U.S. patent application number 14/055540 was filed with the patent office on 2014-04-17 for container fill level detection.
This patent application is currently assigned to Beckman Coulter, Inc.. The applicant listed for this patent is Beckman Coulter, Inc.. Invention is credited to Lukas Bearden, Andreas Donner-Rehm, Martin Mueller.
Application Number | 20140107953 14/055540 |
Document ID | / |
Family ID | 49488684 |
Filed Date | 2014-04-17 |
United States Patent
Application |
20140107953 |
Kind Code |
A1 |
Mueller; Martin ; et
al. |
April 17, 2014 |
CONTAINER FILL LEVEL DETECTION
Abstract
Systems and methods for determining different fill levels of
objects in the containers for disposable and consumable objects are
disclosed. A sensor unit can detect presence of an object passing
into a waste container and different levels of the objects in the
waste container as the objects fill the waste container. When the
waste container is full, a notification message may be generated to
empty or replace the waste container. The sensor unit can also
detect different levels of objects in a consumable container as the
objects are removed from the consumable container. When the
consumable container is empty, a notification message may be
generated to refill or replace the consumable container. In
embodiments of the invention, a notification message may also be
generated for a predetermined level of objects in the
container.
Inventors: |
Mueller; Martin;
(Schliersee-Neuhaus, DE) ; Bearden; Lukas;
(Indianapolis, IN) ; Donner-Rehm; Andreas;
(Stockdorf, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Beckman Coulter, Inc. |
Brea |
CA |
US |
|
|
Assignee: |
Beckman Coulter, Inc.
Brea
CA
|
Family ID: |
49488684 |
Appl. No.: |
14/055540 |
Filed: |
October 16, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61790446 |
Mar 15, 2013 |
|
|
|
61714656 |
Oct 16, 2012 |
|
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Current U.S.
Class: |
702/54 ;
702/55 |
Current CPC
Class: |
G01N 35/0099 20130101;
G01G 19/52 20130101; B65G 11/023 20130101; B25J 19/02 20130101;
B65B 69/00 20130101; G01F 23/2962 20130101; G01B 7/02 20130101;
Y10T 29/49826 20150115; B25J 15/10 20130101; B25J 15/103 20130101;
A61B 50/36 20160201; B25J 15/0475 20130101; G01S 15/04 20130101;
G01B 11/14 20130101; B25J 19/021 20130101; G01F 23/0061 20130101;
G01N 35/00732 20130101 |
Class at
Publication: |
702/54 ;
702/55 |
International
Class: |
G01F 23/00 20060101
G01F023/00; A61B 19/02 20060101 A61B019/02 |
Claims
1. A system for handling objects, the system comprising: a
container for holding the objects; a processor; and a sensor unit
communicatively coupled to the processor, wherein the sensor unit
is configured to generate a first output by detecting a fill level
of objects in the container, and wherein the processor is
configured to determine a number of objects in the container based
on a number of objects counted by the processor and a number of
objects estimated by the processor using the first output.
2. The system of claim 1, wherein the sensor unit is further
configured to generate second outputs by detecting the presence of
objects passing into the container.
3. The system of claim 2, wherein the number of objects counted by
the processor is determined based on the second outputs from the
sensor unit.
4. The system of claim 1, wherein the number of objects counted by
the processor is determined based on outputs generated by an object
handling unit when objects are removed from the container.
5. The system of claim 1, wherein the number of objects in the
container is X, and wherein
X=(N.sub.count*W.sub.count)+(N.sub.meas*W.sub.meas), where
N.sub.count=the number of objects counted by the processor,
W.sub.count=a first weight factor for counted objects,
N.sub.meas=the number of objects estimated using a measurement
based on the first output, and W.sub.meas=a second weight factor
for estimation from measurement.
6. The system of claim 5, wherein N.sub.meas is i determined by the
following formula: N.sub.meas=(H.sub.1* cross sectional area
(container))/volume of the object, where H.sub.1 is the fill
level.
7. The system of claim 1, wherein the processor is further
configured to determine a number of objects that can additionally
fit in the container, which is determined by subtracting the number
of objects in the container from a maximum number of objects that
will fit in the container.
8. The system of claim 1 wherein the container is a waste
container.
9. The system of claim 1 wherein the container is a consumable
container.
10. The system of claim 1, further comprising: a chute coupled to
the container.
11. The system of claim 1, wherein the processor is further
configured to generate an alert when the number of objects in the
container is equal to or exceeds a maximum number of objects that
will fit in the container.
12. The system of claim 1, wherein the objects include at least one
of a tube, a cap, a pipette or a capillary.
13. The system of claim 1, wherein the sensor unit comprises an
ultrasonic sensor.
14. The system of claim 1, wherein the sensor unit comprises a long
range sensor and a short range sensor.
15. The system of claim 14, wherein the long range sensor and the
short range sensor are ultrasonic sensors.
16. The system of claim 14, wherein the long range sensor is an
ultrasonic sensor and the short range sensor is an optical
sensor.
17. The system of claim 1, wherein the objects include specimen
containers.
18. A method comprising: determining, by a processor, an estimated
number of objects in a container based on a first output from a
sensor unit communicatively coupled to the processor; counting, by
the processor, a number of objects; and determining, by the
processor, the number of objects in the container based on the
counting and the estimated number of objects based on the first
output.
19. The method of claim 18, wherein the number of objects in the
container is X, and wherein
X=(N.sub.count*W.sub.count)+(N.sub.meas*W.sub.meas), where
N.sub.count=the number of objects counted by the processor,
W.sub.count=a first weight factor for counted objects,
N.sub.meas=the number of objects estimated using a measurement
based on the first output, and W.sub.meas=a second weight factor
for estimation from measurement.
20. The method of claim 19, wherein W.sub.count and W.sub.meas vary
based on the number of objects in the container.
21. The method of claim 19, wherein W.sub.count is one and
W.sub.meas is zero when there are less than ten objects in the
container.
22. The method of claim 19, wherein W.sub.count is zero and
W.sub.meas is one when there are more than fifty objects in the
container.
23. The method of claim 19, wherein N.sub.meas is determined by the
following formula: N.sub.meas=(H.sub.1*cross sectional area
(container))/volume of the object, where H.sub.1 is the fill
level.
24. The method of claim 18, further comprising: passing an object
into the container; and incrementing, by the processor, a counter
value based on a second output from the sensor unit.
25. The method of claim 18, wherein a number of objects that can
additionally fit in the container is determined by subtracting the
number of objects in the container from a maximum number of objects
that will fit in the container.
26. The method of claim 18, further comprising: removing objects
from the container; and decrementing, by the processor, a counter
value based on an output from an object handling unit.
27. The method of claim 26, further comprising: determining, by the
processor, if the container is filled with objects to a defined
maximum level before removing the object.
28. The method of claim 27, further comprising: generating, by the
processor, an alert message if the container is not filled with
objects to the defined maximum level.
29. The method of claim 18, further comprising: generating, by the
processor, a notification message when a predefined level of
objects in the container is reached.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 61/790,446 filed Mar. 15, 2013 and entitled
"Specimen Gripper." This application further claims priority to
U.S. Provisional Application No. 61/714,656 filed Oct. 16, 2012 and
entitled "Specimen Gripper." All of these applications are herein
incorporated by reference in their entirety for all purposes.
BACKGROUND
[0002] Conventional medical laboratory systems contain many
components for processing patient samples, some of which are
automated and some of which require manual operation. Laboratory
systems today have become more efficient due to those automated
components. However, there are still several components of medical
laboratory systems that can be automated in order to reduce
reliance on human intervention.
[0003] In medical laboratory systems, waste objects such as
specimen containers with expired storage times, secondary test
tubes, etc. may be collected in a waste container for disposal. For
example, a gripper unit attached to a robotic arm may grip waste
objects from various work units in a laboratory system to dispose
them in a waste container. To minimize reliance on human
intervention it is desirable to automatically detect when the waste
container is full.
[0004] Level indicators for containers used in the medical
laboratory systems are known. However, most of the solutions only
relate to detecting a maximum level of the container. One such
approach is discussed in the U.S. Pat. No. 5,918,739 titled "Full
Level Indicator for Medical Disposable Container" by Bilof et al.
However, one problem with this type of system is that a signal is
only sent out when the waste container reaches a maximum level.
Instruments upstream and downstream of the disposal container may
not have time to adjust their processes if the disposal container
only alerts the system when it reaches a maximum level. Instruments
upstream and downstream of the disposal container may have to shut
down to allow the waste container to be emptied.
[0005] Another problem to be addressed, particularly in a
laboratory environment, is that there are a number of different
waste items and consumables (e.g., reagent packs, pipettes, etc.)
that have different dimensions and waste containers also have
different dimensions. Accordingly, simple fill level detectors
would have limited value, since it would be difficult to inform the
system how many more items can fill the container or how many more
items can be removed from the container. As noted above, this
information may be useful when upstream and downstream instruments
need to be informed about how they should operate to minimize
downtime.
[0006] One method that is used to detect a waste fill level using a
waste counter in the existing Beckman Automate.TM. 2500 series
(e.g., in an Aliquoting module) is described. In this system, a
maximum volume of waste, e.g. a thousand units, is hardcoded into
the Automate software and represents the maximum fill level of the
container. For instance, in this system, a discarded changeable tip
is counted as one unit, and a discarded secondary tube is counted
as five units. The waste counter indicates a fill level of the
container as the container is filled with discarded objects. The
current fill level may be loaded from a memory, which may be zero
or a predetermined value. After discarding step, the fill level of
the container (i.e., the waste counter) is incremented by one for
changeable tips or five for discarded secondary tubes. After every
discarding step, the fill level is checked for a maximum level by
the software and the updated fill level is stored in the memory.
When the fill level is more than the maximum volume of the waste
(e.g. hardcoded value), the user or the operator is warned to clear
the waste and reset the waste counter. The actual fill level is
rest and saved into the memory.
[0007] Detecting only the maximum level of the container may be
inefficient in some cases since it may result in overfilling of the
container if the operator does not have sufficient time to react.
Therefore, it would be desirable to get timely information so that
the operator can react in time and can schedule maintenance actions
accordingly.
[0008] Embodiments of the invention address these and other
problems, individually and collectively.
BRIEF SUMMARY
[0009] In some cases, it may be useful to detect a partial fill
level of the waste container. For example, by doing so, it is
possible to adjust the processing speed of upstream and/or
downstream instruments to potentially allow for the replacement
and/or emptying of the waste container. Further, by knowing the
fill level of the waste container, another waste container can be
prepared to replace the waste container that is currently being
used so that the downtime for the overall system is reduced.
Embodiments of the invention relate to systems and methods for
determining different fill levels of containers, in particular,
containers for disposable and consumable objects.
[0010] One embodiment is directed to a system for handling objects,
the system comprising a container for holding the objects, a
processor and a sensor unit communicatively coupled to the
processor. The sensor unit is configured to generate a first output
by detecting a fill level of objects in the container, and the
processor is configured to determine a number of objects in the
container based on a number of objects counted by the processor and
a number of objects estimated by the processor using the first
output.
[0011] Another embodiment is directed to a method comprising
determining by a processor, an estimated number of objects in a
container based on a first output from a sensor unit
communicatively coupled to the processor and counting, by the
processor, a number of objects. The method further comprises
determining, by the processor, the number of objects in the
container based on the counting and the estimated number of objects
based on the first output.
[0012] These and other embodiments of the technology are described
in further detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A further understanding of the nature and advantages of the
different embodiments may be realized by reference to the following
drawings.
[0014] FIG. 1 depicts an example of a Cartesian or gantry robot
with three independently moveable directions x-,y-, and z-.
[0015] FIG. 2 illustrates a block diagram of a system that may be
utilized in a medical laboratory.
[0016] FIG. 3 illustrates certain elements of an exemplary system
comprising a chute arrangement and a sensor unit, in one embodiment
of the invention.
[0017] FIG. 4 illustrates overview of an exemplary specimen output
system according to one embodiment of the invention.
[0018] FIG. 5 illustrates a perspective view of the placement of a
chute arrangement according to one embodiment of the invention.
[0019] FIG. 6 illustrates an ultrasonic sensor arrangement in
accordance with embodiments of the invention.
[0020] FIG. 7 illustrates an exemplary ultrasonic sensor
arrangement 4300 using two ultrasonic sensors, in one embodiment of
the invention.
[0021] FIG. 8 illustrates an exemplary sensor arrangement using one
ultrasonic sensor and one optical sensor, in one embodiment of the
invention.
[0022] FIG. 9 illustrates a method for detecting the fill level of
a container in one embodiment of the invention.
[0023] FIGS. 10A-10C illustrate various fill levels of a waste
container in one embodiment of the invention.
[0024] FIG. 11 illustrates a method for detecting the fill level of
a container with consumable objects, in one embodiment of the
invention.
[0025] FIGS. 12A-12C illustrate various fill levels of a consumable
container in one embodiment of the invention.
[0026] FIG. 13 illustrates an exemplary specimen output system in
one embodiment of the invention.
[0027] FIG. 14 illustrates an arrangement for a bin frame with a
door in one embodiment of the invention.
[0028] FIG. 15 illustrates a method to reset a waste container in
one embodiment of the invention.
[0029] FIG. 16 illustrates a method to reset a consumable container
in one embodiment of the invention.
[0030] FIG. 17 illustrates a block diagram of an exemplary computer
apparatus.
DETAILED DESCRIPTION
[0031] Embodiments of the invention relate to systems and methods
for determining different fill levels of containers, in particular,
containers for disposable and consumable objects.
[0032] Waste containers may be used in a medical laboratory system
to hold waste objects such as test tube waste, test tube cap waste,
capillary waste, pipette tip waste, etc. In one embodiment, a
sensor unit may be configured to detect a fill level of a
container. A processor, coupled to the sensor unit, may be
configured to determine different levels of objects in the
container as the objects fill the container or are removed from the
container based on the fill level detected by the sensor unit. The
sensor unit may also be configured to detect the presence of an
object passing into the container. In some embodiments, a chute may
be configured to pass the object into the container. In one
embodiment, the sensor unit may be used to estimate a fill level of
a container for consumable objects such as capillaries, secondary
test tubes, caps, etc., when a consumable object is removed from
the container.
[0033] A "container" or a bin may be used in a medical laboratory
system to store or contain objects such as specimen containers
(e.g., a sample tubes), caps, capillaries, pipettes, etc. A
container may have a certain height (e.g., three feet or more),
certain length (e.g., two feet or more) and certain width (e.g.,
one foot or more). The container may be of any shape with a
suitable profile such as a rectangle, square, trapezoid,
cylindrical, oval, etc. The container may have a specified maximum
fill capacity, e.g., cubic centimeters, cubit feet, etc., to hold a
number of objects. The container may be made of any suitable
material such as plastic, metal, rubber, etc. The container may or
may not have a lid. In one embodiment, a container may be used to
store disposable objects such as test tube waste, test tube cap
waste, capillary waste, and pipette tip waste, etc. In another
embodiment, a container may be used to store consumable objects
such as capillaries, secondary test tubes, caps, etc.
[0034] "Fill capacity" may include capacity of a container to hold
plurality of objects. In one embodiment, the fill capacity of a
container may include its capacity to hold same types of objects,
for example, plurality of sample tubes, plurality of caps, etc. In
one embodiment, fill capacity of a container may include the number
of objects that can be filled in the container to reach a certain
fill level based on a certain packing density. The fill capacity
may depend on the volume of the container and the volume of the
objects.
[0035] "Fill level" may include a level of a container that has
been filled with one or more objects. A fill level of "zero" may
imply that the container is empty. In one embodiment, the fill
level of a container may imply a distance to the bottom of the
container. When the fill level is equal to close to a height of the
container, the container may be full. The fill level of a container
may vary based on the packing density of the objects deposited in
the container. Further, the density may vary depending upon the
number of objects already in the container. For example, when an
object is dropped in an empty container, the packing density may be
different as compared to when there are already twenty objects in
the container.
[0036] A "sensor unit" may include one or more sensors to detect
and respond to some type of input from the physical environment.
For example, the input could be sound, motion, light, temperature,
pressure, etc. The sensor unit may be configured to generate an
output corresponding to the input or change in input. The output
may be in the form of an electrical signal, an optical signal or
any other suitable form. Different sensors may have different
sensitivity levels to detect the input. The sensors may include
acoustic sensors, ultrasonic sensors, optical sensors, etc. An
ultrasonic sensor may be based on the measurement of the property
of acoustic waves with frequencies above the human audible range.
An ultrasonic sensor may include a transceiver that emits a high
frequency pulse of sound and receives and analyzes the properties
of the echo pulse. In some embodiments, an ultrasonic sensor may
include a short range sensor and a long range sensor.
[0037] A gripper unit according to an embodiment of the invention
may utilize plurality of gripper fingers to grip an object. The
plurality of gripper fingers may comprise two or more (e.g., three,
four or any suitable number) gripper fingers. Each gripper finger
may take a form of an elongated structure that is capable of
gripping an object such as a sample tube or a cap in collaboration
with one or more other gripper fingers. In some embodiments, an
exemplary gripper finger may have a rectangular, axial and/or
longitudinal, cross-section with predetermined thickness (e.g., one
quarter of an inch or more) and length (e.g., three inches or
more). Suitable gripper fingers may be rigid or may have one or
more pivoting regions.
[0038] In some embodiments, a jaw may be coupled to one end
(gripping end) of the gripper finger to aid in gripping the object.
The other end of the gripper finger may be coupled to an assembly
or mechanism along with other gripper fingers that may be operable
to control the gripper fingers for gripping the object.
[0039] The gripper unit may be used in a medical laboratory system
for processing patient samples. In some embodiments, a gripper unit
may be coupled to a robotic arm. Robotic arms may be used for
transportation of specimen containers in various areas of a
laboratory system, such as input, distribution, centrifuge,
decapper, aliquotter, output, analyzer, sorting, recapping,
storage, and secondary tube lift areas. In one embodiment, robotic
arms may be used to lift waste objects using a gripper unit and
discard them into a waste container. For example, waste objects
such as specimen containers may need to be discarded when their
storage time has expired. In another embodiment, the gripper unit
may be used to pick an object stored in a consumable container for
further processing.
[0040] The robotic arm architecture can differ in complexity
dependent upon the given task. FIG. 1 depicts an example of a
Cartesian or gantry robot 1000 with three independently moveable
directions x-, y-, and z-. The gantry robot 1000 shown in FIG. 1
shows a simple robotic arm 1002 that can move up and down. More
complex robotic arms may include, for example, a Selective
Compliant Assembly Robot Arm (SCARA) or an articulated robotic arm
with multiple joint arms.
[0041] In some embodiments of the invention, a gripper unit 1004,
may be coupled to the robot arm 1002. The robot arm 1002 may be
part of the gantry robot 1000 that is configured to move
independently in three, orthogonal directions denoted as 1000A,
1000B and 1000C. As the gripper unit 1004 is transported by the
robot arm 1002, the gripper unit 1004 may transport a specimen
container 1006 held by the gripper unit 1004.
[0042] The gripper unit 1004 may have two or more moveable gripper
fingers 1008, 1010 coupled to a body 1012 to grip the specimen
container 1006. For example, the gripper fingers 1008, 1010 may
move inwardly toward the specimen container 1006 until the specimen
container 1006 is held in a fixed position between the gripper
fingers 1008 and 1010. The gripper fingers 1008, 1010 may also be
configured to spread outwardly to release the specimen container
1006. The robot arm 1002 may be part of a laboratory automation
system, which is further described with reference to FIG. 2.
[0043] FIG. 2 illustrates a block diagram of a system 1100 that may
be utilized in a medical laboratory. The system 1100 may include an
operator 1102 that may use a laboratory automation system 1104 to
process samples (e.g., serum, plasma, gel, packed red blood cells,
etc.). In the exemplary embodiment, the laboratory automation
system 1104 includes the robot arm 1002, a processing unit 1106, a
gripper unit 1114, a sensor unit 1120, a container unit 1128, a
feeder unit 1130 and a chute arrangement 1122. However, a number of
other units (not shown) may be utilized by the laboratory
automation system 1104. For example, the laboratory automation
system 1104 may include various work units such as an input module,
a distribution area, a centrifuge, a decapper, a serum indices
measurement device, an aliquotter and an output/sorter in some
embodiments of the invention. The robot arm 1002 may be part of the
gantry robot 1000. The gripper unit 1114 may be coupled to the
robot arm 1002. The robot arm 1002 and the sensor unit 1120 may be
configured to communicate with the processing unit 1106.
[0044] The processing unit 1106 may include a processor 1108 and a
memory 1110. The processor 1108 may be configured to execute
instructions or code in order to implement methods, processes or
operations in various embodiments. In some embodiments, the
processor may include other suitable processing elements (not
shown), such as a microprocessor, a digital signal processor, a
graphics processor, a co-processor, a microcontroller, etc. In one
embodiment, the processor 1108 may be configured to determine
different levels of the objects in a container as the objects fill
the container or are removed from the container.
[0045] The memory 1110 may be coupled to the processor 1108
internally or externally (e.g., cloud based data storage) and may
comprise any combination of volatile and/or non-volatile memory
such as, for example, buffer memory, RAM, DRAM, ROM, flash, or any
other suitable memory device. In some embodiments, the memory 1110
may be in the form of a computer readable medium (CRM), and may
comprise code, executable by the processor 1108 for implementing
methods described herein. For example, the memory 1110 may comprise
a computer readable medium comprising code, executable by the
processor 1108 to implement a method comprising determining an
estimated number of objects in a container based on a first output
from a sensor unit communicatively coupled to the processor;
counting a number of objects; and determining the number of objects
in the container based on the counting and the estimated number of
objects based on the first output. In some embodiments, the
processor 1108 may be part of a computer system as described with
reference to FIG. 17.
[0046] The memory 1110 may also store other information. For
example, the memory 1110 may include a counter (e.g., a waste
counter) to keep track of the number of objects dropped in a waste
container. The memory 1110 may also include a counter (e.g., a
consumable counter) to keep track of the number of objects removed
from a consumable container. The consumable counter may be
triggered by consumables that are detected by a sensor unit as they
are being removed from the container or each time an object
handling unit (e.g., a robotic arm) removes an object from the
container. The memory 1110 may also store information about maximum
fill levels associated with different containers in the container
unit 1128 to store specific objects. In some embodiments, the
memory 1110 may store geometric dimensions of each object handled
by the laboratory automation system 1104 and also dimensions
associated with different containers in the container unit 1128.
The memory 1110 may also store information relating to different
weight factors that may be used to correct the estimation of the
number of objects dropped or removed from different containers in
the container unit 1128.
[0047] The laboratory automation system 1104 may utilize the robot
arm 1002 to grip a specimen container (e.g., sample tube) using the
gripper unit 1114. The gripper unit 1114 may include a body 1116
and gripper fingers 1118 that are coupled to the body 1116. It will
be understood that the gripper unit 1114 may also include or
interface with other units to enable the gripper unit perform the
intended function. In one embodiment, the gripper unit 1114 may
grip a waste object using the gripper fingers 1118 to discard it
into a waste container that may be part of the container unit 1128.
In another embodiment, the gripper unit 1114 may grip a consumable
object using the gripper fingers 1118 from a consumable container
that may be part of the container unit 1128 to transport it to
another work unit in the laboratory automation system 1104.
[0048] In one embodiment, the gripper fingers 1118 are coupled to
the body 1116. The body 1116 may be in the form of a support
structure or a housing. It may have any suitable shape including a
square or rectangular vertical or horizontal cross section. The
gripper fingers 1118 can be capable of moving with respect to the
body 1116. In one embodiment, the body 1116 may include one or more
mounting structures so that the gripper fingers 1118 are coupled to
the one or more mounting structures. It may also contain the
well-known components (e.g., gears, solenoids, etc.) that allow the
gripper unit to function. The body 1116 may be made of any suitable
material including metal or plastic.
[0049] In one embodiment, the chute arrangement 1122 may include a
top chute 1124, and a bottom chute 1126 coupled to the top chute
1124. In some embodiments, the top chute 1124 may be coupled to the
bottom chute 1126 using an optional adapter or a spacer unit for
compatibility or height adjustments. In embodiments of the
invention, the gripper unit 1114 may grip an object from a rack or
a carrier in an output module and drop it through the chute
arrangement 1122 for discarding it into a waste container that may
be part of the container unit 1128. In one embodiment, the chute
arrangement 1122 includes only a single chute through which objects
such as test tubes, caps, capillaries, pipette tips, etc. may be
dropped into a container.
[0050] The container unit 1128 may include one or more containers.
For example, the container unit 1128 may include one or more waste
containers to store waste or disposable objects such as test tubes,
test tube caps, capillaries and pipette tips, etc. The container
unit 1128 may also include one or more consumable containers to
store consumable objects such as capillaries, secondary test tubes,
caps, etc.
[0051] The feeder unit 1130 may include any suitable feeder system
to feed an object into a container that may be part of the
container unit 1128. For example, the feeder unit 1130 may include
a bowl feeder, a step feeder, a wall feeder, etc. to feed objects
such as capillaries, test tubes, caps, pipette tips, etc. to a
container.
[0052] In one embodiment, the sensor unit 1120 may be in close
proximity of the chute arrangement 1122. The sensor unit 1120 may
be configured to detect the presence of a passing object through
the chute arrangement 1122 into a waste container. The sensor unit
1120 may also be configured to detect a fill level of a waste
container and/or a consumable container. In some embodiments, the
sensor unit 1120 may comprise a short range sensor to detect a
falling object in the chute arrangement 1122 and a long range
sensor to detect a fill level of the container in the container
unit 1128. This is further explained with reference to FIG. 3.
[0053] FIG. 3 illustrates certain elements of an exemplary system
3000 comprising a chute arrangement and a sensor unit, in one
embodiment of the invention.
[0054] The exemplary system 3000 may include the robot arm 1002
coupled to a gripper unit 3002 including gripper fingers 3004. The
gripper unit 3002 may be operable to grip objects, such as specimen
containers, caps, etc., using gripper fingers 3004 to automatically
discard into a waste container 3016.
[0055] In one embodiment, a chute arrangement 3012 may include a
top chute 3006 and a bottom chute 3010 coupled to the top chute
3006 through an optional adapter unit 3008. In another embodiment,
the chute arrangement 3012 may include a single chute to enable the
passing of an object towards the waste container 3016. For example,
the single chute may be a combination or some alternative form of
the top chute 3006 and the bottom chute 3010.
[0056] The gripper unit 3002 may be configured to grip a specimen
container 3014 using the gripper fingers 3004. In embodiments of
the invention, the chute arrangment 3012 helps direct the specimen
container 3014 into the waste container 3016, when the specimen
container 3014 is released by the gripper fingers 3004. The
operation of the chute arrangment 3012 is explained in greater
detail in a co-pending U.S. Patent Application No. (Attorney Docket
No. 87904-883228), by Lukas Bearden, and Martin Muller, filed on
the same day as the present application, and entitled "Chute
Arrangement With Strip-Off Feature", the contents of which are
incorporated by reference in its entirety for all purposes.
[0057] The adapter unit 3008 may be configured as a spacer unit to
provide a height adjustment for mounting the chute arrangment 3012
on a platform. The adapter unit 3008, in combination with the top
chute 3006, may be configured to have a length that is equal to or
greater than the length of the specimen container 3014 such that no
part of the specimen container 3014 can stick to gripper fingers
3004 beyond the chute. The chute arrangment 3012 may be able to
accommodate objects of any suitable dimensions so that the object
does not interrupt the acoustic, light, or other signal used for
detecting the falling object, when the object is in the grasp of
the gripper unit 3002. In one embodiment, the combined length of
the top chute 3006 and the adapter unit 3008 can be adjusted to
accommodate length of different objects that are intended to be
passing through the chute arrangment 3012.
[0058] In some embodiments, the waste container 3016 may be
configured to collect the objects dropped through the chute
arrangment 3012. In one embodiment of the invention, a notification
message may be generated including information about the fill level
of the waste container 3016. For example, the notification message
may include if the waste container 3016 is quarter full, half full,
sixty percent full, three quarters full, nearly full, full or any
other predetermined fill level. This information may help an
operator (e.g., the operator 1102) to determine if the waste
container 3016 needs to be emptied or replaced with another waste
container. Referring back to FIG. 2, in one embodiment, the
container unit 1128 may include one or more waste containers 3016
to collect or store disposable or waste objects such as test tubes,
test tube caps, capillaries, secondary test tubes, pipettes
etc.
[0059] In some embodiments, an ultrasonic sensor unit 3018 may be
in close proximity to the chute arrangment 3012. The ultrasonic
sensor unit 3018 may be configured to detect an object, e.g., the
specimen container 3014, passing through the chute arrangment 3012.
The ultrasonic sensor unit 3018 may also be configured to detect a
fill level of the waste container 3016. In one embodiment, the
ultrasonic sensor unit 3018 may be part of the sensor unit 1120 (in
FIG. 2), and may be configured to communicate with the processor
1108, information relating to a fill level of the waste container
3016. The processor 1108 may communicate with the memory 1110 to
determine different fill levels of the objects in the waste
container 3016 based on certain pre-determined parameters and
information received from the sensor unit 1120 (e.g., dimension of
the object, fill capacity of the container, etc.) and accordingly
send a notification message to the operator 1102.
[0060] In embodiments of the invention, the robot arm 1002 may be
operable to grip an object (e.g., a sample tube) using the gripper
unit 1114 from a carrier or a rack and drop it through the chute
arrangement 1122 into a waste container. This is further explained
with reference to FIG. 4.
[0061] FIG. 4 illustrates overview of an exemplary specimen output
system according to one embodiment of the invention.
[0062] In one embodiment, a specimen output system 4000 may be used
in medical laboratory systems where specimen containers may need to
be discarded, e.g., when the storage time for the specimen
container has expired. The specimen container may be a test tube
containing material for medical analysis, such as blood, serum,
gel, plasma, etc. An output robot 4002 may be used to transport the
specimen containers from various areas of a laboratory system, such
as input, distribution, centrifuge, decapper, aliquotter, analyzer,
sorting, recapping, and secondary tube lift areas. The specimen
output system 4000 may be part of the laboratory automation system
1104.
[0063] The output robot 4002 may utilize the robot arm 1002 for
gripping an object using the gripper unit 1114 from the single tube
carrier rack 4004 and dropping it into the waste container 3016
through the chute arrangment 3012. In one embodiment, the
processing unit 1106 may be in communication with the output robot
4002 to control the output robot 4002 to start and stop the
specimen container discarding process.
[0064] In one embodiment, the waste container 3016 may include a
height 4012, length 4014 and a width 4016 that may be used to
determine a fill level of the waste container 3016. For example,
the height 4012, length 4014, width 4016 and any other geometric
information related to the waste container 3016 may be stored in
the memory 1110 of the processing unit 1106 that may be used by the
processor 1108 in combination with other information, such as
relating to the waste objects, to determine a fill level of the
waste container 3016.
[0065] The specimen containers may be stored in a single tube
carrier rack 4004. A plurality of such racks may be placed in the
deck 4010. The output robot 4002 may comprise a gripper unit (e.g.,
the gripper unit 3002) that may be used to automatically lift a
tube from the single tube carrier rack 4004 for discarding into the
waste container 3016. Even though the exemplary system 4000
illustrates a test tube rack, specimen containers may be picked up
from any handling system, such as a track system or via any test
tube supply mechanism. Further, it will be understood that other
feeders or supply mechanisms may be used to feed discarded objects
through the chute arrangment 3012. For examples, bowl feeders or
step feeders may be used to feed individual objects such as caps
through the chute arrangment 3012 directed towards the waste
container 3016.
[0066] Embodiments of the invention provide for a number of
advantages. For example, by using the chute arrangement,
embodiments of the invention may be used to reliably allow a
specimen container pass into the waste container 3016 when released
by the gripper unit (not shown). Also, the chute arrangement can
allow the waste container 3016 to be separated from other system
components. For example, by not attaching the waste container 3016
to the chute arrangment 3012 or the deckbase 4008, the waste
container 3016 may be removed for emptying or replaced with another
container. As discussed with reference to FIG. 3, the chute
arrangement 3012 may include one or more of the top chute 3006, the
optional adapter unit 3008 and the bottom chute 3010. The bottom
chute 3010 may be mounted on a deckbase 4008 to provide support or
stability. The adapter unit 3008 may be configured to compensate
for the distance between the top chute 3006 and the bottom chute
3010 caused by the deck base 4008, as illustrated with reference to
FIG. 5.
[0067] FIG. 5 illustrates a perspective view of the placement of a
chute arrangement according to one embodiment of the invention.
[0068] As illustrated in FIG. 5, the adapter unit 3008 or other
portion of the top chute 3006 may be inserted into an opening, such
as an opening in the deck 4010, for support or stability. The
bottom chute 3010 may comprise a plurality of mounting tabs for
mounting on the deckbase 4008. However, it is to be noted that any
mechanism may be used to connect the bottom chute 3010 to the
deckbase 4008 or any other stabilizing platform. In one embodiment,
the top chute 3006 may be attached directly to the bottom chute
3010 without the optional adapter unit 3008 or any other
intermediary unit. In another embodiment, the adapter unit 3008 may
be a part of the bottom chute 3010. The adapter unit 3008 may have
a profile that provides an easy alignment with the top chute 3006
(e.g., square shaped or cylindrical profile to match with the top
chute 3006).
[0069] In one embodiment, the deck 4010 and the deckbase 4008 are
part of the laboratory automation system 1104 (e.g., in a storage
unit). In one embodiment, the deck 4010 may hold a plurality of
specimen carrier racks holding a plurality of specimen carriers
carrying multiple specimen containers. Alternatively, the deck 4010
may hold other means of supplying waste objects through the chute
arrangment 3012.
[0070] In some embodiments, the bottom chute 3010 is in close
proximity to the ultrasonic sensor 3018 such that the ultrasonic
signals emitted from the ultrasonic sensor unit 3018 are directed
towards an opening or a side hole in the bottom chute 3010 to
detect an object passing through the chute arrangment 3012. In one
embodiment, an optical sensor may be used in place of the
ultrasonic sensor unit 3018 for short range detection of the
passing objects. The optical sensor may be mounted on the deck base
4008 such that an object falling through the chute arrangment 3012
is in its line of sight. Operation of the ultrasonic sensor 3018 is
further explained with reference to FIG. 6.
[0071] FIG. 6 illustrates an ultrasonic sensor arrangement 4200 in
accordance with embodiments of the invention.
[0072] An ultrasonic sensor 4202 may be configured to be in close
proximity of a deflector chute 4204 in one embodiment of the
invention. The deflector chute and the ultrasonic sensor
arrangement serve more than one purpose in embodiments of the
invention. The ultrasonic sensor 4202 may be configured to detect
presence of an object passing through the deflector chute 4204. The
object may be any object that needs to be collected in a container,
such as discarded specimen samples (e.g., a waste tube 4206),
capillary waste, pipette tip waste or test tube cap waste used in
various modules of a medical laboratory system (e.g., de and
re-capper module, serum indices module, aliquoter module).
[0073] In one embodiment, the deflector chute 4204 is similar to
the bottom chute 3010 of the chute arrangment 3012. In this
specification, the terms deflector chute and the bottom chute may
be used interchangeably. The deflector chute 4204 may have an
opening or a hole 4204A on its side facing an opening 4202A of the
ultrasonic sensor unit 4202 for the ultrasonic sensor unit 4202 to
send and receive ultrasonic waves through the opening 4204A. The
deflector chute 4204 may be configured to couple to a top chute
(e.g., the top chute 3006) or an optional adapter unit (e.g., the
adapter unit 3010) through an opening 4204B. In some embodiments,
the deflector chute 4204 may be integrated with a top chute and/or
an optional adapter unit to form a single chute. The deflector
chute 4204 may also have a deflector surface 4202C to deflect an
ultrasound wave or a signal towards a container 4208 to detect a
fill level of the container 4208.
[0074] In some embodiments, the ultrasonic sensor 4202 may be
configured as a transceiver to transmit and receive ultrasound
waves. The ultrasonic sensor 4202 may be communicatively coupled to
a micro-controller or a processor (e.g., the processor 1108) to
provide the detected information. For example, a transducer in the
ultrasonic sensor 4202 may be configured to transmit ultrasonic
waves in a certain frequency range from the opening 4202A. When an
ultrasonic beam 4210 is emitted from the ultrasonic sensor 4202, if
no passing object close to the opening 4202A interrupts the
ultrasonic beam 4210, the ultrasonic beam 4210 may be downward
reflected towards the container 4208 by the inclined deflector
surface 4204C of the deflector chute 4204. The beam 4210 may
further get reflected from the surface of the container 4208 or
from the objects within the container 4208. The reflected beam 4210
may travel to the deflector surface 4204C and may be directed
towards the opening 4202A of the ultrasonic sensor 4202. The
ultrasonic sensor 4202 can detect the reflected beam 4210 and
generate a first output. In one embodiment, the first output may be
in the form of a constant signal with varying amplitude depending
on the fill level of the container 4208. In one embodiment, the
reflected ultrasonic signal may be amplified by an amplifier in the
ultrasonic sensor 4202 before transmitting it to the processor
1108. The processor 1108 may be configured to determine a fill
level of the container 4208 based on the first output. However,
measurements made by the processor 1108 may not be precise in some
cases, for example, when there are fewer objects (e.g., less than
ten) in the container 4208.
[0075] When an object such as the waste tube 4206 passes in front
of the opening 4202A, the emitted beam 4210 gets interrupted and
sent back to the ultrasonic sensor 4202. Another transducer in the
ultrasonic sensor 4202 may receive the reflected beam 4210 and may
generate a second output to indicate a passing object. For example,
a short pulsed signal may be generated by the ultrasonic sensor
4202 indicating a passing object. The processor 1108 may be
configured to increment a counter based on the second output every
time a passing object is detected by the ultrasonic sensor 4202.
However, there may be possible errors made during counting, for
example, an object may be counted more than once or not counted at
all during the passing to the container 4208. If the beam 4210 is
not interrupted by a falling object, the beam 4210 is deflected
downwards by the deflector surface 4204C of the bottom chute
4204.
[0076] A dead zone may be a zone close to the ultrasonic sensor
4202 in which objects cannot be detected because they deflect the
wave back before the receiver of the ultrasonic sensor 4204 is
operational. An active zone may indicate where the ultrasonic waves
may be reflected back to the ultrasonic sensor 4202 for measuring
the fill level of the container 4208. The ultrasonic wave would
have deflected downwards from the deflector surface 4204C of the
bottom chute 4204 if the beam 4210 was not interrupted by the
falling waste tube 4206. Thus, embodiments may be used to detect
falling objects passing through the dead zone of the ultrasonic
sensor 4202 closer to the sensor face and also to detect the fill
level of a container that may be far away from the ultrasonic
sensor.
[0077] Embodiments utilize ultrasonic sensors based on the
properties of acoustic waves; however, any sensor unit capable of
detecting reflected signals or otherwise detecting falling objects
may be used. The ultrasonic sensor is advantageous as it provides
continuous monitoring of the reflected signal and additionally
avoids unwanted reflections that may occur with other types of
sensor units. An exemplary ultrasonic sensor 4202 available in the
market is Microsonic SICK UM30-213118, having a typical ultrasonic
frequency of 200 kHz and a sensing range of 200-2000 mm.
[0078] In some embodiments, a sensor unit may comprise two
ultrasonic sensors for more precise detection or higher
sensitivity. For example, a short range sensor may be used to
detect a falling object and a long range sensor may be used to
detect the fill level of the container.
[0079] FIG. 7 illustrates an exemplary ultrasonic sensor
arrangement 4300 using two ultrasonic sensors, in one embodiment of
the invention.
[0080] A chute arrangement 4302 may be configured to release a
sample container 4304 into a waste container (e.g., the container
3016) positioned underneath a platform such as the deckbase 4008
through an opening 4310. The output robot 4002 may grasp the sample
container 4304 from a rack or any such sample handling system for
discarding it into the waste container through the chute
arrangement 4302. A horizontally oriented short range ultrasonic
sensor 4306 may be configured to detect falling of the sample
container 4304 into the waste container through the opening 4310. A
vertically oriented long range ultrasonic sensor 4308 may be
configured to detect the filling level of the waste container where
the sample container 4304 may be collected. For example, the long
range ultrasonic sensor 4308 may emit an ultrasonic beam towards
the waste container through an opening 4312 in the deckbase 4008 to
detect the fill level of the waste container. The ultrasonic beam
may get reflected from an object in the waste container or a
surface of the waste container and received by the long range
ultrasonic sensor 4308.
[0081] Having two separate transceivers provides high sensitivity
for individual functions, since in some cases, a single ultrasonic
sensor may not have suitable sensitivity for both long range and
short range functions. In one embodiment, the frequency used for
the short range ultrasonic sensor 2404 is in the range of, e.g.,
300-500 kHz, such as 400 kHz and the frequency used for the long
range ultrasonic sensor 2406 is in the range of, e.g., 100 to 300
kHz, such as 200 kHz.
[0082] FIG. 8 illustrates an exemplary sensor arrangement 4400
using one ultrasonic sensor and one optical sensor, in one
embodiment of the invention.
[0083] In some embodiments, an optical sensor 4402 may be used in
place of the ultrasonic sensor 4306 for short range detection of
the passing objects. The optical sensor 4402 may be mounted on the
deckbase 4008 near the chute arrangement 4302 such that an object
falling through the chute arrangement 4302 is in its line of sight.
The optical sensor 4402 may be configured to detect a change in
light when a sample container passes through the chute arrangement
4302. In some embodiments, the optical sensor 4402 may be
implemented as a light barrier or a light curtain comprising
multiple light barriers in parallel.
[0084] In some embodiments, a fill level of a waste container
(e.g., the container 4208) may be determined using the sensor unit.
As the objects are dropped in the waste container, due to uneven
geometries of the objects such as tubes, the container may not be
filled optimally and uneven stacking of the objects may lead to
heap building in the container. Even though a fill level detected
by the sensor unit may indicate a maximum fill level due to the
heap, a counter value that is used to keep track of dropped objects
may indicate that there may still be space left in the container.
Embodiments of the invention provide a method to reduce the effect
of a possible error made in counting and a possible error made in
measuring a fill level in the container by using both of the values
and weighting the values to determine a fill level. The values may
weighted differently as the objects fill the container. A method to
determine a fill level of a waste container for disposable objects,
such as test tubes, test tube caps, pipettes and capillaries is
described below with reference to FIG. 9 and FIGS. 10A-10C.
[0085] FIG. 9 illustrates a method 4500 for detecting the fill
level of a container in one embodiment of the invention.
[0086] In step 4502, a maximum fill level "H" of a container may be
determined. In one embodiment, the maximum fill level may be
determined by optimally (or non-optimally) filling a container to
its maximum capacity with objects with one or more known geometric
dimensions. Referring back to FIG. 4, a maximum fill level "H" of
the container 3016 may be determined based on the height 4012,
length 4014 and the width 4016 of the container 3016 as well as one
or more known geometric dimensions of the object. Note that based
on the packing density, the maximum fill level "H" may vary for
each type of object and for each type of container.
[0087] In step 4504, a passing object directed to the container is
detected using a sensor unit. Referring back to FIG. 6, the sensor
unit 4202 may be configured to detect the waste tube 4206 falling
into the container 4208. In one embodiment, the falling waste tube
4206 may be detected using a short range portion of the sensor unit
4202. In one embodiment, the falling waste tube 4206 may be
detected using a short range ultrasonic sensor 4306 or an optical
sensor 4402.
[0088] In step 4506, a waste counter value is incremented when the
passing object is detected. For example, a waste counter may be
initialized to zero in the memory 1110 of the processing unit 1106
to which the sensor unit 4202 may be communicatively coupled to. In
some embodiments, if there are already objects in the container,
the waste counter may be initialized to a value determined by the
processor based on a fill level of the container, as discussed
later. When the sensor unit 4202 detects the falling waste tube
4206, it generates an output that is transmitted to the processor
1108. The processor 1108 may communicate with the memory 1110 to
increment the waste counter based on the output. The waste counter
may represent a number of objects counted by the processor 1108.
However, there may be possible errors made during counting, e.g.,
the passing object may be counted more than once or not counted at
all.
[0089] In step 4508, a fill level H.sub.1 of the container is
measured using the sensor unit. Referring back to FIG. 6, in the
absence of the waste tube 4206, the beam 4210 gets reflected
downwards from the deflector surface 4204C of the bottom chute 4204
and further gets reflected from the surface of the waste tube 4206
deposited in the container 4208. Based on the amplitude of the
reflected signal, the sensor unit 4202 may generate an output that
is transmitted to the processor 1108. The processor 1108 may
determine an estimate for a number of objects in the container 4208
using a measurement based on the output. For example, the processor
1108 may determine an estimate for the number of objects in the
container for a given fill level by dividing a volume of the
container for the given fill level (e.g., (H.sub.1* cross sectional
area of the container) by a volume of the object. Embodiments of
the invention may provide an estimate of the fill level that may be
in between zero and full, e.g., quarter full, forty percent full,
half full, eighty percent full, etc. In one embodiment, the output
may be generated by the long range sensor 4308.
[0090] In step 4510, a value for a number of objects in the
container is determined by the processor based on the waste counter
value and the estimate for the number of objects in the container.
In one embodiment of the invention, the waste counter value and the
estimated number of objects are weighted using different weight
factors that may change based on the fill level of the
container.
[0091] As shown in FIG. 10A, a level 4604 represents maximum fill
level "H" of a waste container such as the container 4208. A level
4606 represents a (partial) fill level "H.sub.1" when a waste tube
4602 with at least one known geometric dimension is dropped in to
the empty waste container. In one embodiment, based on the maximum
fill level H, the fill level H.sub.1 and the information that at
least one waste tube 4602 with known geometric dimensions was
dropped in the container, the number of waste tubes that may
possibly additionally fit in the waste container can be calculated
by the processor 1108.
[0092] In step 4512, the value for the number of objects in the
container is corrected by the processor based on a weighted
average. Different objects may have varying dimensions (e.g., a
long side and a short side of the object). As a result of the
varying dimensions, the fill level H.sub.1 may differ significantly
from an ideal level for an optimized packing density of the objects
in the container. In one embodiment, for up to the maximum capacity
or a part of the maximum capacity (e.g., 1/10.sup.th of a maximum
capacity) for a container, the value for the number of objects in
the container may be further corrected as discussed below. In one
embodiment, the corrected value may be used by the output robot
4002 (as shown in FIG. 4) to determine how many more waste tubes
may be dropped (e.g., using the gripper unit 3002) into the
container 3016. Calculating a more realistic fill level of the
container may help to avoid surprises. For example, a waste
container may be full due to irregular stacking, even though a
waste counter may indicate that there is still space left in the
container to hold more objects.
[0093] In one embodiment, the number of objects in the container
may be represented as:
X=(N.sub.count*W.sub.count)+(N.sub.meas*W.sub.meas) Equation
(1)
where,
[0094] N.sub.count=number of counted objects,
[0095] W.sub.count=a first weight factor for counted objects,
[0096] N.sub.meas=number of objects estimated from measurement
and
[0097] W.sub.meas=a second weight factor for estimation from
measurement.
[0098] In one embodiment, N.sub.count is same as the waste counter
that may be incremented by the processor 1108 based on the output
from the sensor unit every time the presence of a passing object is
detected by the sensor unit. N.sub.meas may be calculated by the
processor 1108 based on the output from the sensor unit after
detecting a fill level H.sub.1 of the container. For example, for a
given fill level H.sub.1, the N.sub.meas may be determined by the
processor 1108 using the following equation:
N.sub.meas=(H.sub.1*cross sectional area (container))/volume of the
object. Equation (2)
[0099] The first weight factor W.sub.count and the second weight
factor W.sub.meas may be stored in the memory 1110 and can be
pre-determined by the processor 1108 based on the geometric
dimensions of the object and the container. In one embodiment, the
first weight factor W.sub.count and the second weight factor
W.sub.meas may be used as specified in Table 1 below:
TABLE-US-00001 Objects in the waste container W.sub.count
W.sub.meas 0-10 1 0 11-20 0.75 0.25 21-30 0.5 0.5 31-40 0.25 0.75
41-50 0.1 0.9 51+ 0 1
[0100] After reaching a predetermined count (e.g., approximately
1/10.sup.th of the given maximum capacity) for a container, the
estimation will be more and more precise and may not need to be
corrected any longer. As shown in the exemplary Table 1, when the
number of objects in a container is more than 50, no weight is
given to the number of counted objects (e.g., W.sub.count is zero).
The measured fill level becomes more accurate when more objects are
present in the container.
[0101] As illustrated in FIG. 10B, as additional objects are
dropped into the waste container, the fill level H.sub.1 increases
to a level 4608. As discussed above, the fill level measurement
value may have more weight than the counted value, as the fill
level measurement value may provide a more realistic estimate of
the number of objects in the container.
[0102] In step 4514, a number of objects further fitting in the
container may be determined by the processor. For example, a value
for a number of the objects that will additionally fit in the waste
container may be determined by the processor 1108 by subtracting
the number of objects in the container (from equation 1) from a
maximum number of objects that will fit in the container. In one
embodiment, the maximum number of objects that will fit in the
container may be determined by the processor 1108 by dividing a
volume of the container with a volume of the object for a given
packing density.
[0103] In step 4516, it is determined if the fill level H.sub.1
matches the maximum fill level H. If the fill level H.sub.1 is less
than the maximum fill level H, then additional passing objects may
be detected as shown in step 4504 since the container is not yet
full. As shown in FIG. 10C, if the fill level H.sub.1 matches the
maximum fill level H, the container may be full. In some
embodiments, instead of the maximum fill level H, the fill level
H.sub.1 may be compared with a predetermined value to generate
notification messages for different fill levels. Embodiments of the
invention provide a more realistic estimate of the true fill level
of the container so that an operator or a user can react in time
and can schedule maintenance actions accordingly.
[0104] In step 4518, if the fill level H.sub.1 matches the maximum
fill level H, a notification message may be generated. For example,
the notification message may include an alert message to empty the
container or replace a full container with an empty container.
However, in most cases, there may still be space in the waste
container to the left and right of the highest fill level due to
non-optimal deposit of the objects as they fall in the container.
In one embodiment, the processor 1108 may compare the fill level
H.sub.1 with the predetermined maximum fill level H based on the
output from the sensor unit and may generate the notification
message. In one embodiment, the notification message is provided to
the operator 1102 so that the container may be emptied or replaced
with another empty container. In some cases, it may be desirable to
have the container only partially full, e.g., eighty percent full
or half full. In embodiments of the invention, a notification
message may be generated for a partial fill level of the container.
In some embodiments, it may be advantageous to have a notification
for a partial fill level so that the upstream and downstream
modules may adjust their processes knowing how many more waste
objects can be filled in the container. In some embodiments, a
programmable predetermined level may be stored in the memory 1110
for generating the notification message, e.g., half fill level or
sixty percent fill level.
[0105] In one embodiment, handling of consumable objects (i.e.,
objects that are removed from a container to be consumed later)
will follow a reverse method as compared to the one discussed for
the disposable objects with reference to FIGS. 10A-10C. Handling of
the consumable objects is further discussed with reference to FIG.
11 and FIGS. 12A-12C.
[0106] FIG. 11 illustrates a method 4700 for detecting the fill
level of a container with consumable objects, in one embodiment of
the invention.
[0107] In step 4702, a maximum fill level "H" of a container is
determined. In the beginning, consumable objects may be filled in a
container, e.g., a consumable container 4800, as shown in FIG. 12A,
that may be part of the container unit 1128. In some embodiments,
the consumable objects may be fed into the consumable container
4800 using the feeder unit 1130, such as a bowl feeder or a step
feeder. In one embodiment, the consumable objects may be handled by
an object handling unit that may be part of the laboratory
automation system 1104.
[0108] As shown in FIG. 12A, a level detection sensor may be used
to detect whether the consumable objects were filled in the
consumable container 4800 up to a predetermined maximum level 4802
(e.g., H.sub.1=H). In one embodiment, the level detection sensor
may be part of the sensor unit 1120. For example, the ultrasonic
sensor 4308 may be used to detect the measured fill level H.sub.1,
as discussed with reference to FIGS. 10A-10C. Alternatively, a
light barrier located close to the top of the container (as shown
in FIG. 12A) may be used to detect the level of the filled objects.
If the desired maximum level is not reached, an alert message may
be generated by the processing unit coupled to the appropriate
sensor unit. For example, the alert message may be sent to the
operator 1102 so that the operator 1102 may fill the consumable
container to a defined or predetermined maximum level.
[0109] In step 4704, a consumable counter value is set to a defined
maximum value for a given container and the object. In one
embodiment, the maximum value of the consumable counter may be
determined by the processing unit 1106 based on the known
dimensions (e.g., width, height and length) of the consumable
container and one or more geometric dimensions of the object, as
discussed previously. For example, the maximum value may be
determined by dividing a volume of the container by a volume of the
object for a given packing density. In one embodiment, the
consumable counter value may be stored in the memory 1110 and
controlled by the processor 1108.
[0110] In step 4706, the counter value is decremented when a
consumable object is removed from the container. In some
embodiments, a gripper unit such as the gripper unit 3002 may be
used to remove an object from the consumable container 4800 and
transport it for further processing. For example, the gripper unit
3002 may be used to remove a cap from the container filled with
caps to transport it to a storage unit to close a sample tube for
storage or other purposes.
[0111] In step 4708, the fill level H.sub.1 of the container is
determined using a sensor unit. For example, the long range sensor
4308 may be used to detect the fill level of the consumable
container. As shown in FIG. 12B, the (partial) fill level H.sub.1
may be reduced to a level 4804 as objects are removed from the
consumable container 4800.
[0112] In step 4710, a value for number of consumable objects
remaining in the container is determined. In one embodiment, the
value for the number of objects still remaining in the container
may be determined based on the value of the consumable counter, and
the fill level H.sub.1 as measured by the sensor unit. However, due
to errors in counting, the irregular geometry of the consumable
objects and the varying packing density of the consumable objects
in the container, the value may need to be corrected as fewer
objects are remaining in the consumable container.
[0113] In step 4712, the value is corrected based on a weighted
average using equation (1) as discussed previously. For example,
more weight may be given to the measured fill level N.sub.meas in
the beginning (e.g., the container is almost full) when fewer
objects are removed from the container, whereas, more weight may be
given to the counter N.sub.count towards the end when there are
fewer objects left in the container (e.g., the container is almost
empty). Note that since N.sub.count is initialized to a maximum
counter value and is decremented every time an object is removed,
N.sub.count in equation 1 represents the number of objects
remaining in the container as counted by the processor.
[0114] In step 4714, it is determined if the fill level H.sub.1 is
zero. If the corrected value for the remaining consumable objects
in the container is zero, the container may be empty and may need
to be refilled again. As shown in FIG. 12C, a level 4806 represents
a zero fill level H.sub.1.
[0115] In step 4716, if the fill level is zero, a notification
message may be generated to refill the container. In one
embodiment, the processor 1108 may compare the fill level H.sub.1
to be zero based on the output from the sensor unit and generate
the notification message. In one embodiment, the notification
message is provided to the operator 1102 so that the container may
be refilled or replaced with another full container. In one
embodiment, a notification may be generated for a predetermined
fill level of the container. In some embodiments, it may be
advantageous to have a notification for a partial fill level so
that the upstream and downstream modules may adjust their processes
knowing how many more consumable objects are still remaining in the
container. Thus, an operator or a user may align refill exchange of
different consumables based on a realistic value of the objects
left in the container. For example, a notification message may be
generated when the container is almost empty (e.g., ninety five
percent) instead of completely empty. Therefore, by receiving a
notification message that a first consumable container may be
getting empty soon, a second consumable container may be prepared
without any downtime during the normal operation of the
subsystem.
[0116] In one embodiment, a plurality of containers may be used, as
discussed with reference to FIG. 13.
[0117] FIG. 13 illustrates an exemplary specimen output system
4900.
[0118] As illustrated in the figure, the deck 4010 may be coupled
to an output frame 4906 with a plurality of containers 4904 located
underneath the deck 4010. The plurality of containers 4904 may be
part of the container unit 1128 as shown in FIG. 2. In one
embodiment, discarded objects may be released in one of the
containers 4904. For example, the output robot 4002 may grip an
object using the gripper unit 3002 to drop objects in to one of the
plurality of containers 4904. In another embodiment, the containers
4904 may be filled with consumable objects that can be removed by
the output robot 4002 using the gripper unit 3002 and transported
to another unit for further processing. A system 4902 may be
configured to control the output robot 4002 to grip the objects for
disposal or pick up the consumable objects from the containers
4904. In one embodiment, a sensor unit such as the sensor unit 1120
may be configured to detect the fill level of the containers 4904
in collaboration with the processing unit 1106 that may be part of
the system 4902. As illustrated in the figure, one or more
containers 4904 may be easily removed or replaced without affecting
the whole arrangement.
[0119] FIG. 14 illustrates an arrangement 5000 for a bin frame 5006
with a door 5004.
[0120] A container 5002 may be positioned to collect an object
dropped through the chute arrangment 3012. The bottom part of the
chute arrangment 3012 may be mounted on the deckbase 4008. The
ultrasonic sensor 3018 may be configured to detect a passing object
through the chute arrangment 3012 into the waste container 5002.
The ultrasonic sensor 3018 may also be configured to detect the
fill level of the container 5002. An output robot (e.g., the output
robot 4002) may be configured to control a robotic gripper (i.e.,
gripper unit 3002) to grip an object (i.e., disposable specimen
container) from an object handling unit and drop it though the
chute arrangment 3012. Alternatively, an object may be removed from
the container 5002 filled with the consumable objects. In some
embodiments, after emptying the waste container or refilling the
consumable container, the filling level may need to be reset, as
discussed with reference to FIGS. 15 and 16.
[0121] In one embodiment, to reset the filling level after emptying
the disposable objects from a waste container following steps may
be performed, as discussed with reference to FIG. 15.
[0122] In step 5102, an operator removes the waste container to
empty out the disposable or waste objects. Referring back to FIG.
14, the operator may request opening of the door 5004 to access the
container 5002 to empty out the container. In one embodiment, the
arrangement 5000 may be coupled to the system 4902 that operates as
a controller. The system may notice the removal of the container
5002 or the opening of the door 5004. For example, opening of the
door 5004 may be detected using a light barrier and /or a door
status switch. The sub-system, e.g., the output robot 4002, may
temporarily be set on hold so that the container 5002 is not
accessed while the door 5004 is open and the container 5002 is
removed.
[0123] In step 5104, the operator may insert a waste container. For
example, the operator may insert the container 5002 back after
emptying it out or insert another empty container (e.g., in the
plurality of containers 4904 as shown in FIG. 13). In some
embodiments, the operator may close the door 5004. Closing of the
door may be detected by the system, e.g., using a light
barrier.
[0124] In step 5106, a sensor unit such as the sensor unit 4202
detects a fill level H.sub.1 as discussed previously with reference
to FIGS. 9, 10A-10C.
[0125] In step 5108, the fill level H.sub.1 is compared with the
maximum fill level H to determine if the container 5002 is
empty.
[0126] In step 5110, if the fill level H.sub.1 is equal to the
maximum fill level H, the waste counter is set to zero since the
container 5002 is empty.
[0127] In step 5112, if the fill level H.sub.1 is less than the
maximum fill level H, the waste counter may be set to a value
calculated using the latest average fill height of one piece of
waste object, the latest waste counter, the latest fill level
H.sub.1, and the difference between H and H.sub.1. In one
embodiment, the latest waste counter and the latest fill level
H.sub.1 may be equal to the last value of the waste counter and
H.sub.1 stored in the memory 1110 before the container 5002 was
removed. In some embodiments, the latest average fill height may
represent an average of various fill heights of the waste object
memorized by the system over the use of the system.
[0128] In step 5114, a status of the subsystem may be set to
"functional" again so that the container 5002 may be filled with
more waste objects.
[0129] In one embodiment, when two waste containers are used
instead of a single waste container, one of the two waste container
may be emptied without interrupting the work cycle of the
system.
[0130] In one embodiment, to reset the filling level after
refilling of the consumable objects into a container such as the
container 5002, following steps are performed, as discussed with
reference to FIG. 16.
[0131] To remove a consumable container for refilling by opening a
door, steps 5102 and 5104 are followed, as discussed with reference
to FIG. 15.
[0132] In step 5202, the operator fills in the consumable container
with the standard bulk cargo, e.g., push caps, secondary test
tubes, capillaries, etc. The operator may further insert the
container 5002 and close the door 5004. The system notices the
presence of the consumable container, for example, by detecting
opening of the door 5004 using a light barrier. In one embodiment,
the system may remember that the door was open before so closing
the door may indicate presence of the container 5002.
[0133] In step 5204, the system determines whether consumables were
filled in the container 5002 by means of a level detection sensor.
In one embodiment, an ultrasonic sensor may be used to detect the
fill level H.sub.1 as discussed with reference to FIG. 9. In
another embodiment, a simple light barrier may be used to detect
the level.
[0134] In step 5206, it is determined if the consumables were
filled to a defined maximum level.
[0135] In step 5208, an alert message may be sent to the operator
if the consumables were not filled to a desired maximum level.
[0136] In step 5210, a consumable counter may be set to a defined
maximum value.
[0137] In step 5212, status of the subsystem is set to "functional"
again so that the objects may be removed from the consumable
container as discussed with reference to FIGS. 11, 12A-12C.
[0138] In one embodiment, when two consumable containers are used
instead of a single consumable container, one of the two consumable
containers may be refilled without interrupting the work cycle of
the system.
[0139] As discussed above, embodiments of the invention provide
different fill levels of objects in the container. A notification
message may be sent to an operator for different fill levels so
that an appropriate action may be taken. Further, by making use of
more than one container, the containers may be replaced without
interrupting the work cycle of the system.
Computer Architecture
[0140] The various participants and elements described herein with
reference to the figures may operate one or more computer
apparatuses to facilitate the functions described herein. Any of
the elements in the above description, including any servers,
processors, or databases, may use any suitable number of subsystems
to facilitate the functions described herein, such as, e.g.,
functions for operating and/or controlling the functional units and
modules of the laboratory automation system, transportation
systems, the scheduler, the central controller, local controllers,
etc.
[0141] Examples of such subsystems or components are shown in FIG.
17. The subsystems shown in FIG. 17 are interconnected via a system
bus 10. Additional subsystems such as a printer 18, keyboard 26,
fixed disk 28 (or other memory comprising computer readable media),
monitor 22, which is coupled to display adapter 20, and others are
shown. Peripherals and input/output (I/O) devices, which couple to
I/O controller 12 (which can be a processor or other suitable
controller), can be connected to the computer system by any number
of means known in the art, such as serial port 24. For example,
serial port 24 or external interface 30 can be used to connect the
computer apparatus to a wide area network such as the Internet, a
mouse input device, or a scanner. The interconnection via system
bus allows the central processor 16 to communicate with each
subsystem and to control the execution of instructions from system
memory 14 or the fixed disk 28, as well as the exchange of
information between subsystems. The system memory 14 and/or the
fixed disk 28 may embody a computer readable medium.
[0142] It should be understood that the present technology as
described above can be implemented in the form of control logic
using computer software (stored in a tangible physical medium) in a
modular or integrated manner. Furthermore, the present technology
may be implemented in the form and/or combination of any image
processing. Based on the disclosure and teachings provided herein,
a person of ordinary skill in the art will know and appreciate
other ways and/or methods to implement the present technology using
hardware and a combination of hardware and software
[0143] Any of the software components or functions described in
this application, may be implemented as software code to be
executed by a processor using any suitable computer language such
as, for example, Java, C++ or Perl using, for example, conventional
or object-oriented techniques. The software code may be stored as a
series of instructions, or commands on a computer readable medium,
such as a random access memory (RAM), a read only memory (ROM), a
magnetic medium such as a hard-drive or a floppy disk, or an
optical medium such as a CD-ROM. Any such computer readable medium
may reside on or within a single computational apparatus, and may
be present on or within different computational apparatuses within
a system or network.
[0144] The above description is illustrative and is not
restrictive. Many variations of the technology will become apparent
to those skilled in the art upon review of the disclosure. The
scope of the technology should, therefore, be determined not with
reference to the above description, but instead should be
determined with reference to the pending claims along with their
full scope or equivalents.
[0145] One or more features from any embodiment may be combined
with one or more features of any other embodiment without departing
from the scope of the technology.
[0146] A recitation of "a", "an" or "the" is intended to mean "one
or more" unless specifically indicated to the contrary.
[0147] All patents, patent applications, publications, and
descriptions mentioned above are herein incorporated by reference
in their entirety for all purposes. None is admitted to be prior
art.
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