes a
z-axis rail 116 upon which one or more bearing cars (not shown) are
slidingly engaged and free to translate along the z-axis direction
with high precision. The z-axis translatable carrier 56 is secured
to the bearing car of the z-axis rail assembly 114 and thus the
z-axis translatable carrier 56 is free to move along the z-axis
direction riding on the bearing cars. A threaded rod 118 is secured
to the z-axis translatable carrier. Z-axis stepper motor 122 is
secured to the y-axis translatable carrier 62 by a mount bracket
124 and includes a threaded collar 126 that is in threaded
engagement with the threaded rod 118. Thus, when the z-axis stepper
motor 122 is actuated and the threaded collar 126 rotated, the
threaded rod 118 and z-axis translatable carrier 56 is moved along
z-axis relative to the y-axis translatable carrier 62. As with the
x-axis and y-axis assemblies, the threaded collar 126 of the
stepper motor 122 may include an anti-backlash device 56 in order
to maintain high precision linear movement of the z-axis
translatable carrier 56.
[0104] The positioning of the z-axis translatable carrier 56 along
the z-axis direction may be determined by the use of a homing
switch as discussed above. For the embodiment shown, a homing
switch 128 is disposed in fixed relation to the y-axis translatable
carrier 62 near the top end of the z-axis motion of the z-axis
carrier 56 such that the z-axis carrier 56 activates the homing
switch 128 at the top of the z-axis travel. The homing switch 128
is coupled to the controller 28 which may then "home" the z-axis
translatable carrier 56 at the beginning of each sample transfer
cycle, or at any other desired time, in order to determine the
position of the z-axis translatable carrier 56 thereafter. Such a
homing position determination process may also be manually selected
by a user. The z-axis rail assembly 114 may also optionally include
a linear encoder assembly, such as the linear encoder assemblies
discussed above with regard to the x-axis rail assembly 70 and
y-axis rail assembly 96, if greater precision is desired for the
determination of the position of the z-axis translatable carrier
56.
[0105] The x-axis rail 54 and translatable carrier 58 may be
configured to provide about 10 inches to about 30 inches of travel
in the x-axis direction, more specifically, about 20 inches to
about 25 inches of travel in the x-axis direction. The y-axis rail
98 and translatable carrier 62 may be configured to provide about 8
inches to about 16 inches of travel in the y-axis direction, more
specifically, about 10 inches to about 12 inches of travel in the
y-axis direction. The z-axis rail 116 and translatable carrier 56
may be configured to provide about 2 inches to about 10 inches of
travel in the z-axis direction, more specifically, about 3 inches
to about 5 inches of travel in the z-axis direction.
[0106] As shown in FIG. 6, an imaging camera 132 is secured to the
y-axis translatable carrier 62. The imaging camera 132 may be
configured to have a focal length or range of focus that matches
the distance from the imaging camera 132 to a plane below the
camera 132 that is substantially at the level or plane of nominal
upper surfaces of the functional elements of the work surface 22.
For some embodiments, the work surface 22 may be configured such
that some or all of the functional components thereof have a
nominal upper surface that is at substantially the same z-axis
level or position. This configuration may serve to simplify the
programming of the controller 28 for sample transfer procedures.
This configuration may also allow the imaging camera 132 in a fixed
z-axis position to remain in focus while imaging a nominal upper
surface of the functional components in order to better control the
sample transfer process. A bar coder reader head 134, as shown in
FIG. 2, may also secured to the y-axis translatable carrier 62,
y-axis rail 98 or any other suitable portion of the robotic
positioning system 10. The same arrangement may be desirable for
easy scanning of bar codes disposed on chips, microtiter plates or
the like that are placed on mount blocks of the work surface 22 for
easy identification and obtaining accurate position data of such
components. The bar code reader head 134 may include model
NLV-1001, manufactured by Opticon Corporation, Japan.
[0107] Referring to FIG. 6, the pin tool head assembly 64 is
secured to the z-axis translatable carrier 56 by fasteners such as
screws or bolts and is movable and may be positioned in all three
x, y and z axes. The pin tool head assembly 64 includes a
substantially rigid frame structure 136 having a first vertical
support plate 137 and a second vertical support plate 138 spaced
laterally from the first vertical support plate 137 and disposed
substantially parallel to the first vertical support plate 137. A
bottom plate 139 is secured at a first end to the first vertical
support plate 137 and secured at a second end to the second
vertical support plate 138. The bottom plate 139 has a top surface
and a bottom surface that is substantially parallel to the top
surface. The bottom plate 139 may have a thickness of about 0.05
inches to about 0.5 inches, more specifically, about 0.1 inches to
about 0.2 inches, for some embodiments. The bottom plate 139 may be
oriented substantially perpendicular to both the first and second
vertical support plates 137 and 138. A cover plate 140 is disposed
opposite and spaced vertically from the bottom plate 139. The cover
plate 140 is secured to top surfaces of upper ends of the first and
second vertical support plates 137 and 138 in an orientation that
is substantially perpendicular to both the first and second
vertical support plates. The cover plate 140 may have a thickness
of about 0.05 inches to about 0.5 inches, more specifically, about
0.1 inches to about 0.2 inches, for some embodiments. An open
cavity or window is formed in the middle of the rigid frame 136
between the upper surface of the bottom plate 139, a lower surface
of the cover plate 140, and interior surfaces of both the first and
second vertical support plates 137 and 138.
[0108] An array of pin tools 68 is mounted on the bottom plate 139
and cover plate 140 with a configuration that allows axial
translation of the pin tools 68 relative to the frame structure 136
in an upward direction. The pin tools 68 have an elongate shaft
142, a nominal shaft portion and an enlarged portion of the shaft
142 that may include an enlarged portion 143 in the form of a
collar member 144 to stop axial movement of the pin tool shaft 142
against either the bottom plate 137 or cover plate 140 of the frame
structure 136. For the embodiment shown, the pin tools 68 are
disposed in a 4 by 6 pin array with spacing or pitch between
adjacent pin tools of about 3 mm to about 10 mm, more specifically,
about 4 mm to about 5 mm. The pin tools 68 are disposed in close
fitting holes in the bottom plate 139 that have an inside diameter
or transverse dimension that corresponds to an outer transverse
dimension or diameter of the nominal shaft portion of the elongate
shaft 142 of each respective pin tool 68. The amount of clearance
between an outer surface of each pin tool 68 and an insider surface
of the respective hole in the bottom plate may be about 0.0002
inches to about 0.001 inches. Each pin tool 68 is also disposed in
a mating hole or slot in the cover plate 140 which may have similar
clearance and may provide additional longitudinal stability for
axial movement of the pin tool shaft 142 within the frame structure
136.
[0109] Either or both of the pin tool shaft holes or slots in the
bottom plate 139 or cover plate 140 may have a keyed configuration
that matches a keyed configuration of an outside surface of the pin
tool shaft 142 so as to prevent rotation of the pin tool shafts 142
relative to the frame structure 136, but allow unimpeded axial
movement of the pin tool shafts 142 relative to the frame structure
136. A top portion 146 of the pin tool shafts 142 shown have a "D"
shaped transverse cross section which mates with a respective "D"
shaped hole in the cover plate 140. Although the pin tool head
assembly 64 embodiment shown has a 4 by 6 pin tool array, other
configurations are also contemplated. For example, some arrays of
pin tools 68 of a pin tool head assembly 64 may have a row of about
1 pin tool to about 15 pin tools in conjunction with columns of
about 2 pin tools to about 30 pin tools, for some embodiments. Some
embodiments may have a row of about 3 pin tools to about 10 pin
tools in conjunction with columns of about 2 pin tools to about 15
pin tools.
[0110] For some embodiments, an enlarged portion 143 of the pin
tool shaft 142 may be integrally formed into the shaft 142. For the
pin tool embodiments shown, an enlarged portion 143 of the elongate
shaft 142 of the pin tools 68 is formed by the separate collar
member 144 which may be secured to the elongate shaft 142 by a
variety of suitable methods such as a compression fit, adhesive,
solder or the like. The collar members 144 shown are clips that are
secured by compression fit into circumferential slots or grooves
148 formed into the shafts 142 of the pin tools 68. As the collar
member 144 is larger than the pin tool shaft holes in the bottom
plate, the enlarged portion or collar member 144 comes to a hard
stop against the upper surface of the bottom plate 139 at the end
of downward axial translation of the pin tool shaft 142. The
enlarged portion 143 of the elongate shafts 142 of the pin tools 68
may be biased in an axial direction against the bottom plate 139 of
the frame structure 136 by gravity, a resilient bias member, such
as a helical spring 152, or by any other suitable device or method.
For the embodiment shown, each pin tool 68 is biased against the
bottom plate 139 by a helical spring 152 which is disposed over
each elongate shaft 142 between the lower surface of the cover
plate 140 and an upper surface of the collar member 142 of each pin
tool. A washer or bushing may be disposed adjacent the collar
members 144 between the collar member 144 and spring 152 to provide
a uniform surface for the spring 152 to push against. The helical
spring 152 may have a length in a relaxed uncompressed state that
is longer than the distance between the upper surface of the bottom
plate 139 and lower surface of the cover plate 140 so as to provide
continuous resilient bias against upward axial translation of the
pin tool 68. The bias against upward axial translation may also
increase as the spring member 152 becomes compressed.
[0111] For some embodiments, the pin tool shafts 142 may have a
length of about 1 inch to about 4 inches, more specifically, about
2 inches to about 3 inches. The elongate shafts 142 of the pin
tools 68 may have an outer transverse dimension or diameter of
about 0.03 inches to about 0.1 inches, more specifically, about
0.05 inches to about 0.07 inches, for some embodiments.
[0112] Sample reservoirs 156 may be disposed in distal ends or
portions 158 of the elongate shafts 142 of the pin tools 68, distal
of the enlarged portion 143 of the shaft 142 such which may include
the collar member 144. The collar member 144 is disposed and
mechanically captured in the window of the frame structure 136 with
the distal end 158 of the pin tool shafts 142 extending below the
pin tool shaft holes in the bottom plate 139. In this way, the
distal ends 158 and sample reservoirs 156 of the pin tools 68
extend below the bottom plate 139 and may be used to access
samples, such as arrays of samples disposed in vessels such as
microtiter plates. The distal ends and sample reservoirs 156 of the
pin tools 68 may also be used to access sample deposition sites,
such as arrays of sample deposition sites disposed on a
spectrometry chip. For some embodiments, the width of a slot 162 of
the sample reservoir of the pin tools may be sized to be greater
than an outer lateral transverse dimension of a matrix deposit of a
sample deposition site of a spectrometry chip. In this way, a
sample from the sample reservoir of the pin tool may be deposited
onto the matrix deposit of the chip without the pin tool structure
making contact with the matrix material. In other words, the slot
of the sample reservoir may be configured to straddle the matrix
material of the sample deposition site.
[0113] Some embodiments of the sample reservoir 156 may include a
thin slot 162 having a width of about 0.2 mm to about 0.5 mm, more
specifically, about 0.25 mm to about 0.4 mm, and may have a length
of about 0.1 inches to about 0.5 inches, more specifically, about
0.18 inches to about 0.22 inches, depending on the desired amount
of liquid volume to be delivered. The frame structure 136 and pin
tools 68 may be configured, particularly with regard to the
placement of the collar member 144 relative to the distal end 158
of the pin tools 68, such that the distal ends 158 of the pin tools
68 of a pin tool array are coplanar and all lie substantially in a
plane that is substantially parallel to the work surface 22. Each
pin tool 68 of the array may also be substantially perpendicular to
the work surface 22.
[0114] The work surface 22 is generally configured to be disposed
in a substantially horizontal orientation and may include one or
more functional elements disposed thereon. Because some of the
functional elements of the work surface 22 may include fluids
disposed in enclosures, the substantially horizontal orientation of
the work surface 22 may serve to prevent spillage of the fluids and
provide more consistent operation and sample transfer generally.
FIG. 7 shows an enlarged perspective view of a work surface
embodiment 22 and functional elements disposed thereon. FIGS. 8-11
show additional views and details of the work surface 22 and
functional element embodiments associated therewith.
[0115] The controller 28 as well as other electronics that control
the movement of the pin tool head assembly 64 (that may include a
controller with a processor and other sensitive electronic
components) as well as control and operation of other components of
the transfer device 10 may be disposed above the level of the work
surface 22 of the transfer device. With such a configuration, any
accidental spills of fluid that occur on the work surface 22 will
not compromise the integrity of such electronics.
[0116] For the embodiment shown, the work surface 22 is disposed
beneath the three axis translatable carrier 56 of the three axis
robotic positioning assembly 18 and includes a substantially flat
rectangular surface of a rectangular plate upon which the
functional elements may be directly or indirectly secured or
otherwise mounted. For some embodiments, the work surface 22 itself
may be formed from one or more upper nominal surfaces of one or
more functional elements discussed herein without the inclusion of
a separate flat rectangular surface or plate. For some embodiments,
the rectangular plate of the work surface 22 may have a width of
about 4 inches to about 16 inches, more specifically, about 5
inches to about 10 inches and may have a length of about 10 inches
to about 30 inches, more specifically, about 15 inches to about 20
inches. The plate of the work surface 22 may be secured to frame
members 48 which may in turn be secured to the frame of the housing
12 or other structural members of the sample transfer device 10
with solid mounts or vibration absorbing mounts 52 such as the
rubber mounts shown.
[0117] Referring to FIG. 7, a cleaning block assembly 164 is
disposed on and secured to the work surface plate. The cleaning
block assembly 164 may have one or more functional elements which
are configured to clean each pin tool of a pin tool 68 array of a
pin tool head assembly 64 simultaneously. The cleaning block
assembly embodiment 164 may be machined from a monolithic block of
a strong stable material, such as polymers, such as Delrin.RTM.,
composites and metals, such as stainless steel, aluminum, which may
be anodized, and the like. The cleaning block assembly 164 may
include functional elements in the form of a self-filling
ultrasonic wash station 166 that is self-filled by a gravity feed
supply reservoir 168, pin tool wash or rinse station 172 that
includes an array of regularly spaced rinse tubes or fountains 174
that may correspond to each pin tool 68 of the pin tool head
assembly 64. The rinse station 172 is disposed between the
ultrasonic wash station 166 and a vacuum drying station 176.
[0118] The vacuum drying station 176 includes an array of regularly
spaced vacuum drying orifices 178 that may correspond to each pin
tool of the pin tool 68 head assembly 64. Although not necessary,
it may be desirable for the rinse station 172 and vacuum drying
station 176 to have an array of rinse tubes 174 or vacuum ports or
orifices 178 with a regular spacing that corresponds to the regular
spacing of the pin tool array of a pin tool head assembly 64 to be
used with these stations and an array size at least as big as the
array of pin tools 68 of the pin tool head assembly 64. Even though
it may be acceptable for some pin tools 68 of an array which are
laterally displaced from a functional element of the cleaning block
164 to press against a surface adjacent a rinse tube 174 or vacuum
orifice 178, it may be desirable for all pin tools 68 of an array
to be cleaned simultaneously. As such, it may also be desirable for
an ultrasonic bath 182 to have inner transverse dimensions that are
greater than corresponding outer transverse dimensions of an array
of pin tools to be washed in the ultrasonic wash station 166. It
may also be desirable for the rinse station 172 and vacuum drying
station 176 to have at least as many rinse tubes 174 and vacuum
drying orifices 178 as there are pin tools 68 in a pin tool head
assembly 64 to be cleaned.
[0119] In general, a pin tool array that has been used for
transferring samples, such as liquid samples, may then be moved
over the work surface 22 so as to align the array with the
ultrasonic bath 182 of the ultrasonic wash station 166. The sample
reservoirs 156 and distal sections 158 of the pin tools 68
generally, may then be lowered into the ultrasonic bath 182 such
that any portion of the pin tools 68 that have been exposed to
sample material, will be submerged in the ultrasonic bath 182. An
ultrasonic actuator 184 disposed below the ultrasonic bath 182 and
cleaning block 164 may be activated to as to emit ultrasonic energy
into the bath 182 and promote cleaning and rinsing of each pin tool
68 of the array. The pin tools 68 may be soaked in the ultrasonic
bath 182 with ultrasonic energy agitating the water and surface of
the pin tool 68 for about 1 second to about 2 minutes, more
specifically, about 5 seconds to about 30 seconds, for some process
embodiments. The ultrasonic energy emitted into the bath 182 may
have a power of about 10 watts to about 100 watts, more
specifically, about 20 watts to about 40 watts, and a frequency of
about 20 kHz to about 60 kHz, more specifically, about 30 kHz to
about 50 kHz, and even more specifically, about 35 kHz to about 45
kHz. The ultrasonic wash fluid used in the ultrasonic bath 182 may
include de-ionized water, alcohol, and the like in a volume of
about 10 ml to about 1000 ml, more specifically, about 20 ml to
about 100 ml.
[0120] Referring to FIGS. 7 and 10, an upper nominal surface 186 of
the ultrasonic wash bath 182 is disposed evenly with a nominal
upper surface 188 of the cleaning block assembly 164. The wash bath
is disposed below the upper nominal surface 186 between side walls
formed into the cleaning block and a top actuator surface 192 of an
ultrasonic energy generator or transducer 194. The ultrasonic
energy generator 194 interior volume 182 is disposed below the
ultrasonic bath 182 and secured thereto by multiple fasteners in a
sealed arrangement such that the ultrasonic generator 194 is
coupled directly to the wash fluid within the ultrasonic bath
182.
[0121] The ultrasonic wash bath 182 of the ultrasonic wash station
166 is self-filled by a self-leveling gravity feed system supplied
by a wash fluid reservoir 168. The wash fluid reservoir 168, as
seen in FIG. 7A, may include a generally cylindrical bottle 196
having a ball valve 198 that allows a user to refill the reservoir
168 and couple an outlet port 202 of the reservoir to an inlet port
204 of the ultrasonic wash station 166 without spilling a
significant amount of the wash fluid. The wash fluid reservoir 168
is shown tipped up with the outlet port of the reservoir 168
coupled into the inlet port 204 of the wash station 166. The inlet
port 204 of the wash station 168 is in fluid communication with the
ultrasonic wash bath 182 via a fluid tight conduit (not shown) that
extends between the inlet 204 port and wash bath 182 underneath the
upper nominal surface 188 of the cleaning block 164. The ball valve
198 may include a spherical ball 206 made of an inert material such
as Viton.RTM. rubber or the like which is configured to seal
against an inside lip of the reservoir bottle 196 and provide a
seal. It may be important for the ball 206 of the ball valve 198 to
have an overall density which is greater than the density of the
cleaning fluid to be used in the reservoir 168. As such, it may be
desirable for the ball 206 to have a density which is greater than
water, ethanol alcohol, and other suitable cleaning fluids. The
outlet port 202 of the wash fluid reservoir 168 may include a
cylindrically shaped portion 208 extending from a bottom surface
212 of the reservoir 168. The cylindrically shaped portion 208 may
also have an o-ring or similarly configured resilient seal 214 that
may seal between the cylindrically shaped portion 208 and an inside
surface 216 of the inlet port 204 of the ultrasonic wash station
166. The wash fluid reservoir 168 may have a capacity of about 20
ml to about 1 liter, more specifically, about 40 ml to about 60 ml,
for some embodiments.
[0122] After the ultrasonic wash bath fluid has been used one or
more times, and the operator determines that the wash fluid needs
to be changed, the used wash fluid may then be drained through a
drain port 218 in the ultrasonic wash bath 182 that is in
communication with a flexible fluid tight tube that is coupled to
an optional pump 222. When the pump 222 is activated by the
controller 28 or other user input, the fluid in the ultrasonic wash
182 shown in FIGS. 2 and 12 may be actively drained from the wash
bath 182 through the pump 222 and into a waste fluid tank 224 which
is disposed below the processing chamber 14 and shown in FIG. 2.
The drainage of the wash bath 182 may also be controlled by a
solenoid valve or the like which may optionally be coupled to and
controlled by the controller 28.
[0123] Thus, the controller 28 may be programmed to drain the
ultrasonic wash bath 182 fluid after a predetermined number of
uses. As the wash bath 182 is being drained, new clean ultrasonic
wash fluid begins to refill the wash bath 182 by force of gravity
from the wash fluid reservoir 168 through the fluid tight conduit
and into the wash bath 182. As the wash bath 182 begins to fill,
the back pressure on the outlet port 202 of the reservoir 168
increases until equilibrium is achieved within the interior volume
of the reservoir 168 and wash fluid ceases to flow from the
reservoir 168 into the wash bath 182. When the wash fluid becomes
dirty again after use, the cycle may be repeated until the
reservoir 168 runs out of wash fluid. As such, it may be desirable
to construct the bottle 196 of the reservoir 168 from a transparent
or translucent material or materials that will make the fluid level
within the reservoir 168 visible to a user of the sample transfer
device 10. The fluid reservoir 168 also serves to maintain the
ultrasonic bath 182 at a desired pre-determined level during use
and can be used to automatically add additional cleaning fluid to
replace cleaning fluid lost through evaporation, adherence to pin
tools 68 and pin tool sample reservoirs 156 after a cleaning cycle
or the like.
[0124] An optional overflow channel 226 is disposed around the
inlet port 204 of the wash fluid reservoir 168, the ultrasonic wash
bath 182 and the rinse tubes 174 of the rinse tube station 172. The
overflow channel 226 may serve to confine any spilled cleaning
fluid to the channel 226 and allow the spilled cleaning fluid to
drain down the rinse station drain 228 by force of gravity. The
overflow channel 226 may be cut into the upper nominal surface 188
of the cleaning block 164 to a depth of about 0.05 inches to about
0.4 inches, more specifically, about 0.1 inches to about 0.2
inches. A lip 232 of the upper nominal surface 188 of the cleaning
block 164 surrounds the ultrasonic bath cavity 182 and forms the
upper nominal surface of the ultrasonic wash station 166.
[0125] The rinse station 172 includes a plurality of rinse tubes
174 arranged with a regular pre-determined spacing that may be
configured to match the regular spacing of the pin tools 68 of a
pin tool array to be used with the rinse station 182. The upper
ends 234 of the rinse tubes 178 may lie substantially in a plane
disposed at substantially the same z-axis level. The upper ends 234
of the rinse tubes 174 may also be at substantially the same z-axis
level as the nominal upper level 188 of the cleaning block 164 and
form the nominal upper surface of the rinse tube station 172. The
rinse tubes 174 may be elongate hollow tubes having an inner lumen
236 with an inner transverse dimension or diameter of about 0.05
inches to about 0.2 inches, more specifically, about 0.07 inches to
about 0.1 inches. The inner lumens 236 of the rinse tubes 174 may
be coupled by a manifold assembly to a fluid tight tube in fluid
communication with a rinse pump 238 which is in turn in fluid
communication with a wash fluid supply tank 242 shown in FIG. 3.
Once the pin tool or pin tools 68 of a pin tool head assembly 64
are disposed within the rinse tubes 174, rinse fluid may then be
expelled vertically from the rinse tubes 174 to provide a
continuous flow of rinse fluid over the sample reservoirs 156 and
distal section 158 generally of the pin tools 68. The flow of rinse
fluid may be maintained for about 1 seconds to about 10 seconds,
more specifically, about 3 seconds to about 5 seconds, for some
embodiments. The amount of flow of rinse fluid through each
individual rinse tube 174 may be about 20 ml per minute to about
100 ml per minute, more specifically, about 20 ml per minute to
about 30 ml per minute.
[0126] The rinse fluid may include de-ionized water, alcohol
including ethanol, or any other suitable cleaning fluid. After the
rinse fluid has been expelled from the rinse tubes 174, it flows by
force of gravity over the sides of the rinse tubes 174, into the
overflow channel 226 discussed above and down the rinse station
drain 228. The overflow channel 226 surrounding the rinse tubes 174
may have a depth of about 0.2 inches to about 1 inch, more
specifically, about 0.3 inches to about 0.5 inches, for some
embodiments. The rinse station drain 228 is a relatively large bore
drain that is coupled to the waste fluid tank 224 by a flexible
tubing. The bore of the rinse station drain 228 may have a
transverse dimension or diameter of about 0.2 inches to about 1
inch, more specifically, about 0.3 inches to about 0.8 inches.
[0127] The vacuum drying station 176 includes a plurality of
substantially parallel vertical holes 244 disposed in the cleaning
block 164 arranged in a regularly spaced array that may be
configured to match the regular spacing of the pin tools 68 of a
pin tool head assembly 64 to be dried by the vacuum drying station
176. The vertical holes 178 are formed directly into the material
of the cleaning block 164 having upper apertures or orifices 178
that lie in substantially the same plane as the upper nominal
surface 246 of the vacuum drying station 176. The vertical holes
244 may have an inner transverse dimension or diameter that is
larger or just slightly larger than an outer transverse dimension
or diameter of the pin tools 68 to be used in the vacuum drying
station 176. For some embodiments, the vertical holes 244 may have
an inner transverse dimension or diameter of about 0.04 inches to
about 0.1 inches, more specifically, about 0.07 inches to about 0.1
inches. The vertical holes 244 may have a depth of about 0.1 inches
to about 1 inch, more specifically about 0.3 inches to about 0.5
inches.
[0128] A bottom end or bottom orifice (not shown) of each vertical
hole 244 may be coupled to a manifold which is coupled to a vacuum
holding tank 248, shown in FIG. 2, disposed below the work surface
22 in the lower chamber 44 by a length of flexible tubing (not
shown). The flexible tubing may have a wall thickness and
mechanical integrity suitable for holding a vacuum or partial
vacuum for some embodiments. A valve, such as a solenoid valve (not
shown), which may be coupled to and controlled by the controller
28, may be coupled to the flexible tubing in fluid communication
with the vacuum storage tank 248 and vertical holes 244 in a
configuration that allows the application of stored vacuum in the
tank 248 to be applied to the vertical holes 244 when the pin tools
68 of a pin tool head assembly 64 are disposed within the vertical
holes 244. If the vacuum storage tank 248 has been emptied of most
of the air within the storage tank 248, air will be drawn through
the vertical holes 244 at a high rate of flow and through the
flexible tubing when the solenoid valve is opened in order to fill
the vacuum within the vacuum storage tank 248. For some
embodiments, the vacuum storage tank 248 may have an interior
volume of about 1 liter to about 3 liters, more specifically, about
1.5 liters to about 2 liters. For some embodiments, the vacuum may
be applied to the vertical holes 244 for drying pin tools 68
disposed therein for about 0.1 seconds to about 0.8 seconds, more
specifically, about 0.2 seconds to about 0.4 seconds.
[0129] A relieved slot or channel 252 may be formed into a front
surface of the cleaning block 164 in front of the vacuum drying
station 176. The slot 252 may be configured to accept a rail
feature 254 of a multi-well calibration material supply vessel 256
shown in FIG. 7C. The supply vessel 256 may be detachably disposed
into the slot 252 by sliding the rail feature 254 of the supply
vessel 256 vertically downward into the slot 252 until it hits a
stop point. One or more calibration materials may be disposed in
the individual wells 258 of the supply vessel and the supply vessel
256 then placed in the slot 252 of the cleaning block 164. The
controller 28 may be programmed to dip one or more pin tools 68 to
be used for calibration purposes into a pre-determined well of the
supply vessel 256 in order to draw in calibration material into the
sample reservoir 156 of the pin tool 68 to be used for calibration.
Once the calibration material runs out or gets low, or the user
decides to use another type of calibration material, the supply
vessel 256 may be manually removed from the cleaning block 164 and
replaced with another full supply vessel 256. For some embodiments,
the supply vessel 256 may have about 1 well to about 10 wells, more
specifically, about 2 wells to about 8 wells. FIG. 7D illustrates
and embodiment of a supply vessel 256' having a single well 258'
and a rail feature 254' that may also be configured to engage slot
252.
[0130] The slot 252 of the cleaning block 164 and rail feature 254
and 254' of the supply vessel embodiments 256 and 256' may be
configured such that respective upper nominal surfaces 262 and 262'
of the supply vessel embodiments are disposed above the upper
nominal surface 188 of the cleaning block 164 for some embodiments.
This allows the pin tools 68 to be used for calibration purposes to
dip into the wells 258 of the supply vessels without the remainder
of the pin tools 68 making contact with adjacent cleaning block
elements or structures. As such, the rail feature embodiments 254
and 254' and slot 252 may be configured such that the height of the
nominal surface 262 of the supply vessel 256 may be disposed above
the nominal upper surface 188 of the cleaning block 164 by a
distance that is at least the length of a pin tool 68 that needs to
be inserted into the calibration material plus the distance below
the upper nominal surface of the supply vessel embodiments of the
calibration material.
[0131] Some of the functional elements of the work surface 22 may
be secured to the plate by fasteners such as machine screws or the
like and some functional elements, such as microtiter plates, chips
and chip mount blocks may be releasably secured to the work
surface, or mount block disposed thereon, with elements such as
spring loaded toggles, clips, magnets or the like to allow the easy
and convenient exchange of such functional elements. Functional
elements such as microtiter plates, chips and chip mount blocks may
contain samples to be transferred or sample deposition sites that
need to be changed as processing takes place and progresses. The
work surface shown in FIG. 7 includes two microtiter plate mount
blocks 264 disposed adjacent a chip mount block 266. The microtiter
plate mount blocks 264 are configured to releasably secure
microtiter plates 268 having a uniform and standardized
configuration with an array of sample wells 270. This allows such a
standardized microtiter plate 268 to be easily mounted and removed
from the work surface 22 with some of the important aspects of the
microtiter plate 268 (such as sample well location and upper
nominal surface location) disposed in a consistent position with
respect to the work surface 22.
[0132] The chip mount block 266 may also be releasably secured to a
mount platform 272 which is secured to the work surface 22 and
configured to releasably secure the chip mount block 266 thereto
with spring loaded toggles or the like. This allows the chip mount
block 266 to be preloaded with one or more chips, such as the
spectrometry chip 274 shown in FIGS. 11A and 11B, away from the
work surface 22. The chip mount block 266 that has been preloaded
with chips 274 may then be releasably secured to the mount platform
272 on the work surface 22 by the toggles 276. The mount platform
272 may be sized to have a thickness or otherwise be configured to
position an upper nominal surface 278 of the chip mount block 266
(and chips 274 mounted thereto for some embodiments) at a level
which is even with upper nominal surfaces 188 of the cleaning block
164 and other functional elements disposed on the work surface
22.
[0133] The chip mount block 266 may have one or more chip mount
sites 288 or wells which are configured to releasably secure one or
more chips 274, such as mass spectrometry chips, having at least
one array of sample deposition sites disposed thereon. The chips
274 may be mounted to chip mount sites 282 the chip mount block 266
by gravity, friction, spring loaded toggles, magnets and the like.
The chip mount block 266 may also secure the chips 274 thereto by
having each chip 274 disposed within a cavity of the chip mount
sites 282 formed in an upper surface of the chip mount block 266
which is sized to substantially conform to an outer edge of
pre-selected embodiments of chips 274. Such cavities may be used to
partially mechanically capture the mounted chips 274 and prevent
lateral movement of the chips 274 relative to the chip mount block
266. For the embodiment shown, each chip mount cavity well 282 has
a magnetic source, such as a ferrous magnet 284 disposed in a
bottom surface of the chip mount well 282. Each chip 274 to be used
for such an embodiment, may have a layer of ferrous metal, such as
a disc 286 made of steel or the like, secured to a rear surface 288
of the chip 274 as shown in FIGS. 11A and 11B. When such a chip
embodiment 274 is placed in a chip mount well 282, the magnet 284
of the chip mount well 282 attracts the disc 286 secured to the
chip 274 and holds the chip 274 in the chip mount well 232. By
having the magnet 284 of the chip mount well 282 offset from the
position of the ferrous metal disc 286, the chip 274 may also be
pulled laterally into a corner of the chip mount well 282 in order
to register the position of the corner of the chip 274 to a known
corner of the chip mount well 282 and provide a reliable
positioning of the chip 274 within the chip mount well 282.
[0134] Referring to FIGS. 11A and 11B, each chip 274 may include
one or more arrays of sample deposition sites 292 which are
regularly spaced from each other at periodic intervals on a flat
working surface 293 of the chip 274. Also, as discussed above, each
chip 274 may have a ferrous metal disc or layer 286 disposed on the
rear surface 288 of the chip 274 for releasable mounting purposes.
For some embodiments, an array of sample deposition sites 292 on a
chip 274 may be configured as a square orthogonal array of sample
deposition sites 292 wherein each sample deposition site 292 is
disposed an equal distance away from the adjacent sample sites 292
along orthogonal axes that transect the sample sites 292. Such an
orthogonal array of sample sites 292 may have a spacing between
adjacent sample sites of about 1 mm to about 3 mm, more
specifically, about 1.1 mm to about 1.4 mm. For some embodiments, a
chip 274 may include two, three or more arrays of sample deposition
sites 292, each array having a regular spacing of sample deposition
sites 292. Each of the multiple arrays of sample deposition sites
292 may be square orthogonal, linear or have any other desirable
configuration. It may also be desirable for one or more arrays of
sample deposition sites 292 to have a regular spacing that is
different from one or more other arrays of sample deposition sites
292. It may also be desirable for one or more arrays of sample
deposition sites 292 to have a regular spacing that is off pitch or
out of phase from the pitch or phase one or more other arrays of
sample deposition sites 292. For some embodiments, the ferrous
metal disc 286 may be made from steel, stainless steel, nickel as
well as other suitable ferrous metals. The disc 286 may have a
thickness of about 0.01 inches to about 0.1 inches, and a surface
area of about 0.08 square inches to about 0.15 square inches.
[0135] For some embodiments of the chips 274, the sample deposition
sites 292 may include mass spectrometry sample deposition sites,
such as MALDI sample deposition sites, which may be arranged in one
or more regularly spaced patterns or arrays. For some embodiments,
the chip 274 may include a first array of sample deposition sites
292 for sample processing and a second array of sample deposition
sites 292 for calibration of the processing equipment. For some
embodiments, the regular spacing of the second array of calibration
sample deposition sites 292 may be off-pitch from the regular
spacing of the first array, as will be discussed in more detail
below.
[0136] For many of the applications of the robotic sample transfer
device 10, it is very important to determine the position of the
translatable carriers 56, 58 and 62, and particularly, the three
axis translatable carrier 56 relative to the work surface 22 and
functional elements of the work surface 22. This is very important
so that each pin tool of the pin tool head assembly 64 may be moved
to a known position relative to the functional elements with which
it must interact in order to transfer samples from one location to
another, as well as be moved to known positions of the elements of
the cleaning block 164 for proper cleaning of the pin tools 68. For
example, it may be important for some sample transfer methods to
dip a particular pin tool 68 or set of pin tools 68 into sample
wells 270 of a microtiter plate 268 to a pre-determined depth below
the upper nominal surface of the microtiter plate 268 and take up a
known amount of sample material. The pin tool 68 must then be
accurately moved to a sample deposition site 292, such as a
spectrometry sample deposition site on a chip 274, without hitting
or otherwise interfering with any other elements or components on
the work surface 22. The pin tool 68 be brought into precise
contact with a pre-determined sample deposition site 292 of the
chip 274 with a pre-determined amount of force to deposit a known
amount of sample onto the sample deposition site 292. The pin tool
68 may then be precisely moved to the functional elements of the
cleaning block 164 and be moved through the progression of cleaning
functional elements including the ultrasonic bath 182, rinse
station 172 and vacuum drying station 176. Each of these steps
requires that the pin tool 68 be moved over the bath 182,
respective rinse tube 174 and respective vertical hole or channel
244 of the vacuum drying station 176 and moved vertically downward
into functional coupling with these elements without making contact
with adjacent structures.
[0137] For some embodiments of chips 274, such as some of the
spectrometry chip embodiments discussed above, it may be desirable
to use features of the chip 274 to facilitate the process of
locating or positioning the three axis translatable carrier with
respect to the work surface 22 and functional elements of the work
surface 22. Some methods of registering the position of a pin tool
head assembly 64, and pin tools 68 thereof, of a robotic sample
transfer device 10 relative to sample deposition sites 292 on a
chip 274 include making use of functional elements having an upper
nominal surface at the same z-axis level, for sample transfer
device embodiments that have this feature. That is, some
embodiments of robotic sample transfer devices 10 have a work
surface 22 with a plurality of functional elements, at least two,
three, four or more of which have nominal upper surfaces at
substantially the same z-axis level. Such robotic sample transfer
devices 10 may also have a three axis robotic positioning system 18
with an imaging camera 132 and pin tool head assembly 64 secured to
a translatable carrier thereof. For such embodiments, the nominal
upper surfaces of functional elements disposed on work surface 22
may be imaged with the camera 132 and the image data of the nominal
upper surfaces of the functional elements from the camera processed
by an image processor or the like to determine the approximate
position of the pin tool head assembly 64 relative to the
functional elements.
[0138] For some embodiments of the robotic sample transfer device
10, the controller 28 may include an image processor either as a
separate component or built into the processor thereof which may be
coupled to the imaging camera 132. The approximate position data
obtained by the imaging camera 132 may be used to move the camera
132 to a first chip 274 having an array of regularly spaced sample
deposition sites 292 and an array of regularly spaced fiducial
marks 294 disposed between the sample deposition sites 292.
Thereafter, the fiducial marks 294 on the first chip may be imaged
with the imaging camera 132 and the image data of fiducial marks
294 on the first chip 274 processed by the image processor. As the
fiducial marks 294 on the chip 274 are at known positions relative
to the sample deposition sites 292 on the chip 274, the positions
of the sample deposition sites 292 may then be determined to a high
degree of accuracy. After the fiducial marks have been imaged,
feedback regarding a position of the pin tool head assembly 64 may
be obtained from one or more linear encoders of three axes of a
three axis robotic positioning system. Position may also be
obtained from the controller 28 which has tracked the movement of a
translatable carrier, such as translatable carrier 56 after
carrying out the homing procedure discussed above.
[0139] The position data feedback may then be compared with image
processing feedback and look up table data to determine the precise
position of the pin tools 68 of the pin tool head assembly 64
relative to the sample deposition sites 292 on the first chip 274.
This process may then be repeated for one or more other chips 274.
Such methods may be used to determine the precise position of the
pin tools 68 of the pin tool head assembly 64 with respect to the
sample deposition sites 292 on the first chip 274 is determined to
within about 1 micron to about 10 microns for some embodiments.
[0140] For some embodiments, the location of one or more of the pin
tools 68 of the pin tool head assembly 64 is known with respect to
the position of the center of field of view or other reference
point in the field of view of the imaging camera 132. This position
information may be stored in a look up table or the like of the
processor. For these embodiments, once the imaging camera 132
images a known feature of a functional element, for example a
sample well in the "A-1" position of a microtiter plate, in the
center of field of view of the camera the position information may
then be used to calculate the position the one or more pin tools 68
in the center of the A-1 well for future processing methods. If the
relative position or positions of other features on the work
surface 22 are known relative to the imaged feature, then the
position of these features may also be calculated. For example,
once the position of the "A-1" sample well of a selected microtiter
plate is known, then the relative positions of the remaining wells
of the microtiter plate may also be calculated.
[0141] If the position of the other functional elements of the work
surface 22, such as the ultrasonic bath 182, rinse tubes 174,
vertical holes 244 of the vacuum drying station 176, microtiter
places 268 mounted to microtiter plate mount blocks 264 in addition
to the wells 270 of the plates 268 are known with respect to the
position of the imaging camera center of field of view or some
other reference position in the imaging camera field of view and
this position data is stored in a look up chart, then the position
of any of the functional elements relative to one or more of the
pin tools 68 of the pin tool head assembly 64 can be determined by
the controller 28. Thus, the controller may then use the position
information to move one or more of the pin tools 68 or other
devices secured to the z-axis translatable carrier to the
functional elements for various processing methods. The initial
positioning of the center of field of view or other reference point
of the imaging camera 132 may be carried out manually in order to
teach the controller with regard to the position of each of the
functional elements. For some functional element embodiments, such
as embodiments of the ultrasonic bath 182 of the ultrasonic wash
station, precise position data may not need to be generated as the
bath is sufficiently large to accommodate the pin tools 68 of the
pin tool head assembly 64 with a relatively large amount of space
around the pin tools 68
[0142] The wash fluid supply tank 242 may be disposed in the lower
storage tank chamber 44 below the work surface 22 and processing
chamber 14 as shown in FIG. 3. An external wash fluid supply tank
coupling may be disposed on or in fluid communication with the wash
fluid supply tank 242 for optionally coupling additional capacity
to the internal wash fluid tank 242. As discussed above, the wash
fluid tank 242 is coupled to the rinse tubes 174 of the rinse
station 172 by flexible tubing through a fluid pump 238 shown in
FIG. 12. The wash fluid supply tank 242, as shown in more detail in
FIG. 14 may have a substantially rectangular shape having a length
of about 10 inches to about 25 inches, a width of about 5 inches to
about 10 inches, and a height of about 4 inches to about 8 inches.
The wash fluid tank 242 may be made from lightweight durable
polymer materials such as polyethylene, polypropylene and the like
and may have a capacity of about 1 liter to about 10 liters, more
specifically, about 2 liters to about 4 liters. The wash fluid tank
242 may include a liquid level sensor disposed in a wall of the
tank 242 that is configured to measure the level of fluid disposed
within the tank. The tank may also include a removable access cover
or plate that is generally disposed on a top surface of the tank
and configured to allow access by an operator to the interior
volume of the tank for cleaning, maintenance etc. The tank may also
include two or more orifices for fluid communication with fill
tubes, drain tubes and the like.
[0143] The waste fluid storage tank 224 may also be disposed in the
lower storage tank chamber 44 below the work surface 22 and
processing chamber 14 adjacent the rinse fluid supply tank 242, as
shown in FIG. 3. An external waste fluid storage tank coupling may
be disposed on or otherwise in fluid communication with the waste
fluid storage tank 224 for optionally coupling additional capacity
to the internal waste fluid storage tank 224. As discussed above,
the waste fluid tank 224 is in fluid communication with the gravity
drain 228 of the rinse station 172 by flexible tubing. The waste
fluid tank 224 is also in fluid communication with the ultrasonic
wash bath 182 of the ultrasonic cleaning station 166 through a
flexible tubing and fluid pump 222 that may be used to drain the
ultrasonic bath 182. The waste fluid storage tank 224, as shown in
more detail in FIG. 13 may have a substantially rectangular shape
having a length of about 10 inches to about 25 inches, a width of
about 5 inches to about 10 inches, and a height of about 4 inches
to about 8 inches. The wash fluid tank 224 may be made from
lightweight durable polymer materials such as polyethylene,
polypropylene and the like and may have a capacity of about 1
liters to about 100 liters, more specifically, about 2 liters to
about 4 liters. The waste fluid tank 224 may include a liquid level
sensor disposed in a wall of the tank 224 that is configured to
measure the level of fluid disposed within the tank. The tank may
also include a removable access cover or plate that is generally
disposed on a top surface of the tank and configured to allow
access by an operator to the interior volume of the tank for
cleaning, maintenance etc. The tank 224 may also include two or
more orifices for fluid communication with fill tubes, drain tubes
and the like. Either or both of the wash fluid supply tank 224 and
waste fluid tank 242 may be coupled to visual tank fluid level
indicators (not shown) on side walls of the housing 12 in order to
allow an operator of the system to quickly and intuitively check
the fluid levels of the tanks 224 and 242. For some embodiments,
the visual indicators may include lengths of clear tubing coupled
to the interior cavity of the tanks and extending along a vertical
slot cut in the respective side wall of the housing with the end of
the clear tubing extending to a location above the top of the tank
to which it is coupled. The clear tubing disposed adjacent the
vertical slot may also contain a floating ball to visually
highlight the level of liquid in the clear tubing.
[0144] Referring again to FIG. 12, the pump housing assembly 296 is
shown that includes the fluid pump 238 used for moving rinse fluid
from the wash fluid supply tank to the rinse tubes 174 of the fluid
rinse station 172. A vacuum pump 298 coupled to the vacuum storage
tank 248 and configured to generate a vacuum within an interior
volume of the vacuum storage tank 248 is also disposed within the
pump housing 296. The fluid pump 222 coupled between the ultrasonic
wash bath 182 and waste fluid storage tank 224 is also disposed
within the housing 296. A solenoid valve 299 for coupling the
vacuum within the interior volume of the vacuum storage tank 248 to
the vacuum drying orifices 178 of the vacuum drying station 176 is
also disposed in the pump housing assembly 296. The rinse fluid
pump 238, vacuum pump 298, solenoid valve 299 and ultrasonic bath
emptying pump 222 may all be coupled to and controlled by the
controller 28 so as to be activated and stopped at appropriate
times or intervals for proper cleaning of pin tools 68 or other end
results.
[0145] For some applications of system calibration as well as other
methods of use of the robotic sample transfer device embodiments
10, it may be desirable to have a single pin tool 68 of a pin tool
array of a pin tool head assembly 64 deployed or otherwise
configured for use. It may also be desirable to have a reduced
number of pin tools 68 of a pin tool array configured for use,
while the remaining pin tools of the pin tool array are disposed in
a retracted state in an upward direction or otherwise deactivated
from use. For some embodiments of pin tool head assemblies 64, a
pin tool displacement block may be used to selectively retract one
or more pin tools 68 of a pin tool array in a proximal or upward
direction so as to leave only the desired active pin tools 68
extending downward and configured for use.
[0146] Some embodiments of a pin tool displacement block for
selectively displacing at least one pin tool 68 of a pin tool head
assembly 64 of a robotic sample transfer device 10 in an axial
direction include a block body having a bottom surface and a
plurality of parallel slots formed into the block body portion. The
parallel slots may be substantially perpendicular to the bottom
surface with a predetermined regular spacing configured to
correspond to regular spacing of pin tools 68 of a pin tool head
assembly 64. The parallel slots may have a transverse dimension
which is sized to allow easy movement of a width of a nominal shaft
of the pin tools in the slots but restrictive of movement of an
enlarged portion of the shaft of the pin tools.
[0147] The block body portion may also include at least one
relieved portion or channel that may extend from the top surface of
the block body portion in a direction which is substantially
perpendicular to the bottom surface in one or more of the parallel
slots. The relieved portion may have a transverse dimension sized
to allow easy movement in an axial downward direction of not only
the nominal shaft portion of a respective pin tool 68 but also and
enlarged portion of a pin tool shaft and be configured to
mechanically capture the enlarged portion of a pin tool disposed
therein in a lateral direction. The enlarged portion of the pin
tool shaft may be greater in transverse dimension than the
transverse dimension of the slot but less in transverse dimension
than a transverse dimension or diameter of the relieved portion and
which extends from a top surface of the block body towards the
bottom surface. For some embodiments, the parallel slots may have a
width of about 0.04 inches to about 0.2 inches, more specifically,
about 0.07 inches to about 0.1 inches, and a spacing or pitch of
about 0.1 inches to about 0.5 inches, more specifically, about 0.15
inches to about 0.2 inches. Some embodiments may have a slot length
of about 0.2 inches to about 2 inches, more specifically, about 0.5
inches to about 1.2 inches, and even more specifically, about 0.7
inches to about 1 inch. For some embodiments, the relieved portion
or channel may have a diameter or transverse dimension of about 0.1
inches to about 0.3 inches, more specifically, about 0.15 inches to
about 0.25 inches, and even more specifically, about 0.18 inches to
about 0.22 inches.
[0148] For some embodiments, the enlarged portion of a shaft of a
pin tool 68 may include a collar member and the stop surface of the
at least one relieved portion may be configured to prevent axial
movement of the collar member and mechanically capture a collar
disposed therein member to prevent lateral displacement of the
block body when the block is deployed in a pin tool head assembly
64. If more than one relieved portions or channels are disposed in
a single block body portion, it may be desirable for the relieved
portions to have a regular spacing that corresponds to a regular
spacing of the pin tools 68 of a pin tool head assembly 64 for
which the block is to be used.
[0149] For some embodiments, the relieved portion or channel may
extend either partially or completely from the top surface of the
block body portion to the bottom surface of the block body portion.
For some embodiments wherein the relieved portion extends only
partially from the top surface of the block body portion, the
relieved portion may terminate at a stop surface which is spaced
from the bottom surface. The top surface and bottom surface of the
block body portion may be substantially flat and substantially
parallel to each other for some embodiments. Some embodiments of
pin tool displacement blocks may have a reversible configuration
wherein when the block is oriented in a first direction and
deployed, a first pin or set of pins is active and when flipped
over 180 degrees or otherwise oriented a second direction and
deployed, a second pin or set of pins is active which is different
from the first set. For such embodiments, it may be desirable for
the relieved portions to extend only partially from a first surface
to a second surface of the block body portion.
[0150] Embodiments of the block body portion may optionally include
a handle member extending from and secured to the body portion for
more convenient handling by a user of the device. The handle member
may be a thin but rigid extension of the material of the block body
portion that is easily gripped by a user and extends away from the
block body portion with material relieved from both the top surface
and bottom surface to allow easy access and gripping. The block
body may be made from an inert material, such as Teflon.RTM.,
Delrin.RTM. or the like and may have a width of about 0.4 inches to
about 3 inches, more specifically, about 0.8 inches to about 1.2
inches, a length of about 0.5 inches to about 4 inches, more
specifically, about 1.5 inches to about 2.5 inches, and a height or
thickness of about 0.2 inches to about 1.5 inches, more
specifically, about 0.3 inches to about 0.7 inches.
[0151] FIGS. 15 and 16 illustrate a simplified pin tool
displacement block 300 having a single slot 302 with a single
relieved portion or channel 304 disposed in the slot 302. The
relieved portion 304 extends from a top surface 306 of the block
body 308 portion towards a bottom surface of the block body portion
and extends through the block body portion 308 completely from the
top surface 306 to a bottom surface 312, as shown in FIG. 16. The
pin tool displacement block 300 may have the same or similar
features, dimensions or materials as the features, dimensions or
materials of the pin tool displacement block embodiments discussed
above.
[0152] FIG. 17 is an elevation view of a simplified pin tool head
assembly 314 having a first pin tool 316 and second pin tool 318
mounted in a frame 322 of the pin tool head assembly 314. The frame
322 includes a first side plate 324, a second side plate 326, a
bottom plate 328 and a cover plate 330. All four plates are secured
to adjacent plates at their ends in a perpendicular orientation.
The first and second side plates 324 are substantially parallel to
each other and the cover plate 328 and bottom plate 330 are
substantially parallel to each other. The pin tools 316 and 318,
which may have the same or similar features, dimensions or
materials as the features, dimensions or materials of the pin tool
embodiments 68 discussed above, have a "D" shaped transverse cross
section in an upper portion that mates with a corresponding "D"
shaped hole in the cover plate 330. A resilient member in the form
of a helical spring 152 is disposed over each pin tool 316 and 318
between the cover plate 330 and washer 154 disposed towards the
bottom of each pin tool 316 and 318. The washers 152 of the pin
tools 316 and 318 are held axially in place by compression clips or
collar members 144 that are secured to circumferential grooves 148
in an outer surface of each pin tool shaft 142. As such, each pin
tool 316 and 318 is resiliently biased in a downward direction both
by the weight of the pin tool itself and the helical spring 152.
The helical springs 152 have an axial length in a relaxed
uncompressed state that is longer than the distance between an
inside surface of the cover plate 330 and inside surface of the
bottom plate 328.
[0153] FIGS. 18 and 19 illustrate an embodiment of a method of
displacing a pin tool of the pin tool head assembly 314 of a
robotic sample transfer device with the pin tool displacement block
300 discussed above. As shown in FIG. 18, the pin tool head
assembly 314 is brought down vertically into contact with a flat
surface 332 in order to displace the pin tools 316 and 318 axially
in an upward direction. In this position, the enlarged portions of
the pin tool shafts or collar members are displaced axially from
the inside surface of the bottom plate 328 as shown. The slot 302
of the pin tool displacement block 300 is then aligned with the row
of pin tools 316 and 318 and advanced into the pin tool head
assembly 314 as shown by arrow in FIG. 18. Once the relieved
portion 304 in the slot 302 of the pin tool displacement block 300
is aligned coaxially in a vertical direction with the first pin too
shaft 316, the pin tool head assembly 314 may then be raised and
retracted from the flat surface 332 to allow the pin tools 316 and
318 of the pin tool head 314 assembly to resume a relaxed state. As
the pin tool shafts 316 and 318 return to their nominal relaxed
positions, the collar member 144 of the first pin tool 316 passes
through the relieved portion 304 of the pin tool displacement block
144 and comes to rest on the inside surface of the bottom plate
328. However, the collar member 144 of the second pin tool 318
comes to rest on the upper surface of the pin tool displacement
block 300 in an axially retracted state with the distal tip of the
pin tool axially retracted from the plane of the first pin tool by
a length, indicated by arrow 334, which is substantially equal to
the thickness or height of the pin tool displacement block 300.
[0154] FIGS. 20A-20D illustrate an embodiment of a pin tool
displacement block 336 for use with a 6.times.4 pin tool array of a
pin tool head assembly 64. The pin tool displacement block 336
includes 6 parallel slots 338 that have a regular spacing that is
configured to match that of an array of pin tools of a pin tool
head assembly 64. A single relieved channel 342 is disposed in a
second parallel slot 338 of the block 336 in order to allow a
single pin tool in a 2-2 position of the array to be configured for
use after deployment of the pin tool displacement block into the
pin too head assembly. The pin tool displacement block 336 may have
some or all of the features, dimensions or materials as the
features, dimensions or materials of any of the pin tool
displacement blocks discussed above. The pin tool displacement
block 336 includes a first parallel slot, a second parallel slot, a
third parallel slot, a fourth parallel slot, a fifth parallel slot
and a sixth parallel slot. The pin tool displacement block includes
a block body 334 having a bottom surface 346 with the 6 parallel
slots formed into the block body portion 344 substantially
perpendicular to the bottom surface 346 with a predetermined
regular spacing that may be configured to correspond to regular
spacing of pin tools 68 of a pin tool head assembly 64. The
parallel slots 338 may have a transverse dimension which is sized
to allow easy movement of a width of a nominal shaft of the pin
tools 68 in the slots 338 but restrictive of movement of an
enlarged portion 143 of the shaft of the pin tools 68. For some
embodiments, the parallel slots 338 may have a width of about 0.04
inches to about 0.02 inches, more specifically, about 0.07 inches
to about 0.1 inches, and a spacing or pitch of about 0.1 inches to
about 0.5 inches, more specifically, about 0.15 inches to about 0.2
inches. Some embodiments may have a slot 338 length of about 0.2
inches to about 2 inches, more specifically, about 0.5 inches to
about 1.2 inches, and even more specifically, about 0.7 inches to
about 1 inch. For some embodiments, the relieved portion or channel
342 may have a diameter or transverse dimension of about 0.1 inches
to about 0.3 inches, more specifically, about 0.15 inches to about
0.25 inches, and even more specifically, about 0.18 inches to about
0.22 inches.
[0155] The relieved channel 342 extends from the top surface 348
completely through the block body portion 344 in a direction which
is substantially perpendicular to the bottom surface 346. The
relieved channel or portion 342 may have a transverse dimension
sized to allow easy movement in an axial downward direction of not
only the nominal shaft portion of a respective pin tool 68 but also
and enlarged portion 143 of a pin tool shaft and be configured to
mechanically capture the enlarged portion 143 of a pin tool 68
disposed therein in a lateral direction. Embodiments of the block
body portion 344 may optionally include a handle member 352
extending from and secured to the body portion for more convenient
handling by a user of the device. The handle member 352 may be a
thin but rigid extension of the material of the block body portion
344 that is easily gripped by a user and extends away from the
block body portion with material relieved from both the top surface
348 and bottom surface 346 to allow easy access and gripping. The
block body 344 may be made from an inert material, such as
Teflon.RTM., Delrin.RTM. or the like and may have a width of about
0.4 inches to about 3 inches, more specifically, about 0.8 inches
to about 1.2 inches, a length of about 0.5 inches to about 4
inches, more specifically, about 1.5 inches to about 2.5 inches,
and a height or thickness of about 0.2 inches to about 1.5 inches,
more specifically, about 0.3 inches to about 0.7 inches.
[0156] FIGS. 21A-21D illustrate an embodiment of a pin tool
displacement block 360 for use with a 6.times.4 pin tool array. The
pin tool displacement block 360 includes 6 parallel slots 362 that
may have a regular spacing that is configured to match that of an
array of pin tools of a pin tool head assembly 64. Two relieved
channels 364 are disposed in each of a second parallel slot, a
fourth parallel slot, and a sixth parallel slot in order to allow
six pin tools to be configured for use after deployment of the pin
tool displacement block into the pin too head assembly. Other than
the 6 relieved channels 364, the pin tool displacement block of
FIGS. 21A-21D may have the same features, dimensions or materials
as those of the pin tool displacement block of FIGS. 20A-20D
discussed above. The relieved channels of the pin tool displacement
block are disposed at the 2-2, 2-4, 4-2, 4-4, 6-2 and 6-4 positions
of the array and extend completely through the block body portion
of the pin tool displacement block 360.
[0157] For some embodiments, a method for selectively displacing at
least one pin tool 68 of a pin tool head assembly 64 of a robotic
sample transfer device 10 may include the use of a pin tool
displacement block 370 having a block body with a bottom surface
and a plurality of parallel slots formed into the block body
portion. The parallel slots may be substantially perpendicular to
the bottom surface with a predetermined regular spacing configured
to correspond to regular spacing of pin tools 68 of a pin tool head
assembly 64. The parallel slots may have a transverse dimension
sized to allow easy movement of a width of a nominal shaft of the
pin tools 68 in the slots but restrictive of movement of an
enlarged portion of the shaft of the pin tools. The pin tool
displacement block may also include at least one relieved portion
or channel in a slot which has a transverse dimension sized to
allow easy downward movement of the enlarged portion of a pin tool
shaft which is greater than the transverse dimension of the slot
and which extends from a top surface of the block body towards the
bottom surface. An array of pin tools of a pin tool head assembly
64 are axially displaced by depressing the distal ends of the pin
tools 68 against a flat surface. The pin tool displacement block
may then be deployed into the pin tool head assembly such that the
parallel slots of the pin tool displacement block slide over rows
of the array of pin tools of the pin tool head assembly. The pin
tools 68 are then allowed to return to a relaxed state by
retracting the pin tool head assembly from the flat surface with at
least one of the pin tools remaining displaced in an axially
retracted and relaxed state.
[0158] FIGS. 22-24 illustrate an embodiment of a reversible pin
tool displacement block 370. The reversible pin tool displacement
block 370 may have some or all of the features, dimensions or
materials as those of the pin tool displacement block embodiments
300, 336 and 360, discussed above. The reversible pin tool
displacement block 370 essentially combines the functions of the
pin tool displacement blocks 336 and 360 of FIGS. 20A-20D and FIGS.
21A-21D discussed above. When the block 370 is oriented in a first
direction and deployed, a first pin tool or set of pin tools is
active and when the block is flipped over 180 degrees or otherwise
oriented a second direction and deployed, a second pin tool or set
of pin tools is active which is different from the first set. The
reversible pin tool displacement block embodiment 370 shown allows
a single pin tool to be configured for used while deployed on a
first side 372 while maintaining all remaining pin tools of a
6.times.4 pin tool array in a retracted state. The reversible pin
tool displacement block 370 allows 6 pin tools to be configured for
used while deployed on a second side 374 while maintaining all
remaining pin tools of a 6.times.4 pin tool array in a retracted
state.
[0159] For the reversible pin tool displacement block embodiment
370, it may be desirable for relieved portion or portions 376 to
extend only partially through the block body portion 370 and
terminate at a stop surface 378 which is spaced from a surface of
the block opposite the opening of the relieved channel 376. The
first surface 372 and second surface 374 of the block body 370
portion may be substantially flat and substantially parallel to
each other for some embodiments. FIG. 22 illustrates the pin tool
displacement block 370 with the first side 372 up showing 6
relieved channels 380 that allow six pin tools 68 to be active or
usable when the pin tool block 370 is deployed on the second side
374 with the second side down. FIG. 24 illustrates the pin tool
displacement block 370 with second side 374 up showing a single
relieved channel 382 that allow a single pin tool to be active or
usable on the first side when the first side is down.
[0160] Some method embodiments of dispensing calibration material
onto a chip 274, such as a spectrometry chip, may include the use
of a chip 274 having an array of regularly spaced sample deposition
sites 292 disposed on a substantially flat working surface 293 of
the chip 274. The chip 274 may also include at least one sample
deposition site 292 for receiving calibration material which is
also disposed on the flat working surface 293 of the chip 274. The
method embodiments may include the use of a robotic sample transfer
device 10 having a pin tool head assembly 64 with an array of
regularly spaced pin tools 68. Distal ends 158 of the pin tools 68
of the pin tool head assembly 64 are disposed substantially
coplanar in a relaxed state and have a regular spacing which is the
same as or otherwise matched to the regular spacing of the first
array of sample deposition sites 292 of the chip. The spacing of
the pin tools 68 may also be an integer multiple of the spacing of
the sample deposition sites of the chip 274 and configured to align
with the array of regularly spaced sample deposition sites 292 of
the chip 274 or a subset thereof.
[0161] Generally, it is desirable to dispense calibration material
very selectively to only those sample deposition sites 292 that are
intended for use with calibration materials. As such, it is
desirable to avoid dispensing calibration material or otherwise
contaminating sample deposition sites 292 which are not intended
for use in calibration with calibration material. For some method
embodiments, it may be useful to use a reduced number of pin tools
68 of a pin tool head assembly 64 in order to avoid such
contamination or inadvertent material transfer. For some such
method embodiments, all but one of the pin tools 68 of the pin tool
head assembly 64 is displaced to a retracted non-usable state by
deploying a pin tool displacement block 336, such as pin tool
displacement block shown in FIGS. 20A-20D, into the pin tool head
assembly 64. The pin tool block 336 may be deployed in the pin tool
head assembly 64 as shown in FIGS. 18 and 19 and discussed in the
accompanying text above. A sample reservoir 156 of the usable pin
tool 68 of the robotic sample transfer device 10 may then be loaded
with calibration material by dipping the pin tool 68 into a well
containing calibration material. The calibration material may then
be dispensed from the usable pin tool 68 of the robotic sample
transfer device 10 to a sample deposition site 292 for receiving
calibration material. During the deposition of the calibration
material to the sample deposition site 292, the functioning pin
tool 68 containing the calibration material extends distally below
the pin tools 68 that are held in a retracted state by the pin tool
displacement block 336. As such, while the functioning pin tool tip
156 is moved distally into contact with the sample deposition site
292 for deposition of the calibration material, the pin tools 68
which are displaced by the pin tool displacement block 336 do not
contact the chip.
[0162] In addition to dispensing calibration materials by methods
that include controlling the number of active pin tools 68 of a pin
tool array 64, calibration material may also be deposited on
selected sample deposition sites 292 of a chip 274 or the like by
using a full array of pin tools 68. The full array of pin tools 68
may be used with a chip 274 having a first array of regularly
spaced sample deposition sites 292 disposed on a substantially flat
working surface 293 of the chip 274. The chip 274 may also have at
least one sample deposition site 292 for receiving calibration
material which is also disposed on the flat working surface 293 of
the chip 274 and which is off pitch with respect to the regular
spacing of the first array of regularly spaced sample deposition
sites 292 of the chip 274, as shown in FIGS. 11A and 11B.
[0163] A robotic sample transfer device 10 having a pin tool head
assembly 64 may also be used for the calibration method. The pin
tool head assembly 64 may have an array of regularly spaced pin
tools 68 with distal ends 158 which are substantially coplanar with
each other in a relaxed state. The pin tools 68 of the pin tool
array also have a regular spacing which is the same as or otherwise
corresponds to the regular spacing of the first array of sample
deposition sites 292 or an integer multiple thereof. The regular
spacing of the pin tools 68 is also configured to align with the
array of regularly spaced sample deposition sites 292 of the chip
274 or a subset thereof.
[0164] During a calibration process embodiment, sample reservoirs
156 of the array of regularly spaced pin tools 68 of the robotic
sample transfer device 10 may be loaded with calibration material.
Only the pin tool reservoir or reservoirs 156 that will be
depositing the calibration material onto the desired calibration
material sample deposition site will be loaded with calibration
material for some embodiments. The calibration material may then be
dispensed from the pin tools 68 of the robotic sample transfer
device 10 to the at least one sample deposition site 292 for
receiving calibration material. During deposition of the
calibration material, the pin tools 68 which are not aligned with
sample deposition sites 292 for receiving calibration material are
off pitch with respect to the first array of regularly spaced
sample deposition sites 292 of the chip. As such, the pin tools 68
do not contact any of the regularly spaced sample deposition sites
292 of the first array. FIG. 25 illustrates two pin tool distal
ends 158 disposed over sample deposition sites 292 of a second
array of sample deposition sites which are regularly spaced and off
pitch from the first array. The sample deposition sites 292 of the
second array are configured to receive calibration material which
is being dispensed from the sample reservoirs 156 of the distal
tips 158 of the pin tools 68 to the calibration sample deposition
sites 292 of the chip 274 as shown. Also shown are two pin tool
distal ends 158 disposed between and not aligned with the sample
deposition sites of the first array of sample deposition sites 292
for receiving normal sample deposition. For some embodiments, the
first array of regularly spaced sample deposition sites includes an
array of regularly spaced mass spectrometry sample deposition
sites.
[0165] FIG. 26 illustrates a main screen of an embodiment of the
user interface 26 discussed above. The main screen or main menu is
arrived at after a user logs onto the device 10 by entering a user
name and password into the system through the user interface 26.
From the main screen of the user interface 26, a user may navigate
the various programming controls of the device 10 in a convenient
and user friendly manner. For the embodiment shown, along the top
row of the screen, a "home" button 400 may be touched by the user
to manually send the pin tool head assembly 64 of the device 10 to
a home position located generally towards the front and left side
of the processing chamber 14. A "system status" button 402 takes
the user to a screen that provides detailed information regarding
the current status of the integrated robotic positioning device 10.
Status data such as the identification of the current user,
computer identification, hard drive capacity, volatile memory
capacity, software version, x, y, and z positions of the pin tool
head assembly 64, safety interlock status, temperature and humidity
within the processing chamber 14, wash fluid tank 242 and waste
fluid tank 224 fluid levels as well as other information may be
displayed on the status screen or screens. The "exit" button 404
takes the user back to the fundamental operating system interface
of the processor 32. For example, for processor embodiments 32
using a Windows.RTM. type operating system, the exit button 404
will return the user back to a Windows.RTM. desktop. A "help"
button 406 allows the user to access a help database with
information regarding the programming, use and operation of the
device 10 with regard to the type of options available on the
screen displaying the help button 406. Generally, for some
embodiments, each screen of the user interface 26 may have a help
button 406. At the bottom row of the main screen, a "log off"
button 408 is used to log off the current logged on user of the
system 10. A "shut down" button 410 shuts down the system 10.
[0166] A "maintenance" button 412 on the main screen takes a logged
on user to a maintenance screen illustrated in FIG. 27. The
maintenance screen includes the status button 402, exit button 404
and help button 406 discussed above. The maintenance screen also
includes a "load chips and MTPs" button 414, a "load solution"
button 416, a "fill supply tank" button 418, a "clean pins" button
420, a "complete cycle" button 422, a "drain solution" button 424,
an "drain supply tank" button, 426 and a "condition pins" button
428. The load chips and MTPs button 414 moves the pin tool head
assembly 64 of the system 10 to a far left and rear position in
order to make room for the user to load sample chips 274 or a chip
block 266 onto the work surface 22 of the device 10. The load
solution button 416 moves the pin tool head assembly 64 to the far
right and rear position of the processing chamber 14 in order to
make room for a user to load or unload the supply reservoir 168.
The fill supply tank button 418 prompts the user to position the
fluid valves in the lower storage tank chamber 44 in communication
with the supply tank such that the supply tank 242 may be filled
from an external tank. After the user is prompted to manually
configure the valves, de-ionized water may be pumped into the
supply tank with a self priming pump disposed within the housing
12. The pump may be configured to automatically turn off once the
tank 242 is filled. The user may then be prompted to switch the
valves manually back normal operating mode. The controller may then
execute a priming routine to clean out air from the tubing or lines
between the tank 242 and the rinse station. To accomplish this, the
water may be pumped to the rinse station at about 5 percent to
about 10 percent normal flow using a pulsed modulation technique.
For this pulsed technique, the pump may be run at full speed for a
short period of time and then stopped for an interval before
restarting again. For some embodiments, the pump may be run for
about 5 msec to about 15 msec and stopped for about 85 msec to
about 95 msec. The pulse intervals are short enough that the pump
appears to run continuously to the user, but is only achieving a 5
percent to 10 percent duty cycle.
[0167] The clean pins button 420 runs a protocol for cleaning the
pins 68 of the pin tool head assembly 64 by immersing the pins in
the ultrasonic bath for an extended period of time. For some
embodiments, the pin tools 64 may be soaked for about 15 minutes to
about 45 minutes, more specifically, for about 25 minutes to about
35 minutes. During the soaking process, the ultrasonic bath may
contain a cleaning solution such as pure ethanol. The pin tools may
be treated with a subsequent standard cleaning cycle after the soak
that may include a water rinse in the rinse station, drying in the
vacuum drying station, ultrasonic cleaning with water in the
ultrasonic bath and a final drying in the vacuum drying
station.
[0168] A complete cycle button 422 initiates a standard cleaning
cycle, as discussed above, including a water rinse in the rinse
station, drying in the vacuum drying station, ultrasonic cleaning
with water and alcohol in the ultrasonic bath and a final drying in
the vacuum drying station. For some embodiments, an equal mix of
de-ionized water and ethanol alcohol may be used for the ultrasonic
cleaning bath. The drain solution button 424 turns on the pump 222
and drains the ultrasonic bath of the ultrasonic wash station. As
the ultrasonic bath is drained, it may be refilled by the reservoir
168 until the reservoir is emptied.
[0169] The drain supply tank button 426 turns on the rinse fluid
pump continuously until the rinse fluid supply tank 242 is emptied.
This may be used to lighten the device 10 in anticipation of
transporting the device 10, performing maintenance in the lower
chamber or the like. The condition pins button 428 initiates a
protocol whereby the pins 68 of the pin tool head assembly 64 are
soaked in a cleaning solution, such as a 1 molar solution of NaOH
which may be disposed within selected wells of a microtiter plate.
The pins 68 may be soaked for about 5 minutes to about 15 minutes
and then treated with a standard clean cycle as discussed above.
This process may be carried out every week or so in order to
condition the pins 68.
[0170] Referring back to FIG. 26, a "mapping" button 430 takes the
user to a mapping screen shown in FIG. 28. The mapping screen
allows the user to input some preliminary information about the
sample transfer process desired. For example, for some embodiments,
the user may be prompted with a request to select a microtiter
plate format, such as a 96 or 384 well plate. Next, the user may be
prompted to select a chip format and thereafter the number of the
chips to be used. Once this information has been entered, mapping
information presented visually by a grid 432 representing the
microtiter plate wells and grid 434, representing the chip sample
deposition sites, may be selected and stored by a "save" button 436
to track the mapping to be used. Chip buttons 438 may be used to
select the chip number to be loaded with samples taken and the
"MTP" arrow buttons 439 may be used to select the microtiter plate
from which to load samples. The "exit" button 440 may be used to
exit the mapping screen. In addition, a two dimensional bar code of
a selected chip 274 may be tied to a bar code of a specific
microtiter plate by the controller. The controller may also store
the mapping configuration selected between the chip and microtiter
plate along with some additional data including time stamp data,
microtiter plate and chip configuration data and the like. All of
this data may be transferred to a sample tracking database server
or other data storage device.
[0171] Referring again to FIG. 26, a "methods" button 442 takes the
user to a methods screen shown in FIG. 29. The methods screen
includes the exit button 404, status button 402 and help button 406
on the top row which may have the same functions as discussed
above. Also on the top row of the methods screen are an "open"
button 442 and a "save" button 444. The open button 442 allows a
user to open a predetermined set of method transfer parameters and
the save button 444 allows a user to save a predetermined set of
method transfer parameters. A "run transfer" button 443 takes the
user to the "run transfer" screen shown in FIG. 30 and discussed
below. At the bottom of the methods screen are three tabs, with the
"setup" tab 445 being selected for the methods screen embodiment
shown. Within a "mapping file" section 446 of the methods screen
for setup, a user may select a predetermined mapping file as
generated from the mapping screen of FIG. 28 for use in a transfer
method. A "browse" button 448 may be used to browse a plurality of
predetermined mapping files created by a user. An "analysis"
section 450 of the methods screen includes a "volume check" check
box 452 and a "sample tracking" check box 454. If the user selects
the volume check box 452, each sample deposited onto a sample
deposition site of a chip 274 may be imaged by the imaging camera
and the image taken processed in order to estimate the volume of
each sample deposited onto a sample deposition site. The volume
check parameters of a deposited sample may be determined by the
volume, average diameter, y-axis direction diameter, x-axis
direction diameter, circumference and area of one or more deposited
samples. The average volume for samples deposited and standard
deviation of volume of samples deposited may also be determined. If
the sample tracking box is checked by a user, bar code data
associated with microtiter plates 268 and corresponding chips 274
will be saved to a file that may be later accessed by a user in
order to confirm a transfer method.
[0172] A "scout plate" section 456 allows a user to select a
particular chip type from the number of chips such as a 4 chip
scout plate or a 10 chip scout plate. A "spectrochips" section 458
includes "chip selection" buttons 460 numbered 1-10 for a 10 chip
mount block (or 1-4 if a 4 chip mount block was selected in section
456) which allows a user to select a particular chip from the
number of chips of the chip mount block type previously selected to
receive transferred samples for a particular method.
[0173] Referring again to the bottom of the methods screen, if the
"cleaning" tab 462 is selected for the screen, additional sections
(not shown) are available to the user which allow a user to set
cleaning cycle parameters such as dwell time in a particular
cleaning station functional element and the like. The
"aspirate/dispense" tab 464 provides options on a screen (not
shown) for the amount of time that the sample reservoir of the pin
tools 68 dwell in a sample reservoir while aspirating a sample, the
depth to which a pin tool 68 is moved into a sample well of a
microtiter plate and the speed of the pin tool 68 as it enters and
leaves a sample well of a microtiter plate. The user may also set
the dwell time of a pin tool 68 as it contacts a sample deposition
site of a chip, the speed of the pin tool as it approaches a
surface of the chip and the length of compression of the resilient
member which biases the pin tool 68 against the upper surface of
the chip once the tip of the pin tool 68 makes contact. These
parameters may affect the amount of sample aspirated or taken up by
a pin tool 68 and the amount of sample deposited to a sample
deposition site. These parameters may also affect the speed and
efficiency of the transfer method and prevent damage to the chips
274 or microtiter plates as well as prevent loss of samples or
contamination due to splashing as a result of excessive speed of
the pin tool 68 during a transfer.
[0174] Referring again to FIG. 26, a "transfer" button 466 takes
the user to a run transfer screen shown in FIG. 30. A top row on
the run transfer screen again includes the exit button 404, status
button 402, and help button 406 that may have he same functions as
discussed above. An "open method" button 470 at the top of the
screen allows a user to open a previously determined set of method
parameters. A "flow" button 472 allows a user to access the method
screen while running a transfer and change method parameters during
the transfer process. A "volume check" button 474 allows a user to
access and review volume check data for data collected when the
volume check box 452 on the method screen is selected.
[0175] A live video image of the transfer process may be displayed
in video block 476 as well as a graphic of the transfer status of
sample deposition on chips 274 of a selected chip mount block shown
on a chip status block 478. Microtiter plate status blocks 480 and
482 show the transfer status of two selected microtiter plates 268
in current use including a graphic display of sample wells that
have already been transferred and which wells are full and have not
yet been transferred to a sample deposition site of a chip 274.
"Stop", "pause", "step" and "run" buttons are disposed at the
bottom of the run transfer screen which allow a user to stop, pause
or run a selected transfer process. The step button may pause after
every dispense cycle to allow the user to update method parameters
or view volume check data. The use may then press the step button
again to continue the cycle in the transfer or press the run button
to finish the transfer process without automatically pausing after
each dispense cycle.
[0176] Referring back to FIG. 26, a "configure" button 486 takes
the user to a configure screen shown in FIG. 31. A top row on the
configure screen again includes the exit button 404, status button
402, and help button 406 that may have he same functions as
discussed above. Also on the top row of the configure screen are an
"open" button 442 and a "save" button 444. The open button 442
allows a user to open a predetermined set of method transfer
parameters and the save button 444 allows a user to save a
predetermined set of method transfer parameters.
[0177] At the bottom of the configure screen, a row of tabs allows
the user to select sub-screens that provide options for selecting
movement parameters for various predetermined process steps that
the device 10 may carry out. The tabs at the bottom of the
configure screen include a "calibrant" tab 490, a "dry rinse" tab
492, a "dry wash" tab 494, a "MTP" or microtiter plate tab 496, a
"rinse" tab 498, a "spectochip" tab 500 and a "wash" tab 502. A tab
with a set of laterally oriented arrows may be selected to show
additional tabs (not shown) including a "general" tab, a "bar code"
tab and a "calibration" tab. For each of these tabs, generally,
motion parameters for the pin tool head assembly for the process
corresponding to each tab may be selected or preset. for example,
for the configure screen show in which the calibrant tab 490 is
selected, the z axis motion acceleration, z axis motion velocity, z
down position and calibrant dip time may be preset and saved. These
settings may be determined by moving a sliding setting bar 503A
disposed in a setting box or by directly entering numerical data in
a data box 503B disposed below the sliding setting bar. Once these
settings are selected and saved, they may be tested for each
process indicated by the tabs by actuating the "test" button 504.
Some additional features include functions of the barcode tab which
allow a user to turn the bar code reader function on and off. The
bar code reader function may be carried out by the bar code reader
head for scanning linear bar codes on microtiter plates 268 as well
as the imaging camera which may be used to scan two dimensional bar
codes disposed on the chips 274.
[0178] The general tab screen has a variety of settings and also
includes a button which allows a user to reset all of the settings
of the configure screens to the factory default settings. The
calibration tab screen provides the user with predetermined
settings that may not be changed often. For example, the
calibration tab screen may provide a data box to enter the position
offset of a pre-selected pin tool 68 of the pin tool head assembly
64, such as pin tool "A-1", with respect to the position of the
center of the field of view of the imaging camera. Once this is
properly set, any feature, functional element or the like which is
imaged by the imaging camera in the center of the field of view may
then be accessed by a pin tool by instructing the processor to move
the pin tool 68 in the distance and direction of the known offset,
which may serve as a single entry look up table for such
motion.
[0179] Referring to FIG. 26, a "motion" button 510 takes the user
to a motion screen shown in FIG. 32. A top row on the motion screen
again includes the exit button 404, status button 402, and help
button 406 that may have he same functions as discussed above. Also
on the top row of the configure screen is a "save" button 444 that
may be used to store settings. A home button 400 is also disposed
on the motion screen to have the pin tool head assembly moved to
the home position.
[0180] The motion screen of FIG. 32 allows a user to select general
motion parameters for motion acceleration, velocity and large move
distance for translation of the pin tool head assembly in the x, y
and z axes, with the buttons for selecting the axis of interest
indicated by buttons 512, 514 and 516 respectively. Data selections
for these parameters may be entered by clicking and moving a
sliding bar 518 or by direct data entry into a data box 520
disposed below the sliding bar 518. Arrows 522 disposed on either
side of the data boxes allow a user to click the arrows and adjust
the parameters in the data boxes by fixed increments. A set of
arrows 524 are disposed on the right hand side of the screen and
allow a user to manually move or jog the pin tool head assembly by
predetermined increments. A toggle button 526 allows users to
select between large movement increments and small movement
increments, each of the increments being selected or set by the
sliding bar 528 or by direct data entry into data box 530. One of
the uses of the functions on the motion screen is to teach the
processor of the device 10 where the locations of the various
components or functional elements reside on the work surface. For
example, a user may wish to teach the processor the location of a
first microtiter plate disposed on the microtiter plate mount block
of the work surface. The user may use the jog buttons 524 in either
large movement or small movement mode to position the pin tool head
array 64 above the predetermined corner of the first microtiter
plate. Fine adjustments may be made with visual feedback by the
user to align the pin tools 68 with the predetermined wells of the
microtiter plate.
[0181] Once this positioning has been achieved, the user may select
a "check" button 532 disposed at the top of the motion screen which
then takes the user to the "deck plate" screen shown in FIG. 33. A
top row on the deck plate screen includes the exit button 404,
status button 402, and help button 406 that may have he same
functions as discussed above. Also on the top row of the deck plate
screen are an "open" button 442 and a "save" button 444. The open
button 442 allows a user to open a predetermined set of method
transfer parameters and the save button 444 allows a user to save a
predetermined set of method transfer parameters.
[0182] The deck plate screen also includes a variety of buttons
that may be used to allow a user to store position data generated
from the position sensors such as the encoder strip assemblies and
store that known position data so as to associate the position data
to a known component of functional element of the work surface.
There are two basic approaches to use of the deck plate screen. The
first is a manual teach mode which may be entered from the check
save button 532 of the motion screen wherein know position data is
stored so as to correspond to know functional elements or
components of the device 10. A manual mode in the deck plate screen
allows a user to direct the pin tool head to a known,
pre-programmed position and also allows the used to carry out basic
single event procedures, such as washing, drying, rinsing etc.
[0183] If the position information for each of the functional
elements of the work surface 22 is taught to the processor, a
database or lookup type table may be generated for use as to
absolute and relative positions of the functional elements as well
as other components. For example, from the motion screen of FIG.
32, the pin tool head array may be moved by a user using the jog
buttons 524 to the A-1 position of the first microtiter plate
disposed on the work surface of the device. Once the pin tools are
properly positioned, a "microtiter plate type" button 536 may be
touched and toggled so as to select a microtiter plate type that
matches the type mounted to the work surface. For some embodiments,
the toggle choices may include a 96 well or 384 well microtiter
plate. A "first microtiter plate" button 538 may then be touched to
indicate that the pin tools 68 are disposed in the first microtiter
plate and not the second microtiter plate which may be selected by
"second microtiter plate" button 540. A graphic image of the first
microtiter plate is displayed on block 542 and the second
microtiter plate on block 544. If the position data and component
selection has been properly made, the user may then select the
"check save" button 546 at the top of the screen which saves the
data to the memory storage unit of the controller 28 or other
suitable device. This same procedure may be applied to the teaching
of position data of the pin tool head assembly and pin tools 68
thereof by using the "pin tool" button 548, the bar code reader
head assembly by using the "bar code reader" button 550, and the
camera by using the "camera" button 552. These position data
teaching procedures generally apply to the pin tool head assembly
64 and microtiter plates, however, the same or similar procedures
for teaching position data to the controller 28 may also be used
for the pin tool head assembly 64 with respect to the chips
274.
[0184] For such a procedure, the pin tool head may be manually
moved to a predetermined location with respect to a chip 274
mounted in a chip mount block on the work surface. Such positioning
may be carried out by using manual jogging movement from the
position screen discussed above. Once the pin tools 68 are properly
positioned with respect to a component for functional element, the
component or functional element may be identified by touching the
corresponding button, such as the "pin tool" button 553.
Thereafter, the type of chip 274 being used may be selected by the
"chip type" button 554 to select between a 384 site chip, a 96 site
chip or any other suitable configuration. The specific chip 274
over which the pin tools 68 are located may then be selected by
touching one of the "chip number" buttons 556 that correspond to
the chip being used. If the position data and component selection
has been properly made, the user may then select the "check save"
button 546 at the top of the screen which saves the data to the
memory storage unit of the controller 28 or other suitable device.
This same procedure may be applied to the teaching of position data
of the pin tool head assembly and pin tools 68 thereof, as well as
the position of other components, by using other buttons on the
screen. For example, position data for the 2-d bar code on a chip
may be taught by using the "bar code reader" button 558, and the
camera by using the "camera" button 560. The position data related
to the calibration material vessel 256 may be taught by using the
"calibration vessel" button 562.
[0185] Once one or more position data sets have been taught to the
controller 28, there are other features on the deck plate screen
that allow a user to carry out basic functions on an as needed
basis. For example, a user may initiate a wash cycle by touching
"wash cycle" button 564, a rinse cycle by touching "rinse cycle"
button 566 or a dry cycle by touching "dry cycle" button 568. A
"calibration vessel home" button 570 may be used to move the pin
tool head assembly 64 to the calibration vessel 256. A "pin tool
selection" button 572 may be used to select or toggle between
various pin tool array configurations, such as a single pin tool, 6
pin tool array or 24 pin tool array as well as others. A
"configuration screen" button 574 may be touched by a user to jump
to the configuration screen, a "motion screen" button 576 may be
used to jump to the motion screen and a "vision screen" button 575
may be used to jump to the vision screen shown in FIG. 34.
[0186] The vision screen includes controls that allow a user to
turn the imaging camera 132 on and off and move the camera to a
desired position manually with a set of jog arrows 580 which may be
toggled between large movement steps and small movement steps with
a "toggle" button 582. The live video image block 584 allows the
user to see the work surface 22 and functional elements and
components thereof through the imaging camera lens while the camera
is being positioned with the jog arrow buttons 580. The vision
screen may also be used in conjunction with the deck plate screen
for manual teaching of positions and relative positions of the pin
tool head, bar code reader and imaging camera with respect to the
work surface 22 and functional elements thereof. Work surface
components may be viewed on the video image block 584 and aligned
with a cross hair centering reticle 586 positioned in the center of
the field of view of the imaging camera so that the position of the
viewed and aligned component may be know with regard to the
position of the imaging camera 132. If the position of the center
of field of view of the imaging camera is know with respect to
other components of the device 10, this positioning data may be
stored or otherwise used to calculate the position of other
components. If the imaging camera is aligned with a component at a
position that is useful to be taught to the controller 28, the
"check" button 532 may be selected to take the user to the deck
plate screen discussed above for manual teaching of position as
discussed above.
[0187] A top row on the vision screen includes the exit button 404,
status button 402, and help button 406 that may have he same
functions as discussed above. Also on the top row of the vision
screen are an "open" button 442 and a "save" button 444. The open
button 442 allows a user to open a predetermined set of method
transfer parameters and the save button 444 allows a user to save a
predetermined set of method transfer parameters. A "configuration"
button 588 allows a user to set a variety of imaging parameters
such as exposure, gain and further adjustment of jog movement
parameters such as the length of the large and small movement jog
steps. The safety interlock indicator 590 indicates whether the
safety interlock switch is engaged or disengaged. An "illuminator"
button 592 toggles an illumination light source for the imaging
camera 132 on and off. A "zoom" button 594 zooms the field of view
in the live image block 584 in and out and a "video on" button 596
toggles the imaging camera 132 on and off.
[0188] A set of "chip type" buttons 598 allows a user to select the
type of chip 274 being imaged or otherwise used on the work surface
22. A selection may be made between a 96 site chip and a 384 site
chip. A set of selection arrows 600 allow a user to choose from a
menu of predetermined image processing algorithms 601 which may be
used to confirm the position of the imaging camera relative to a
feature or component of interest. Examples of the algorithms
include a 2-d bar code algorithm, an align a 96 site chip
algorithm, an align a 384 site chip algorithm, an align a 96 well
microtiter plate algorithm, an align a 384 well microtiter plate
algorithm, a calibrate pins algorithm, a calibrate pixels
algorithm, and a volume check algorithm. The calibrate pins
algorithm determines the center of the field of view of the imaging
camera with respect to the position of a particular pin tool, such
as the A1 positioned pin tool. The calibration of pixels algorithm
uses the known distance between two fiducial marks on a chip 274 to
calculate the number of pixels of the imaging camera per millimeter
on the plane of the work surface. The "measure" button 602 may be
used or selected in order to initiate a selected algorithm process
once the camera has been positioned in a desired location. The
"run" button 604 may be selected to move the pin tool head
assembly, bar code reader or camera to a position on the work
surface 22 corresponding to the algorithm selected to be run.
[0189] In addition to embodiments described above, other similar
embodiments, such as those discussed below, may also be used in the
same or similar manner as discussed above. For some embodiments, a
pin protection block tool assembly for selectively displacing at
least one pin tool 68 of a pin tool head assembly 64 of a robotic
sample transfer device 10 may be used. Using the pin protection
block tool allows the user to select any number of active pin tools
by selective deactivation of the pin tools not being used in the
standard 24 pin tool head 64. For instance, if the user wants only
a single pin tool active, the user may use the pin protection block
tool assembly in conjunction with a pin tool displacement block
having a single pin configuration to selectively deactivate all but
one of the pin tools 68 (e.g., deactivate 23 of 24). The pin
protection block tool assembly, as shown in FIGS. 37A-37C, is used
for upwards axial displacement of the pin tools 68 and pin tool
collars 143 within the pin tool head assembly 64 prior to insertion
of a pin tool displacement block. The pin protection block tool
assembly has body 610 which is substantially rectangular in shape
and has raised edges 614 which act as a hard stop to the downward
movement of the lower surface, which in turn may prevent the user
from over compressing the pins and damaging the pin array and
holder, while allowing adequate room for inserting a pin tool
displacement block (also referred to as a pin too displacement
comb) of pin tool head assembly 64 of robotic sample transfer
device 10. The pin protection block tool assembly has a top surface
and a bottom surface which is substantially parallel to the top
surface, and a plurality of non penetrating cylindrical bores
machined into the block body, arranged with a predetermined regular
spacing configured to correspond to regular spacing of pin tools 68
of a pin tool head assembly 64. At least two pins extending from or
through the bottom surface of the pin protection block tool
assembly are configured to register the pin protection block tool
assembly in fixed lateral alignment with the holes of the vacuum
drying station 176. The pins serve to secure the pin protection
block tool assembly to the vacuum drying station 176, for use in
selectively displacing one or more pins in the pin too head
assembly 64. Pin protection block tool assembly body 610 also has
spacing element 612 which fits into the channel machined into
vacuum drying station 176 (see FIG. 7) that allows proper
orientation and fitting of the pin protection block tool assembly
for selectively displacing one or more pins in the pin too head
assembly 64. Spacing element 612 acts as a keying feature such that
the pin protection block assembly may only be inserted in one
orientation, thus preventing the user from incorrectly mounting the
pin protection block assembly and potentially damaging the pin
tools 68 or the pin tool head 64. The pin protection block tool
assembly embodiment may be machined from a monolithic block of a
strong stable material, such as polymers, such as Delrin.RTM.,
composites and metals, such as stainless steel, aluminum, which may
be anodized, and the like.
[0190] The regularly spaced cylindrical bores in the upper surface
of the pin protection block tool assembly may be of sufficient
diameter to allow a lower part of the tapered portion 158 and
slotted tip 162 of pin tool shaft 142 to enter the opening, yet
narrow enough for the upper tapered portion of pin tool shaft 142
to come to rest against the edge and inner wall surface of the
cylindrical bores in the pin protection block tool assembly (see
FIG. 42). The pin tools resting on an upper part of the tapered
portion 158 of slotted pin too tip 162 may prevent damage to the
lower slotted portion of the pin tool 68, by focusing downward
pressure on the sturdier upper part of the tapered portion 158 of
pin tool 68. The diameter of pin protection block tool assembly
holes maybe in the range of about 0.01 to about 0.1 inches, and
more specifically in the range of about 0.05 to about 0.06 inches
in diameter. The depth of the holes in the pin protection block
tool assembly maybe greater than the length of the tapered portion
of the pin tool shaft, such that when the pin tool head assembly 64
comes to rest on the raised edges 614 of the pin protection block
tool assembly body 610, the pin tools 68 may be suspended above the
bottom of the machined holes and the pin tools may be held in place
by contact an upper part of the tapered portion 158 of pin tool
shaft 142 and the edges of the cylindrical bores in the pin
protection block tool assembly body. The depth of the
non-penetrating cylindrical bores of the pin protection block tool
assembly may be in the range of about 0.1 to about 1 inch and more
specifically in the range of about 0.3 to about 0.4 inches in
depth.
[0191] In some embodiments, the pin protection block tool assembly
is used in conjunction with a plunger mechanism assembly, as shown
in FIGS. 38A-38B and 39A-39B. The plunger mechanism assembly may be
useful for downward displacement of the z-axis carrier and pin tool
assembly which translates to upwards axial displacement of the pin
tools 68, relative to pin tool head 64, to allow insertion of
various comb insert blocks, which allow the selective displacement
of one or more pin tools 68 in a pin tool head assembly 64. The
plunger mechanism assembly includes a collar 620 and plunger handle
630.
[0192] Referring now to FIGS. 38A-38B, plunger mechanism collar 620
is substantially cylindrical with a central concentric stepped
cylindrical bore in the material of the collar. The plunger
mechanism assembly embodiment may be machined from a monolithic
block of a strong stable material, such as polymers, such as
Delrin.RTM., composites and metals, such as stainless steel,
aluminum, which may be anodized, and the like. The outer diameter
622 of the plunger mechanism collar may be in the range of about
0.5 to about 3 inches and more specifically in the range of about
1.5 to about 2 inches in diameter. The central concentric stepped
cylindrical bore has two different diameters (624, 626), which when
viewed from a top down position assumes the configuration shown in
FIG. 38A. The larger of the two inner diameters 624 may be machined
to a depth from the top of the collar in the range of about 1.20 to
about 1.45 inches, and more specifically about 1.35 to about 1.39
inches. The diameter of this larger of the inner bores may be in
the range of about 0.1 to about 1 inch and more specifically in the
range of about 0.4 to about 0.6 inches. The smaller of the two
diameters 626 may be formed from the bottom of the larger diameter
to the bottom of the collar forming an opening with a diameter in
the range of about 0.1 to about 0.4 inches and more specifically in
the range of about 0.23 to about 0.27 inches in diameter. Plunger
mechanism assembly collar 620 allows functional coupling to both
the plunger 630 of the plunger mechanism assembly and the threaded
rod 118 of the z-axis translatable carrier 56, which carries pin
tool assembly 64. In some embodiments plunger mechanism collar 620
functions as an additional positional stop to prevent over
compressing the axial springs 152 or the pin tool tips 156 of the
pin tools. In some embodiments plunger mechanism collar 620
functions as a guide to prevent lateral displacement of the
threaded shaft 118, thus minimizing the potential for damage to the
z-axis translatable carrier mechanism by bending or flexing
threaded shaft 118, during axial displacement. In some embodiments
plunger mechanism 620 provides both functions.
[0193] Referring now to FIG. 39A-39B, plunger 630 of the plunger
mechanism assembly may be configured to allow fitment into plunger
mechanism assembly collar 620. Plunger 630 may be in the range of
about 1 to about 4 inches in height, and more specifically in the
range of about 1.55 to about 1.85 inches in height. Plunger 630 may
be formed with a main shaft 634 with a diameter in the range of
about 0.3 to about 0.7 inches, and more specifically in the range
of about 0.4 to about 0.6 inches in diameter. This main shaft
enlarges to a cylindrical plunger handle 632 with a diameter in the
range of about 0.5 to about 3.0 inches and more specifically in the
range of about 1.5 to about 2 inches in diameter. The base of the
plunger handle shaft 634 contains a cylindrical bore 636 with a
diameter in the range of about 0.1 to about 0.4 and more
specifically in the range of about 0.23 to about 0.27 inches in
diameter. The depth of cylindrical bore 636 may be in the range of
about 0.01 to about 0.2 inches and more specifically in the range
of about 0.08 to about 0.12 inches in depth. The plunger mechanism
assembly handle 630 may be so configured to allow functional
coupling to both the plunger mechanism assembly collar 620 and the
threaded rod 118 of the z-axis translatable carrier 56, which
carries pin tool assembly 64.
[0194] FIG. 38B is a cross sectional view of the central concentric
stepped cylindrical bore of the plunger mechanism collar 620 which
shows where the plunger handle 630 and the threaded rod 118 of
z-axis translatable carrier 56 are brought into functional coupling
in the interior of collar 620 of the plunger mechanism assembly. In
some embodiments the plunger mechanism assembly may be assembled
and functionally coupled to the threaded shaft 118 of z-axis
translatable carrier 56 to enable upwards axial displacement of the
pin tool tools 68, relative to the pin tool head 64, to allow
insertion of various comb insert blocks, enabling the selective
displacement of one or more pin tools 68 in a pin tool head
assembly 64. As described previously, the pin tool head assembly 64
may be placed on a hard surface with the tips of the pin tools
resting directly on the hard surface (see FIG. 18 and FIG. 19). For
some embodiments the comb insert block assembly may be used to
suspend the tips of the pin tools 68 over the machined cylindrical
bores of the comb insert block assembly with the main shaft of the
pin tools 68 supporting the pin tools as the threaded collar 118 in
functional contact with pin tool head assembly 64 may be depressed
using the plunger mechanism assembly functionally coupled to the
threaded shaft 118 or z-axis translatable carrier 56, causing the
upwards axial displacement of the pin tool collar member 143,
relative to the pin tool head 64. Use of the comb insert block
assembly reduces the possibility of damage to the pin tools 68 by
eliminating placing the tapered portion 158 and slotted tip 162 of
pin tool shaft 142 in direct contact with a hard surface.
[0195] As described previously, it may be desirable to selectively
alter the number of pins being used in the pinhead tool 64, without
physically changing out the pinhead tool. For some embodiments, a
method for selectively displacing at least one pin tool 68 of a pin
tool head assembly 64 of a robotic sample transfer device 10 may
optionally include providing a pin protection block tool assembly
and a plunger mechanism assembly in addition to the pin tool insert
block. Such a method embodiment may be initiated using the user
interface 26 and navigating the various programming controls of
device 10. The commands for altering pin tool configuration are
located in the "Maintenance Screen" accessed from the main menu.
Once in the "Maintenance Screen", the "Change Insert" button may be
selected to initiate the method for selectively displacing at least
once pin tool 68 in the pin tool head assembly 64.
[0196] Upon program initiation, the pin tool head may be moved away
from the vacuum drying station 176 of the cleaning and drying
portion of device 10, facilitating removal of any vacuum plates or
calibration wells, and allowing positioning of the pin protection
block tool assembly. The pin protection block tool body 610 of the
pin protection block tool assembly may be positioned using the
aligning element 612 and pins 616. Pins 616 are reversibly
operationally coupled with holes in the vacuum drying station 176.
Once the pin protection block tool assembly is in place, "Continue"
may be selected using the user interface 26 and device 10 moves pin
tool head 64 over the pin protection block tool assembly. Pin tool
head 64 is automatically lowered approximately 5 mm, placing the
narrowest part of the tapered portion 158 of pin tools 68 within
the cylindrical bores of the pin protection block tool assembly.
The user may then functionally couple the plunger mechanism to the
threaded shaft 118, and apply downward pressure to compress the pin
tool head 64 the remaining distance to bring the bottom plate 139
of pin tool head 64 in contact with pin protection block assembly
raised edges 614, as illustrated in FIG. 42. FIG. 42 illustrates
the functional coupling of the comb insertion block assembly, pin
tool head 64, threaded shaft 118, Z-axis step motor 126, y-axis
translatable carrier 62, z-axis translatable carrier, plunger
mechanism collar 620, and plunger 630, all used in concert to allow
selective displacement of pin tools 68 in a pin tool head 64.
Downward pressure, as shown by the downward arrow in FIG. 42, may
be applied to plunger 630 through plunger handle 632 which pushes
pin tools 68 against the pin protection block tool assembly which
in turn serves to push the pin tool collars 143 up, relative to pin
tool head 64, allowing the insertion of a pin tool insert comb.
After the pin tool comb insert (336 or 360) is inserted, the
plunger mechanism assembly may be removed, which allows the pin
tool head to come back to a relaxed state. "Continue" may be
selected on the user interface 26, and device 10 completes the pin
tool selection program. In some embodiments, device 10 may provide
the user with visual prompts. In some other embodiments device 10
may provide the user with auditory prompts. In yet other
embodiments, device 10 may provide the user with video clips
showing the procedure being performed. In some embodiments device
10 may provide a combination of visual prompts, auditory prompts,
and video clips to aid the user in completing the pin tool
displacement block insert procedure.
[0197] As previously described and illustrated in FIGS. 20A-20D and
FIGS. 21A-21D, pin tool displacement blocks may be used that enable
the selective displacement of one or more pin tools 68 in a pin
tool head assembly 64. FIGS. 35A-35D and FIGS. 36A-36D illustrate
embodiments of pin tool displacement blocks. Pin tool comb 336' and
360' of FIGS. 35A-35D and 36A-36D may have features, dimensions, or
materials that are the same or similar to those of 336 and 360 in
FIGS. 20A-20D and 21A-21D. Additionally the methods useable for
insertion of the previously described and illustrated pin tool
displacement blocks maybe the same as the methods used to insert
the additional embodiments of the pin tool displacement blocks.
[0198] Referring now to FIG. 35A-35D, in some embodiments a pin
tool comb insert allowing the displacement of all but one pin tool
68 is provided. This embodiment of a pin tool displacement block
(pin tool comb insert) has raised edges 339 which act as an
orientation keying feature which prevents the pin tool displacement
block from being inserted incorrectly. That is, raised edges 339
may confer a unidirectional orientation to the pin tool
displacement block. Pin tool comb insert 336' may also be
configured to have a chamfered forward upper edge to allow the user
easier insertion into the pin tool head 64.
[0199] Referring now to FIG. 36A-36D, in some embodiments a pin
tool comb insert allowing the displacement of all but six pin tools
68 is provided. This embodiment of a pin tool displacement block
(pin tool comb insert) has raised edges 363 which act as an
orientation keying feature which prevents the pin tool displacement
block from being inserted incorrectly. That is, raised edges 363
may confer a unidirectional orientation to the pin tool
displacement block. Pin tool comb insert 360' may also be
configured to have a chamfered forward upper edge to allow the user
easier insertion into the pin tool head 64.
[0200] While pin tool displacement blocks have been described
herein for applications that selectively displace all but one or
all but 6 pin tools, pin tool numbers other than 1, 6 or 24 maybe
used. The number and pattern of pin tools selectively displaced and
thereby inactivated may be 1, 2, 3, 4, 5, 6, 7 . . . up to 23, when
using a 24 pin tool head. This may be achieved by an alternative
configuration of pin tool displacement blocks, and the disclosure
herein is not meant to limit the embodiments contemplated to 1, 6,
or 24 active pin tools 68.
[0201] In some embodiments where the number of pin tools being
actively used has been selectively altered, a dry station plate
assembly may be provided that may be configured to correspond to
the pattern of the pin tools selected to be active. The dry station
plate assembly allows for selective use of the vacuum drying
station 176 vertical holes 178 as drying orifices. This allows the
user to direct the vacuum to only those pin tools 68 actively being
used in any particular application. The dry station plate assembly
may be machined from a monolithic block of a strong stable
material, such as polymers, such as Delrin.RTM., composites and
metals, such as stainless steel, aluminum, which may be anodized,
and the like. The dry station plate assembly may also be cut or
machined from Lucite.RTM., polycarbonates, acrylic and the like.
Dry station plate assemblies for any number of openings
corresponding to a desired number of selectively activated pin
tools 68 are contemplated herein as well as the embodiments
described below. In general the dry station plate assembly (640,
650) may be substantially rectangular in shape, the size and shape
corresponding with the size and shape of pin tool head 64. The
height of the dry station plate assembly body (642, 652) may be in
the range of about 0.01 to about 1 inch, more specifically in the
range of about 0.1 to about 1 inch and most specifically be in the
range of about 0.2 to about 0.5 inches in height. The dry station
plate assemblies may have at least 3 holes machined through the
body to allow insertion of seating pin dowels, the holes being of
sufficient diameter to allow the use of pin dowels (644, 654) that
fit within the nominal diameter of the vacuum dry station 176
vertical holes 178, and allow functional coupling of the dry
station plate assembly to the vacuum drying station. The use of dry
station plate assemblies may reduce the waste of vacuum in the
vacuum holding tank by channeling vacuum to only the openings 178
that correspond to active pin tools 68, and blocking off all other
openings through which vacuum might be wasted. Additionally, if the
unused holes are not blocked using the dry station plate
assemblies, all vacuum flow will be through the unblocked holes and
minimal flow will be through the holes containing pin tools. This
may cause the pins to not be sufficiently dried, which in turn may
lead to cross contamination of samples.
[0202] Referring now to FIGS. 40A-40C, in some embodiments a vacuum
drying station plate assembly 640 which blocks all but one vertical
hole 178 in the vacuum drying station 176 is provided. Vacuum
drying station plate assembly 640 includes plate body 642, pin
dowels 644 and pin tool opening 646. The embodiment of dry station
plate assembly 640 may be used in conjunction with the pin tool
insert comb that selectively displaces or deactivates all but one
pin tool 68.
[0203] Referring now to FIGS. 41A-41C, in some embodiments a vacuum
drying station plate assembly 650 which blocks all but six vertical
holes 178 in the vacuum drying station 176 is provided. Vacuum
drying station plate assembly 650 includes plate body 652, pin
dowels 654 and pin tool openings 656. The embodiment of dry station
plate assembly 650 may be used in conjunction with the pin tool
insert comb that selectively displaces or deactivates all but six
pin tools 68.
[0204] In general, a wide variety of techniques can be implemented
consistent with the principles the invention and no attempt is made
herein to describe all possible techniques. With regard to the
above detailed description, like reference numerals used therein
refer to like elements that may have the same or similar
dimensions, materials and configurations. While particular forms of
embodiments have been illustrated and described, various
modifications can be made without departing from the spirit and
scope of the embodiments of the invention. Accordingly, it is not
intended that the invention be limited by the forgoing detailed
description.
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