U.S. patent application number 14/435429 was filed with the patent office on 2015-10-22 for system and method including specimen gripper.
The applicant listed for this patent is Beckman Coulter, Inc.. Invention is credited to Santiago Allen, Lukas Bearden, Andreas Donner-Rehm, Mark Gross, Sophia Lauterbach, Martin Mueller, Edward A. Murashie, Stephan L. Otts, Stefan Rueckl, Allan Trochman.
Application Number | 20150298321 14/435429 |
Document ID | / |
Family ID | 49488684 |
Filed Date | 2015-10-22 |
United States Patent
Application |
20150298321 |
Kind Code |
A1 |
Gross; Mark ; et
al. |
October 22, 2015 |
SYSTEM AND METHOD INCLUDING SPECIMEN GRIPPER
Abstract
A system is disclosed. The system may include any suitable
combination of a sensing gripper unit, a gripper unit with
removable gripper fingers, an element or chute arrangement for
separating gripper fingers from an object being gripped, and a
detection system for detecting the level of objects in a container
such as a waste container. The system may be used in a laboratory
environment where objects such as specimen containers, caps, and
tubes are manipulated.
Inventors: |
Gross; Mark; (Laguna Niguel,
CA) ; Murashie; Edward A.; (Santa Ana, CA) ;
Allen; Santiago; (Yorba Linda, CA) ; Trochman;
Allan; (Corona, CA) ; Rueckl; Stefan;
(Garching bei Muenchen, DE) ; Otts; Stephan L.;
(Brownsburg, IN) ; Mueller; Martin;
(Schliersee-Neuhaus, DE) ; Lauterbach; Sophia;
(Buxheim, DE) ; Bearden; Lukas; (Indianapolis,
IN) ; Donner-Rehm; Andreas; (Stockdorf, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Beckman Coulter, Inc. |
Brea |
CA |
US |
|
|
Family ID: |
49488684 |
Appl. No.: |
14/435429 |
Filed: |
October 16, 2013 |
PCT Filed: |
October 16, 2013 |
PCT NO: |
PCT/US2013/065280 |
371 Date: |
April 13, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61714656 |
Oct 16, 2012 |
|
|
|
61790446 |
Mar 15, 2013 |
|
|
|
Current U.S.
Class: |
422/67 |
Current CPC
Class: |
G01S 15/04 20130101;
G01G 19/52 20130101; B65G 11/023 20130101; B25J 19/02 20130101;
G01N 35/00732 20130101; G01F 23/0061 20130101; G01B 7/02 20130101;
Y10T 29/49826 20150115; A61B 50/36 20160201; B25J 15/103 20130101;
G01N 35/0099 20130101; B65B 69/00 20130101; B25J 19/021 20130101;
B25J 15/0475 20130101; B25J 15/10 20130101; G01B 11/14 20130101;
G01F 23/2962 20130101 |
International
Class: |
B25J 15/10 20060101
B25J015/10; G01B 11/14 20060101 G01B011/14; G01B 7/02 20060101
G01B007/02; G01G 19/52 20060101 G01G019/52; G01N 35/00 20060101
G01N035/00; B25J 19/02 20060101 B25J019/02 |
Claims
1. A system for use in manipulating a specimen container, the
system comprising: a gripper unit for gripping the specimen
container, the gripper unit comprising a mounting structure, a
plurality of gripper fingers, a plurality of release elements
respectively coupling the gripper fingers in the plurality of
gripper fingers to the mounting structure, and a sensing device,
wherein the sensing device is configured to produce an output; and
a processor, wherein the processor is configured to determine a
dimension or a weight of the specimen container based on the
output.
2. The system of claim 1, wherein the sensing device is a sensing
potentiometer and the processor is configured to determine the
dimension of the specimen container.
3. The system of claim 1, wherein the sensing device is a load cell
and the processor is configured to determine the weight of the
specimen container.
4. The system of claim 1, wherein the plurality of gripper fingers
comprises a first gripper finger and a second gripper finger, and
wherein the system further comprises: an optical sensor system
including a light source communicatively coupled to the processor
and a light receiver communicatively coupled to the processor,
wherein the light source is coupled to the first gripper finger and
the light receiver is coupled to the second gripper finger.
5. The system of claim 4, wherein each release element comprises a
plate and a first sliding element coupled to the plate, wherein the
first sliding element is configured to pass through corresponding
cavities in the mounting structure and a gripper finger in the
plurality of gripper fingers.
6. The system of claim 5, further comprising: a second sliding
element coupled to the plate, wherein the second sliding element is
configured to enable the first sliding element to release the first
gripper finger when the second sliding element is pressed.
7. The system of claim 4, wherein the release element comprises a
first sliding element, and wherein the system further comprises: a
lever coupled to the mounting structure, and wherein the first
sliding element is configured to release the first gripper finger
when the lever is rotated in a first direction.
8. The system of any claim 1, wherein the system further comprises
a robot arm coupled to the gripper unit.
9. The system of claim 1, further comprising a chute arrangement
below the gripper unit.
10. The system of claim 9, further comprising a container
positioned under the chute arrangement.
11. The system of claim 1, further comprising at least one of a
decapper, an aliquoter, and an analyzer.
12. A system for manipulating objects, the system comprising: an
element comprising a tubular body comprising a central axial bore
running the length of said body with a first open end and a second
open end, the first end including two or more slots parallel to the
axis of the central axial bore; a container for holding objects
passing through the tubular body; a sensor unit configured to
generate a first output by detecting a fill level of the container,
and a processor configured to determine different levels of the
objects in the container as the objects fill the container or are
removed from the container based on at least the first output.
13. The system of claim 12, wherein the sensor unit is further
configured to generate a second output by detecting the presence of
an object passing into the container.
14. The system of claim 12 or claim 13, wherein the objects are
waste objects.
15. The system of claim 12, 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.
16. The system of claim 12, wherein the tubular body is part of a
chute arrangement, wherein the chute arrangement further comprises
an adapter unit coupled to the tubular body and a bottom chute
coupled to the adapter unit.
17. The system of claim 16 further comprising a platform, wherein
the chute arrangement is mounted to the platform.
18. The system of claim 12, wherein the tubular body has a square
shaped profile.
19. The system of any of claim 12, further comprising at least one
of a decapper, an analyzer, and an aliquoter.
20. The system of claim 12, further comprising a gripper unit
comprising a plurality of gripper fingers, wherein the gripper unit
is positioned above the tubular body.
21. The system of claim 12, further comprising: a gripper unit
comprising a mounting structure, a plurality of gripper fingers,
and a plurality of release elements respectively coupling the
gripper fingers in the plurality of gripper fingers to the mounting
structure, and wherein the processor is configured to determine a
dimension or a weight of the specimen container based on a second
output from the sensor unit, and wherein the gripper unit is
positioned above the element and the container.
22. The system of claim 12 further comprising: a gripper unit
comprising a mounting structure, a plurality of gripper fingers,
and a plurality of release elements respectively coupling the
gripper fingers in the plurality of gripper fingers to the mounting
structure.
23. The system of claim 12, further comprising: a gripper unit,
wherein the processor is configured to determine a dimension or a
weight of the specimen container based on a second output from the
sensor unit, and wherein the gripper unit is positioned above the
element and the container.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a non-provisional application of and
claims the benefit of priority of U.S. Provisional Application No.
61/790,446 filed on Mar. 15, 2013, and U.S. Provisional Application
No. 61/714,656 filed on Oct. 16, 2012, each of which is herein
incorporated by reference in its entirety for all purposes.
BACKGROUND
[0002] Conventional medical laboratory systems contain many
segments for processing patient samples, some of which are
automated and some of which require manual operation. Laboratory
systems have become more efficient due to those segments which have
become automated. However, there are still several components of
medical laboratory systems that can be automated in order to reduce
the time it takes for an analysis of a sample, the reliance on
human intervention, and the space required to house such systems. A
number of other improvements to conventional laboratory automation
systems are also desirable to improve the speed and reliability of
sample processing.
[0003] When automating sample tube manipulation processes (loading,
uploading devices, such as racks, instruments, conveyors) that are
normally performed by lab technicians, additional handling is
required to manage unknown variations in specimen containers. Such
variations may include sticky labels, various specimen container
diameters and heights, different cap styles, different cap colors,
etc. Such variations may result in the mishandling of specimen
containers, and may result in dropping, misplacing, or breaking the
specimen container. If this occurs, the processing speed and
processing quality can be affected. Further, such variations may be
hazardous to lab technicians, and can result in cross contamination
problems.
[0004] Other problems to be addressed relate to the speed of
processing in laboratory automation systems. It takes time for
automated systems to automatically characterize a specimen
container, e.g., a sample tube, if there are many types of specimen
containers in a laboratory. It also takes time for automated
systems to automatically characterize specimens inside of the
specimen containers if there are many types of specimens in a
laboratory. In automated specimen processing systems, the
throughput and speed of processing specimens is of primary
importance. Hence, there is a need for an improved automation
system for efficient management of the samples.
[0005] The use of robot arms in various areas of an automated
specimen processing system is known. A robotic arm unit can couple
to a gripper unit for gripping specimen containers using gripper
fingers. However, the gripper fingers of the gripper unit may not
be easily replaceable. For example, the gripper fingers may need to
be repaired due to wear or service.
[0006] In some cases, the gripper unit may need to perform
different functions using special gripper fingers customized for
each function. This may require frequently exchanging the gripper
fingers. For example, a gripper unit may be used as a tube gripper,
a recapper or a decapper in a laboratory automation system. It may
be desirable to change the gripper fingers in the gripper unit in
these situations.
[0007] In some cases, the entire gripper unit may need to be
demounted and remounted when the gripper fingers need to be
replaced or repaired. Additionally, mounting or demounting of the
fingers may require tools (e.g., a screw driver) and a certain
amount of time (e.g., for removal of the screws). This can lead to
sample processing delays. In such cases, it is desirable to have
the flexibility of quickly and easily replacing the gripper fingers
without requiring tools (e.g., a screwdriver) and without the need
to demount the entire gripper unit to exchange the fingers.
[0008] Also in automated specimen processing 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. However, in some cases, when
the gripper unit releases the waste object into the waste
container, the waste object may get stuck to the gripper unit and
may not separate from the gripper unit. For example, there may be
contamination on the outside surface of the waste object (e.g.,
from a prior aliquotting process) that may cause the object to
stick to the gripper fingers. In another example, a label on the
waste object may have come off or the glue from the label may have
caused the object to be stuck to the gripper fingers during the
waste disposal process. In such cases, human intervention may be
required to remove the waste object from the gripper unit. This
causes processing delays and requires a human being to correct the
problem. Furthermore, in this process, contamination may be
transported with the gripper fingers from one waste object to
another, thus further increasing the likelihood of spreading the
contamination.
[0009] In some cases, to minimize reliance on human intervention it
may be desirable to automatically detect when the waste container
is full. Level indicators for containers used in the medical
laboratory systems are known. 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.
[0010] 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
(or a human operator) need to be informed about how they should
operate to minimize downtime.
[0011] 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 aliquotting 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.
[0012] 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.
[0013] Embodiments of the invention address these and other
problems, individually and collectively.
BRIEF SUMMARY
[0014] Embodiments of the invention relate to systems and methods
for handling specimen containers.
[0015] One embodiment of the invention system for use in
manipulating a specimen container. The system includes a gripper
unit for gripping the specimen container. The gripper unit
comprises a mounting structure, a plurality of gripper fingers, a
plurality of release elements respectively coupling the gripper
fingers in the plurality of gripper fingers to the mounting
structure, and a sensing device, wherein the sensing device is
configured to produce an output. The system further includes a
processor, where the processor is configured to determine a
dimension or a weight of the specimen container based on the
output.
[0016] Another embodiment of the invention is directed to a system.
The system comprises an element comprising a tubular body
comprising a central axial bore running the length of said body
with a first open end and a second open end, the first end
including two or more slots parallel to the axis of the central
axial bore, a container for holding objects passing through the
tubular body, and a sensor unit configured to generate a first
output by detecting a fill level of the container. The system
further comprises a processor configured to determine different
levels of the objects in the container as the objects fill the
container or are removed from the container based on at least the
first output.
[0017] These and other embodiments of the technology are described
in further detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A further understanding of the nature and advantages of the
different embodiments may be realized by reference to the following
drawings.
[0019] FIG. 1 depicts an example of a Cartesian or gantry robot
with three independently moveable directions x-,y-, and z-.
[0020] FIG. 2 depicts a block diagram of a system in one
embodiment.
[0021] FIG. 3 depicts a gripper unit having sensing capabilities in
one embodiment.
[0022] FIG. 4. depicts a linear potentiometer and a fiber optic
system in one embodiment.
[0023] FIG. 5. shows an illustrative specimen carrier with cutouts
to allow optical access to a specimen container in one
embodiment.
[0024] FIG. 6. shows an illustrative fiber optic system having
multiple light sources in one embodiment.
[0025] FIG. 7 shows an exemplary laser emitting diode and
photodiode optical sensing system in one embodiment.
[0026] FIGS. 8A-8B illustrate a ball screw assembly for closing
gripper fingers of a gripper unit about a specimen container.
[0027] FIGS. 9A-9D show a worm drive assembly for closing gripper
fingers of a gripper unit about a specimen container.
[0028] FIGS. 10A-10D show a slotted disc assembly for closing
gripper fingers of a gripper unit.
[0029] FIGS. 11A-11B show a planetary gear assembly for closing
gripper fingers of the gripper unit.
[0030] FIGS. 11C-11D show sections of the specimen gripper viewed
from below planetary gear system.
[0031] FIG. 12 depicts a gripper unit that provides the capability
for quick exchange of gripper fingers, in one embodiment of the
invention.
[0032] FIGS. 13A-13C illustrate a release element in a first
embodiment of the invention.
[0033] FIGS. 14A-14B illustrate the gripper finger release assembly
in a closed position, in one embodiment of the invention.
[0034] FIG. 15 illustrates the gripper finger release assembly in
an open position, in one embodiment of the invention.
[0035] FIG. 16 illustrates a release element in a second embodiment
of the invention.
[0036] FIGS. 17A-17C illustrate a release element in a third
embodiment of the invention.
[0037] FIG. 18A illustrates a typical gripper unit operable to grip
a specimen container.
[0038] FIG. 18B illustrates a prior art robotic gripper that may be
used as a strip-off element for caps.
[0039] FIG. 19 illustrates certain elements of an exemplary system
comprising a chute arrangement, in one embodiment.
[0040] FIGS. 20A-20B illustrate close up views of a top chute
comprising an element, in one embodiment.
[0041] FIG. 21 illustrates a top chute arrangement with a square
shaped profile, in one embodiment of the invention.
[0042] FIG. 22 illustrates a close up view of the placement of a
chute arrangement, in one embodiment.
[0043] FIG. 23 illustrates overview of an exemplary specimen output
system in one embodiment.
[0044] FIG. 24 illustrates a flow chart for a method of releasing
an object through a chute arrangement, in one embodiment of the
invention.
[0045] FIG. 25 illustrates certain elements of an exemplary system
comprising a chute arrangement and a sensor unit, in one
embodiment.
[0046] FIG. 26 illustrates an exemplary ultrasonic sensor
arrangement using two ultrasonic sensors, in one embodiment.
[0047] FIG. 27 illustrates an exemplary sensor arrangement using
one ultrasonic sensor and one optical sensor, in one
embodiment.
[0048] FIG. 28 illustrates a method for detecting the fill level of
a container in one embodiment.
[0049] FIGS. 29A-29C illustrate various fill levels of a waste
container in one embodiment of the invention.
[0050] FIG. 30 illustrates a method for detecting the fill level of
a container with consumable objects, in one embodiment.
[0051] FIGS. 31A-31C illustrate various fill levels of a consumable
container in one embodiment of the invention.
[0052] FIG. 32 illustrates an exemplary specimen output system in
one embodiment of the invention.
[0053] FIG. 33 illustrates an arrangement for a bin frame with a
door in one embodiment of the invention.
[0054] FIG. 34 illustrates a method to reset a waste container in
one embodiment of the invention.
[0055] FIG. 35 illustrates a method to reset a consumable container
in one embodiment of the invention.
[0056] FIG. 36 depicts a block diagram of an exemplary computer
apparatus.
DETAILED DESCRIPTION
[0057] Embodiments of the present invention relate to a gripper
unit, which may be referred to as a smart gripper or a specimen
gripper. Some embodiments, as will be described in more detail
below, are advantageous because they provide systems for gathering
various data related to a specimen container, such as detection of
the presence of a specimen container within the gripper unit,
measurement of specimen container dimensions and weight, detection
of specimen container contents, specimen tube identification, etc.
Some or all of this information can be gathered during a specimen
container transport or manipulation process. Further, because the
gripper unit has the ability to characterize a specimen container
as well as the specimen inside of it, there is no need to provide
for separate characterization equipment, thereby reducing space
requirements and expense. One embodiment of the invention provides
an improved automated process by simultaneously performing multiple
measurements and analytical processes on the specimen container,
thereby providing for faster processing of the sample that resides
in the specimen container. In some embodiments, measurements of a
specimen container may be used to determine how many specimen
containers can fit in a container with known dimensions.
[0058] The specimen container may be a sample tube. A sample tube
may contain material for medical analysis, such as blood, serum,
plasma, etc. In some cases, the sample tube may need to be decapped
or recapped for storage, processing, discarding, etc. In some
cases, the sample tube may need to be discarded when the storage
time of the sample tube has expired or due to some other
reasons.
[0059] The gripper unit may be used in a medical laboratory system
for processing patient samples. The gripper unit may be equipped
with one or more means for detecting information about specimen
containers that it grips. 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, analyzer, output, sorting, recapping, and
secondary tube lift areas.
[0060] A gripper unit according to embodiments 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. In some embodiments,
a jaw may be coupled to one end (gripping end) of a 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.
[0061] A gripper unit may also be used as a decapper for removing
caps from the specimen containers or as a recapper for attaching
caps to the specimen containers. In such cases, the gripper unit
may require specialized gripper fingers to perform different
functions. However, the gripper fingers of a gripper unit may not
be easily replaceable. Further, in some case, exchanging the
gripper fingers may involve loose parts, such as screws or pins.
Additionally, mounting or demounting of the fingers may require
tools (e.g., a screw driver) and a certain amount of time (e.g.,
for removal of the screws). In order to demount the fingers, it may
be necessary to destroy the parts, such as pins, that couple the
gripper fingers to a body of the gripper unit. Further, in some
cases, screws can fall into the system during removal of the
fingers. Such problems can lead to sample processing delays since
the gripper unit may not be usable during that period. One
embodiment of the invention includes devices to enable replacement
of gripper fingers without the need for tools and without the need
to demount the entire gripper unit to exchange gripper fingers.
[0062] Specimen containers such as sample tubes may be used to hold
specimens for medical analysis. In some cases, a specimen container
may need to be discarded after the specimen has been processed or
the storage time of the specimen container has expired. A gripper
unit may also be used to grip and transport waste specimen
containers to discard them into a waste container. However, in some
cases, when the gripper unit releases the specimen container into
the waste container, the specimen container may get stuck to the
gripper unit and may not be automatically released. For example,
the outside surface of the specimen container may be sticky due to
contamination, glue from a label stuck to the specimen container,
etc. In such cases, human intervention may be required to remove
the specimen container to minimize the processing delays.
Furthermore, contamination may be transported with the gripper
fingers from one specimen container to another, thus further
spreading the contamination. One embodiment of the invention are
directed to systems and methods including a chute arrangement
comprising an element implementing a strip-off feature that is used
to restrain an object such as, a test tube, a cap, etc. gripped by
the gripper fingers of a gripper unit, as the object is released by
the gripper fingers.
[0063] As the waste objects are released in a waste container, the
waste container may become full and may need to be emptied or
replaced with another container. Similarly, a container with
consumable objects may need to be refilled again when all the
consumable objects have been removed. Another embodiment of the
invention provides systems and methods to detect different fill
levels of objects in a container using a sensor unit as the objects
fill the container or are removed from the container. As the
objects are dropped in the waste container, due to uneven
geometries of the objects such as tubes, the container may not be
optimally filled 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 the dropped
objects may indicate that there may still be space left in the
container. Embodiments of the invention provide for 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
more realistic fill level. These values may weighted differently as
the objects fill the container. Thus, an operator or a user can
react in time and can schedule maintenance actions accordingly.
[0064] Prior to discussing embodiments of the invention,
description of some terms may be helpful in understanding
embodiments of the invention.
[0065] A "cavity" may include a hole or an opening through which an
object can pass through. In one embodiment, a cavity may be a hole
in a gripper finger through which a sliding element can pass
through for coupling the gripper finger to a gripper unit. The
dimensions of the cavity may be such so as to allow the sliding
element to easily slide through the cavity. In one embodiment, a
cavity may have a circular cross-section with a diameter slightly
bigger than the diameter of the sliding element (e.g., if the
sliding element is cylindrical in shape with a circular
cross-section). In one embodiment, the length of the cavity may
depend upon the width of the gripper finger where the cavity is
located. In embodiments of the invention, a cavity may be located
at or near the non-gripping end of the gripper finger, where the
gripper finger is coupled to the gripper unit.
[0066] In some embodiments, a cavity may also be a hole in a
mounting structure of the gripper unit. In one embodiment, there
may be plurality of cavities in the mounting structure for allowing
the coupling of the plurality of gripper fingers to the body of the
gripper unit. In some embodiments, a gripper finger release
assembly may couple to the mounting structure of the gripper unit
via two cavities, where each cavity may have different
dimensions.
[0067] An element according to an embodiment of the invention may
include a hollow tubular body comprising a first end and a second
end. The first end of the body may include a plurality of slots to
enable a plurality of gripper fingers gripping an object surrounded
by the body of the element to separate from the object through the
plurality of slots. The body of the element may have a square
profile, a cylindrical profile or any suitable profile, which can
accommodate an object that needs to be discarded, e.g., a specimen
container, a cap, etc. The first end of the body may be open and
integrated with an open end of each slot in a plurality of slots.
In some embodiments, a second end of the body may be coupled to
another device or unit. An element may also operate as a chute for
directing a specimen container towards a container. In embodiments
of the invention, the terms "stripping element", "strip-off
element" and "top chute" may be used interchangeably.
[0068] A "central axial bore" may include an opening along an axis
of a body. A central axial bore may be defined by a body with any
suitable shape and may be of any suitable length. For example, the
body defining the central axial bore may have a volume slightly
larger than the volume of an object with any suitable profile
(square, cylindrical, etc.) and may have a length slightly longer
than the object.
[0069] In one embodiment of the invention, an element body
comprising a central axial bore may be configured to surround an
object, e.g., a specimen container, within the central axial bore.
For example, if the specimen container is a sample tube, the
diameter of the bore may be large enough to accommodate a sample
tube held by a plurality of gripper fingers within the bore. In
embodiments of the invention, the central axial bore may include
any hollow cylindrical forms including square shaped forms.
[0070] A "slot" may include a narrow opening. A slot may have any
suitable length. In some embodiments, a slot may be sized so that
it is slightly wider than a gripper finger or a jaw attached to the
gripper finger. The slot may also have any suitable shape including
a rectangular shape. In one embodiment, a slot may be elongated,
arranged axially parallel to an axis of the element body and may be
open at the first end of the element.
[0071] In embodiments of the invention, a plurality of slots may be
integrated in the body of an element. The number of slots in the
plurality of slots may be equal to the number of gripper fingers
gripping an object surrounded by the body of the element. There may
be two, three, four or a suitable number of slots in the plurality
of slots to allow each gripper finger in the plurality of gripper
fingers to grip the object through a slot. In one embodiment,
plurality of slots includes at least two slots. Each of the
plurality of slots may have a rectangular shape with a length
smaller than a length of the body of the element and a width large
enough to allow a gripper finger to move easily in and out of the
slot. In one embodiment, the length of the element may be five
inches, whereas, the length of each slot in the plurality of slots
may be three inches, and the width of each slot may be one half
inch of less in some embodiments.
[0072] 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.
[0073] A "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 to be contained by the container.
[0074] A "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.
[0075] A "sensor unit" may include one or more sensors or sensing
devices 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 the 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.
[0076] 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.
[0077] 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.
[0078] 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. One embodiment of the invention provides an assembly to
replace the gripper fingers 1008, 1010 without demounting or
mounting the gripper unit 1004 and without the need of tools. The
robot arm 1002 may be part of a laboratory automation system as
further described with reference to FIG. 2.
[0079] 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, packed red blood cells,
etc.). In the exemplary embodiment, the laboratory automation
system 1104 may include the robot arm 1002, a processing unit 1106,
a gripper unit 1114, a sensor unit 1120, a chute arrangement 1122,
a container unit 1128 and a feeder unit 1130. 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 an input module, a distribution area, a
centrifuge, a decapper, a serum indices measurement device, an
analyzer, a storage module, an aliquotter and an output/sorter in
some embodiments of the invention. Further, the robot arm 1002,
gripper unit 1114 and the sensor unit 1120 may be communicatively
coupled to the processing unit 1106. The robot arm 1002 may be part
of the gantry robot 1000.
[0080] The processing unit 1106 may include a processor 1108, a
memory 1110, and an analog to digital converter (ADC) 1112. The
processor 1108 may further include a programmable logic controller
(PLC) 1108A. In one embodiment, the ADC 1112 can be part of the PLC
1108A. 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.
[0081] 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 of the invention, the
processor 1108 may be configured to receive various outputs
provided by different sensors that may be associated with the
sensor unit 1120 and/or the gripper unit 1114 and communicatively
coupled to the processor 1108. For example, in some embodiments of
the invention, the sensor unit 1120 may include a sensing
potentiometer may be communicatively coupled to the processor 1108.
The potentiometer can be configured to produce an output based on a
distance between the two gripper fingers in the plurality of
gripper fingers when a specimen container is gripped in the
plurality of gripper fingers. The processor 1108 can be configured
to determine a dimension (e.g., a diameter) of the specimen
container based on the output. In other embodiments, a load cell in
the gripper unit may be communicatively coupled to the processor
1108. The processor 1108 can be configured to determine a weight of
the specimen container based on an output of the load cell. In some
embodiments, a light source coupled to a first gripper finger in a
plurality of gripper fingers gripping a specimen container and a
light source coupled to a second gripper finger in a plurality of
gripper fingers gripping the specimen container may be coupled to
the processor 1108. The processor 1108 can be configured to
determine information (e.g., presence, length, liquid level and
characteristics, etc.) associated with the specimen container
gripped by the plurality of gripper fingers. The processor 1108 can
also be configured to enable the robot arm 1002 to move the gripper
unit 1114 to function as a tube gripper, a recapper or a decapper.
In some embodiments, the processor 1108 can also be configured to
disable movement of the gripper unit 1114 by the robot arm 1002
when the gripper fingers need to be exchanged. In some embodiments,
the processor 1108 can be configured to determine different fill
levels of objects in a container (e.g., a part of the container
unit 1128) based on an output from one or more sensors in the
sensor unit 1120, configured to detect the fill level of the
container, and some pre-determined parameters, as the objects fill
the container or are removed from the container.
[0082] 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. In some embodiments, the processor 1108
may be part of a computer system as described with reference to
FIG. 36.
[0083] The memory 1110 may also store other information. In some
embodiments, such information may include identification data for
various specimens and specimen containers, gripper unit weight
information, data correlating potentiometer outputs to specimen
dimensions, data correlating load sensor outputs to specific
weights, data correlating characteristics of different light
signals to different container types and/or specimen types. By
identifying the liquid characteristics of one or more liquid
samples within the specimen container, the samples may be processed
differently. For example, a specimen container with a first
characteristics of one or more liquid samples within the specimen
container could be directed to a storage unit by a gripper unit
(coupled to a robotic arm), whereas, a specimen container with a
second characteristics of one or more liquid samples within the
specimen container could be directed to a centrifuge.
[0084] In some embodiments, the memory 1110 may also store data
related to different types of gripper fingers that may be coupled
to the gripper unit for performing different functionalities. For
example, when the gripper unit is used as a tube gripper, a first
set of gripper fingers may be used, whereas, when the gripper unit
is used as a decapper, a second set of gripper fingers may be used,
and, when the gripper unit is used as a recapper, a third set of
gripper fingers may be used, etc. In some embodiments, information
stored in the memory 1110 may also include data related to
different types of release elements that may be used for exchange
of gripper fingers.
[0085] The memory 1110 may store information relating to types and
geometric dimensions of various objects (e.g., caps, sample tubes,
secondary tubes, capillaries, pipettes, etc.) handled by the
laboratory automation system 1104. In some embodiments, this
information may be used by the processor 1108 to determine the
number of objects that may fit in a container given a fill capacity
of the container. In some embodiments, 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
remaining in a container.
[0086] The PLC 1108A may be configured to receive, store, analyze
and/or process data from the ADC 1112, the gripper unit 1114 or any
other unit interfacing with the gripper unit 1114. In some
embodiments, the PLC 1108A may include one or more of a
microcontroller, a digital to analog converter, an analog to
digital converter, an amplifier, timer, memory, power circuit or
any other support logic.
[0087] The ADC 1112 may be configured to receive an analog input
(voltage or current) and convert it to a digital value
corresponding to the magnitude of the analog input. The ADC 1112
may be implemented as a delta sigma converter, a high-speed
pipeline converter, a successive approximation register or any such
suitable type of converter.
[0088] 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. The
gripper unit 1114 may be coupled to the sensor unit 1120 and the
robot arm 1002. In some embodiments, the gripper fingers 1118 may
be removably coupled to the body 1116 so that one or more of the
gripper fingers may be replaced with another gripper finger. It is
understood that the gripper unit 1114 may also include or interface
with other units to enable the gripper unit perform the intended
function.
[0089] 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 one embodiment, the top chute 1124 may be in the form of
an element implementing a strip-off feature to restrain an object
gripped by the gripper fingers of a gripper unit as the object is
released by the gripper fingers. 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 may include only a single
chute through which objects such as test tubes, caps, capillaries,
pipettes, etc. may be dropped into a container.
[0090] 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 pipettes, 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.
[0091] 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, pipettes, etc. to a
container.
[0092] The sensor unit 1120 may include plurality of sensors,
wherein one or more sensors of the plurality of sensors may be
coupled to the gripper unit 1114. The sensor unit 1120 may be
configured to detect/provide information associated with the
specimen containers that may be used by the processing unit 1106
for efficient processing of samples. In some embodiments, the
information provided by various sensors may be used to determine
dimensions of the specimen container (e.g., diameter, length,
etc.), the cap color, level and characteristics of one or more
samples contained in the specimen container, etc. For example, the
sensor unit 1120 may include a sensing potentiometer for
determining a dimension (e.g., a diameter) of the specimen
container, and/or an optical/fiber optic sensor system for
determining a presence of the specimen container and/or liquid
characteristic/level, a length of the specimen container, etc. In
one embodiment, the gripper unit 1114 may be configured to work in
conjunction with a load cell to determine a weight of the specimen
container.
[0093] In one embodiment, one or more of the sensors in 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 an
object passing 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. A
number of such waste containers and/or consumable containers may be
part of the container unit 1128. In some embodiments, the sensor
unit 1120 may comprise a short range sensor such as an ultrasonic
sensor or an optical sensor to detect a falling object through the
chute arrangement 1122 and a long range sensor such as an
ultrasonic sensor to detect a fill level of the container.
[0094] The gripper fingers 1118 may include a plurality of gripper
fingers including a first gripper finger, a second gripper finger,
etc. The plurality of gripper fingers may comprise two or more
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.
[0095] In one embodiment, the gripper fingers 1118 and the sensor
unit 1120 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, while the sensor unit 1120 may be
stationary and fixed to and/or enclosed by 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. In some embodiments, the gripper
fingers 1118 may be coupled to the one or more mounting structures
through a release element such that one or more gripper fingers may
be replaced (e.g., for service or repair) without
demounting/mounting the gripper unit 1114. In one embodiment, one
or more sensors of the sensor unit 1120 may be coupled to the one
or more mounting structures. The body 1116 may be made of any
suitable material including metal or plastic. In some embodiments,
the body 1116 may include or be coupled to a gripper finger release
assembly comprising one or more release elements. This release
assembly allows one to easily and quickly exchange gripper fingers
without using tools.
[0096] In some embodiments, the body 1116 may include or couple to
one or more assembly units that allow for opening and closing of
the gripper fingers 1118. For example, the body 1116 may include a
worm drive assembly, a slotted disc assembly or a planetary gear
assembly for closing or opening the plurality of gripper fingers
about the specimen container. These assembly units are described in
further detail below.
[0097] In one embodiment, the gripper unit 1114 may grip an object
using the gripper fingers 1118 from a carrier or a container
holding a plurality of such objects. One or more sensors coupled to
the gripper unit 1114 may determine various characteristics
associated with the object (e.g., dimensions, weight, presence,
type, etc.) while the object is gripped by the gripper fingers
1118. In some embodiments, if the object contains a specimen,
specimen characteristics may also be determined. If the object is a
waste object and needs to be disposed, the gripper unit 1114 may
drop the object through the chute arrangement 1122 into one of the
waste containers in the container unit 1128. The sensor unit 1120
may detect passing of the object through the chute arrangement 1122
into the container and also detect a fill level of the container as
the objects fill the container. Alternatively, if the object is a
consumable object, the gripper unit 1114 may grip an object from a
consumable container and transport the gripped object to another
module for further processing. The processor 1108 may determine a
fill level of the container as the objects fill the container or
are removed from the container based on an output from the sensor
unit 1120 and some other parameters associated with the object and
the container. In some embodiments, one or more of the gripper
fingers 1118 may be replaced or removed for repair or service, etc.
without demounting the entire gripper unit 1114.
I. Sensing Specimen Gripper
[0098] One embodiment of the invention provides systems and methods
for gathering data related to a specimen container. For example,
data such as the presence of a specimen container within a gripper
unit, the measurement of specimen container dimensions and weight,
detection of specimen container contents, specimen tube
identification, etc. may be gathered. Embodiments provide an
improved automated process by simultaneously performing multiple
measurements and analytical processes on the specimen container,
thereby providing for faster processing of the sample that resides
in the specimen container.
[0099] FIG. 3 depicts a gripper unit 1200 having sensing
capabilities in one embodiment.
[0100] The gripper unit 1200 may include a sensing potentiometer
1202, first and second mounting structures 1204 and 1206, gripper
fingers 1208 and 1210, an optical sensor unit 1218, and a pneumatic
actuator 1224. A load sensor unit 1226 may be used in conjunction
with the gripper unit 1200. The gripper unit 1200 may be coupled to
the robot arm 1002 (in FIG. 1) and can grip a specimen container
1212 using the gripper fingers 1208 and 1210.
[0101] In some embodiments, the specimen container 1212 is gripped
by replaceable jaws 1214 and 1216 coupled to the gripper fingers
1208 and 1210, respectively. The replaceable jaws 1214, 1216 can
have any suitable shape or size, and are desirable since they can
be replaced to accommodate sample tubes of different shapes. For
example, the jaws 1214, 1216 may have facing convex surfaces to
accommodate the convex surface of the specimen container 1212.
Thus, in some embodiments, surfaces of the jaws 1214, 1216 may be
cooperatively configured with respect to a surface of the specimen
container 1212. In embodiments of the invention, the jaws 1214,
1216 can also be easily replaced when they are worn or defective.
In some embodiments, the replaceable jaws can be made of any
suitable material including a soft or hard plastic material. In
some embodiments, the jaws 1214, 1216 may be integrally formed with
the gripper fingers 1208, 1210, thus forming unitary
structures.
[0102] In one embodiment, the specimen container 1212 may have a
cylindrical shape with a circular cross-section. In one embodiment,
a diameter of the specimen container 1212 can be interpreted as a
width of the specimen container 1212 (i.e., as measured by an outer
diameter of the specimen container 1212) or a length of a straight
line passing through the center of the specimen container 1212 and
connecting with two points on the surface of the specimen container
1212.
[0103] In one embodiment, the specimen container 1212 may have a
cap 1220. The cap 1220 may have a cylindrical shape with a circular
cross-section and a diameter slightly larger than the diameter of
the specimen container 1212 and a length relatively shorter than
the length of the specimen container 1212. It will be understood
that other shapes and sizes of the specimen container 1212 and the
cap 1220 are possible that can be gripped by the gripper unit 1200.
The cap 1220 may have a specific color such as red, green, or
blue.
[0104] The mounting structures 1204 and 1206 may be part of a body
1230 of the gripper unit 1200. In one embodiment, the mounting
structures 1204 and 1206 have a similar shape and each mounting
structure 1204, 1206 is coupled to a corresponding gripper finger
1208, 1210. For example, the mounting structure 1204 is coupled to
the gripper finger 1208 and the mounting structure 1206 is coupled
to the gripper finger 1210. In one embodiment, each of the mounting
structures 1204 and 1206 comprise a rectangular structure with a
certain thickness (e.g., quarter inch) and means for coupling to
various sensor units and the gripper fingers.
[0105] In one embodiment, the sensing potentiometer 1202 is
disposed between the first and second mounting structures 1204 and
1206. In one embodiment, the sensing potentiometer 1202 includes
housing with a rectangular cross-section and support for coupling
to the mounting structures 1204 and 1206. The sensing potentiometer
1202 may include a resistive element with varying resistance. In
one embodiment, the sensing potentiometer 1202 is a linear
potentiometer which provides a resistance value that changes
proportionally to the distance between the gripper fingers 1208 and
1210. The sensing potentiometer 1202 may be configured to produce
an output based on a distance between the gripper fingers 1208 and
1210. In one embodiment, the output is a voltage value
corresponding to the resistance value of the linear potentiometer
1202 that may be provided to the PLC 1108A. When a specimen
container such as the specimen container 1212 is gripped by the
gripper fingers 1208 and 1210, a diameter of the specimen container
1212 can be determined based on a signal corresponding to the
resistance value of the linear potentiometer 1202. The gripper
fingers 1208, 1210 can move inwardly towards each other when they
are used to secure the specimen container 1212.
[0106] In one embodiment, the pneumatic actuator 1224 is disposed
between the first and second mounting structures 1204 and 1206. In
one embodiment, the pneumatic actuator 1224 includes housing with a
rectangular cross-section and support means for coupling to the
mounting structures 1204 and 1206. In one embodiment, the pneumatic
actuator 1224 is configured to control the movement of the gripper
fingers 1208, 1210. In some embodiments, the positions of gripper
fingers 1208 and 1210 can be determined based on the control signal
to the pneumatic actuator 1224. In one embodiment, the diameter of
the specimen container 1212 can be determined based on a signal
sent to (or received from) the pneumatic actuator 1224 indicating
the position of one or both gripper fingers 1208, 1210. In some
embodiments, the pneumatic actuator 1224 may consist of a piston, a
cylinder and valves or ports.
[0107] In one embodiment, the optical sensor unit 1218 may be
arranged between the first and second mounting structures 1204 and
1206 using support means. The optical sensor unit 1218 may include
one or more optical sensors. For example, the gripper unit 1200 may
have an optical sensor (e.g. OPB732WZ by Optek) including a light
emitting diode and a phototransistor. The light emitting diode can
transmit light toward the cap 1220 of the specimen container 1212
and the phototransistor can sense light reflected from the cap
1220. The output current of the phototransistor can be proportional
to the amount of light reflected, providing an indication of the
distance between the phototransistor of the optical sensor 1218 and
the top of the cap 1220.
[0108] The gripper unit 1200 can be configured to pick up the
specimen container 1212 at a uniform distance from the bottom of
the specimen container 1212, allowing the specimen container length
from the bottom of the tube 1212 to the top of the cap 1220 to be
determined based on the distance between the optical sensor 1218
and the cap 1220. For example, a voltage corresponding to the
current output of the phototransistor can be received by the PLC
1108A and can be used to determine the distance between the optical
sensor 1218 and the cap 1220 and corresponding length of the
specimen container 1212. In some cases, the length of the specimen
container 1212 may be used to identify the type of sample contained
in the specimen container 1212 if samples of the same type are in
samples tubes with similar lengths. In one embodiment, a camera
controller 1222 can be used to provide instructions to and receive
data from the optical sensor 1218. The light reflected from the cap
1220 may be used for other purposes as well. For example, in some
embodiments, the color of the cap 1220 can be determined thereby
identifying the particular specimen container associated with the
cap.
[0109] Some embodiments of the invention are directed to methods.
Such methods include transmitting light generated by a light
emitting diode directed towards a cap of the specimen container
(e.g., cap 1220 of the specimen container 1212), and receiving
light reflected from a surface of the cap of the specimen container
by a photo transistor communicatively coupled to a processor (e.g.,
processor 1108). The photo transistor is configured to generate a
signal corresponding to a quantity of reflected light from the
surface of the cap of the specimen container.
[0110] In some embodiments, the optical sensor 1218 of the gripper
unit 1200 is a camera, such as a CMOS color camera (e.g., OV7680
Color CMOS VGA by OmniVision). An optical sensor that is a camera
can provide information about the specimen container, such as a cap
color. The camera can also provide information about a rack of
specimen tubes (e.g., sample tubes), such as filled and unfilled
rack positions.
[0111] A load sensor unit 1226 may be used in conjunction with
gripper unit 1200. The load sensor unit 1226 may comprise a load
cell 1228 that may operate as a transducer to convert a force into
an electrical signal. In one embodiment, the load sensor unit 1226
may be arranged on top of the gripper unit 1200. The load cell 1228
can generate a signal that can be used to determine a weight, such
as a combined weight of the specimen container 1212 and the gripper
unit 1200. For example, an output of the load cell 1228 may be
provided to the PLC 1108A via the ADC 1112. In one embodiment, the
output is on the order of a few millivolts and may require
amplification by an amplifier. Some types of load cells may include
hydraulic load cells, pneumatic load cells, or strain gauge load
cells. The PLC 1108A can further process the output of the load
cell 1228 to determine a weight of the specimen container 1212. The
load cell 1228 may be, e.g. an FS20 load cell by Measurement
Specialties. A known weight of the gripper unit 1200 can be
subtracted from the combined weight to determine the weight of the
specimen container 1212. This weight can be used, for example, to
aid in balancing the centrifuge buckets in a centrifuge.
[0112] Some embodiments of the invention are directed to methods.
Such methods may include gripping the specimen container using a
plurality of gripper fingers, and generating, by a load cell, an
output. In one embodiment, the gripped specimen container is
weighted in a lifted or elevated position. A processor
communicatively coupled to the load cell may determine a weight of
the specimen container based on the output.
[0113] Certain components of the gripper unit 1200 described with
reference to FIG. 3 can be further understood as described with
reference to the system diagram of FIG. 4. In FIG. 4, as in FIG. 3,
the gripper fingers 1208 and 1210 of the gripper unit are
configured to grip a specimen container such as the specimen
container 1212. The gripper unit 1200 may comprise a linear
potentiometer 1310 (e.g., corresponding to the linear potentiometer
1202 of FIG. 3) that may be used to determine a weight of the
specimen container 1212. The gripper unit 1200 may also include one
or more optical sensor systems for determining information related
to the specimen container 1212 and/or the contents of the specimen
container 1212.
[0114] The linear potentiometer 1310 may include mechanical
components 1316 and 1318 coupled to the gripper fingers 1208 and
1210, respectively. The linear potentiometer 1310 may include a
resistor 1312 (e.g., 5 K.OMEGA.) and a resistor 1314 (e.g., 5
K.OMEGA.). In one embodiment, a power supply 1302 may represent a
positive supply voltage (e.g., VCC) and a power supply 1304 may
represent a negative supply voltage (e.g., GND). As gripper fingers
1208 and 1210 slide inward to grip the specimen container 1212, the
mechanical components 1316 and 1318 move relative to one another,
changing the resistance value of the linear potentiometer 1310. A
signal having a voltage value proportional to the resistance value
of the linear potentiometer 1310 can be received by the PLC 1108A
via the ADC 1112. The diameter of the specimen container 1212 can
be determined based on the voltage value. It will be recognized
that other sensing devices can be used in lieu of a linear
potentiometer to determine the diameter of a specimen
container.
[0115] Voltages corresponding to resistance values of the linear
potentiometer 1310 can be calibrated in association with positions
of the gripper fingers 1208 and 1210 (e.g., at full open, full
close, and 1-100 intermediate positions, such as two to thirty
intermediate positions, e.g. ten positions). In this manner,
nominal voltage ranges can be associated with various tube
diameters as well as full open, full close, and/or "illegal"
conditions. Illegal conditions may indicate an error state. For
example, if the gripper unit was commanded to grip a specimen
container and a detected voltage (associated with the linear
potentiometer 1310 and/or pneumatic actuator 1224) indicates a full
closed condition, an error has occurred because the closed
condition indicates that no specimen container was gripped. In
another example, if the gripper unit was commanded to grip the
specimen container and a detected voltage indicates a full open
condition, an error has occurred because the gripper fingers 1208
and 1210 have not closed on a specimen container, which could
indicate an obstruction or a binding in the gripper unit.
[0116] The configuration of one or more sensors in association with
the gripper unit 1200 allows development of truth tables. The truth
tables may associate various conditions, such as full open, full
closed, and diameter of tube gripped, with values corresponding to
distances between the gripper fingers 1208 and 1210. An illegal
condition may occur when a determined distance between the gripper
fingers 1208 and 1210 does not match an acceptable value for the
current state of the gripper unit. For example, if the gripper unit
has been commanded to grip a tube but a diameter determined by the
linear potentiometer 1310 for the tube is not an accepted value for
tube diameter, an illegal condition may occur. In another example,
if a gripper is at a full open position as detected by the linear
potentiometer 1310 and a presence sensor indicates the presence of
a tube, a truth table may associate this combination of conditions
with a potential "dangling tube" condition. An alert could be
generated based on the dangling tube condition by the PLC 1108A
that may be provided to the operator 1102.
[0117] Some embodiments of the invention utilizing the
potentiometer may also include methods. Such methods may comprise
gripping the specimen container using a plurality of gripper
fingers, and then generating, by a sensing potentiometer, an output
based on a distance between two gripper fingers in the plurality of
gripper fingers. A processor (e.g., processor 1108) coupled to the
sensing potentiometer may determine a dimension such as a diameter
of the specimen container based on the output.
[0118] In some embodiments, an optical sensor system may be used to
detect whether a specimen container is present between the gripper
fingers. In another example, an optical sensor system can be used
to determine one or more liquid levels of sample material (e.g.,
serum, plasma, gel, packed red blood cells etc.) within the
specimen container. Where multiple liquid types are present in a
specimen container, the locations of interfaces between different
liquid types can be determined. An optical sensor system can be
used to determine a serum index. The liquid characteristics of one
or more liquids within the specimen container can also be
determined based on an attenuation of a signal from the light
source as detected by the light receiver. In some embodiments, an
optical sensor system can be used to determine one or more
dimensions of a specimen container, such a length of a specimen
container. An optical sensor system may further determine the
presence and/or color of a cap of a specimen container.
[0119] The optical sensor system can include a radiation source
(such as a light source) and a radiation receiver (such as a light
receiver). A typical light source emits electromagnetic radiation
in the visible spectrum. The term "light" as used herein may refer
to any radiation. The radiation source may be, for example, a fiber
optic source, a light emitting diode (LED), a laser diode, or a
laser. The radiation receiver (also referred to as a "detector")
may be, for example, a fiber optic receiver or a photodiode. An
amplifier may be coupled to the output of the detector for
amplifying the received attenuated signals.
[0120] In one embodiment, an optical sensor system can include a
fiber optic system including a fiber optic source 1306 and a fiber
optic receiver 1308, as illustrated in FIG. 4. The fiber optic
source 1306 may be coupled to a transmitter 1320 (e.g., U2-Keyance
Transmitter) and the fiber optic receiver 1308 may be coupled to a
receiver 1322 (e.g., U2-Keyance Receiver). In one embodiment, the
fiber optic system is part of the sensor unit 1120. The fiber optic
source 1306 and the fiber optic receiver 1308 may be embedded with
and coupled to the surfaces of the gripper fingers 1208 and 1210,
respectively, and/or the jaws 1214 and 1216. In other embodiments,
the fiber optic source 1306 and the fiber optic receiver 1308 may
be attached to elongated structures forming at least part of the
gripper fingers 1208, 1210. Alternatively, the fiber may be
threaded through the gripper fingers. It will be recognized that
other configurations may be used to connect the fiber to the
surfaces of the gripper fingers. In some embodiments, an inline
right angle connector or adapter is used in locations where the
fiber traverses a corner that exceeds the bending tolerance of the
fiber.
[0121] The presence or absence of the specimen container 1212
between the gripper fingers 1208 and 1210 can be determined based
on a signal received by the PLC 1108A from the fiber optic receiver
1308. For example, if no specimen container is located between the
gripper fingers 1208 and 1210, light emitted from the fiber optic
source 1306 is received by the fiber optic receiver 1308. In this
example, a signal is received by the PLC 1108A from the fiber optic
receiver 1308 indicating the absence of a specimen container. When
a specimen container is located between the gripper fingers 1208
and 1210, the light emitted from the fiber optic source 1306 is not
received by the fiber optic receiver 1308 because the specimen
container blocks some or all of the emitted light from the fiber
optic source 1306. In this case, a signal is received by the PLC
1108A from the fiber optic receiver 1308 indicating the presence of
a specimen container.
[0122] In some embodiments, measurements can be performed using the
fiber optic system. For example, gripper fingers with the fiber
optic source 1306 and the fiber optic receiver 1308 can be moved
along a vertical axis relative to the specimen container 1212. Such
a measurement is performed while the gripper fingers are not
gripping the specimen container 1212. For a specimen container
length measurement, gripper fingers with the fiber optic source
1306 and the fiber optic receiver 1308 can be lowered from a point
above the specimen container 1212 (where the fiber optic receiver
1308 receives a beam of light emitted from the fiber optic source
1306 because the specimen container 1212 does not break the beam),
along the length of the specimen container 1212 (where the fiber
optic receiver 1308 does not receive a beam of light emitted from
the fiber optic source 1306 because the specimen container 1212
breaks the beam), to a point below the specimen container 1212
(where the fiber optic receiver 1308 receives a beam of light
emitted from the fiber optic source 1306 because the specimen
container 1212 does not break the beam). The length of the specimen
container 1212 can be determined based on the distance traversed by
the gripper fingers over which the beam from the fiber optic source
1306 was attenuated or broken. One or more liquid levels in the
specimen container 1212 can be similarly determined.
[0123] FIG. 5 shows an illustrative specimen carrier with cutouts
to allow optical access to the specimen container. A specimen
carrier 1400 used to transport a specimen container may have one or
more slots 1402 to allow a specimen container 1406 to be visible to
the optical sensing system. Slots 1402 may have a vertical
orientation to allow the gripper unit to perform measurements by
traversing the length of the specimen container 1406 while the
specimen container is held upright within the specimen carrier
1400. In some embodiments, the specimen carrier 1406 may allow for
gripper fingers 1208, 1210 to move below the underside of the
specimen container 1406 as shown by the space 1404 below the
specimen container 1406. For example, the specimen carrier may have
a lip or other feature to support the specimen container to create
space between the underside of the specimen container and the lower
interior surface of the specimen carrier. The gripper fingers 1208,
1210 can determine the length of the tube by moving along the
length of the specimen container 1406 from above the top of the
specimen container to below the underside of the specimen
container, such that a radiation source and/or radiation receiver
are aligned with one or more slots 1402.
[0124] In an alternative embodiment of a fiber optic system, the
fiber optic receiver 1308 determines an amount by which light
emitted from the fiber optic source 1306 is attenuated. For
example, the amount by which the light is attenuated relative to a
baseline light level may be determined. The baseline light level
may be a predetermined value or may be established during a state
when it is known that no obstruction exists between fiber optic
source 1306 and the fiber optic receiver 1308.
[0125] The optical sensor system may include two or more light
sources. Each light source may have an associated light receiver,
such as a fiber optic receiver or photodiode. Alternatively, light
from two or more fiber optic sources may be detected by a single
light receiver using an optical device for mixing light.
Alternatively, a beam combiner may be used to direct light from
different light sources in parallel toward a specimen
container.
[0126] FIG. 6 shows an illustrative fiber optic system 1500 having
multiple light sources. In one embodiment, the fiber optic system
1500 is part of the sensor unit 1120. The fiber optic system 1500
includes a first light source 1502 and a second light source 1504
coupled to a first gripper finger 1510 and a detector 1506 coupled
to a second gripper finger 1512.
[0127] The first gripper finger 1510 and the second gripper finger
1512 may be part of a gripper unit, such as, the gripper unit 1200.
The first light source 1502 is arranged to apply a first signal
beam having a first characteristic wavelength (in the range of 200
nm-1700 nm, such as between 800 nm-1200 nm, e.g., 980 nm) to a beam
combiner (not shown) which directs the first transmitted signal
toward a location on a specimen container 1508. The first light
source can be detected by the detector 1506, such as a fiber optic
receiver or photodiode. The second light source 1504 can be
arranged to apply a second signal beam having a second
characteristic wavelength (e.g., in the range of 200 nm -1700 nm,
such as between 1000 nm-1400 nm, e.g., 1050 nm) to the beam
combiner at a slightly shifted position from the first signal beam.
The beam combiner can direct the second emitted signal beam
parallel to the beam path of first emitted signal beam toward a
slightly different location on the specimen container 1508. The
second signal beam can be detected by the detector 1506. The output
signal of the detector 1506 can be received by the processor 1108
for storage (e.g., in the memory 1110) and/or processing. The
wavelength of light for the first light source 1502 may be selected
such that the attenuation of the light through a particular fluid
is minimal, allowing the first light source 1502 to be used as a
reference. The wavelength of light for the second light source 1504
may be selected such that the attenuation is predictable for a
fluid of interest.
[0128] Characteristics of various liquids within a specimen
container (e.g., specimen container 1212), such as the opacity of
the liquids, may vary. The varying liquid characteristics allow
determination of liquid type of material in a specimen container
based on a determination of the attenuation of light passing
through the liquids. Measurement of the quantity of each of
multiple liquids in a container may also be determined in this way.
For example, serum and gel are mostly transparent to visible light
while red blood cells are substantially opaque. Further, gel is
transparent to infrared light while red blood cells and serum are
substantially opaque. Accordingly, when a specimen container has
gel (e.g., a synthetic gel for separating serum from red blood
cells), it is possible just using infrared light to "see through"
different sections. The infrared light reading is strong when the
infrared light beam passes through air, drops when the infrared
light beam is directed toward the serum, is relatively strong when
directed toward the gel, and drops again when directed toward the
red blood cells. A sample level detection system is described in
detail in U.S. Provisional Patent Application No. 61/556,667, filed
Nov. 7, 2011 and entitled "Analytical System and Method for
Processing Samples" and PCT/US2012/063931 entitled "System and
Method for Processing Samples," filed on Nov. 7, 2012, which are
incorporated by reference in their entirety for all purposes.
[0129] Laky or chylous samples, of lipemic, hemolytic or icteric
patients commonly interfere with other laboratory tests that use
optical methods. Thus, for reliable sample handling automation, it
is desirable to measure serum index before a sample is committed to
an analyzer for testing to avoid erroneous measurements. Liquid
characteristics of laky or chylous liquids can be determined based
on an attenuation of a signal from the light source as detected by
the light receiver. Liquid characteristics used in specimen
processing are described in detail in U.S. Provisional Patent
Application No. 61/701,360, filed Sep. 14, 2012 and entitled
"Analytical System with Capillary Transport," which is incorporated
by reference.
[0130] FIG. 7 shows fingers of a gripper unit (e.g., gripper unit
1200) with an illustrative laser emitting diode (LED) and
photodiode optical sensing system 1600. In one embodiment, the
optical sensing system 1600 is part of the sensor unit 1120. It
will be recognized that an optical sensor system including one or
more LEDs and one or more photodiode detectors could be used in
lieu of the fiber optic system described above. In one embodiment,
a first LED 1608 having a first wavelength and a second LED 1610
having a second wavelength may be coupled to the surface of a first
gripper finger (or gripper fingertip or jaw) 1602 that faces a
specimen container 1606. A photodiode 1612 may be coupled to a
second gripper finger 1604 opposite the first gripper finger 1602
such that it's in a line of sight of the LEDs 1608 and 1610. It
will be understood that for wired LEDs 1608, 1610 and the
photodiode 1612, wirings may pass through the first and second
gripper fingers 1602, 1604. Alternatively, wireless components may
be used.
[0131] The photodiode 1612 may be configured to receive the light
transmitted by the LEDs and convert it to a current or voltage that
may be provided to the PLC 1108A for further processing, e.g., for
determining liquid level or characteristics and/or length of the
tube, etc. The photodiode 1612 may be silicon based, germanium
based or any other suitable type of photodiode.
[0132] Some embodiments of the invention may be directed to
methods. Such methods may include transmitting, by a light source,
an optical signal, the light source coupled to a first gripper
finger in a plurality of gripper fingers gripping the specimen
container. The method also includes receiving, by a light receiver,
the optical signal, the light receiver being coupled to a second
gripper finger in the plurality of gripper fingers gripping the
specimen container, and then determining, by a processor (e.g.,
processor 1108) coupled to the light source and the light receiver,
information associated with the specimen container gripped by the
plurality of gripper fingers. Such information may relate to the
presence or absence of a specimen container between the gripper
fingers, the type of liquid or liquids inside of the specimen
container, the type or specimen container, the height of the liquid
in the specimen container, the height of the specimen container,
etc.
Gripper Unit Closure Assemblies
[0133] In various embodiments, the gripper unit may have various
assemblies for closing the gripper fingers to clasp a specimen
container. Some embodiments allow the gripper unit to grip tubes of
different diameters and heights.
[0134] In some embodiments, closure of the gripper fingers about a
specimen container is caused by rotation of gripper fingers around
a pivot point. FIGS. 8A-8B illustrate a ball screw assembly for
closing gripper fingers 1702 of a gripper unit 1700 using a ball
screw 1704 to cause rotation around a pivot point 1706. A ball
screw linear actuator translates rotational motion to linear
motion. The ball screw 1704 uses ball bearings in a helical raceway
to form a precision screw. FIG. 8A shows the gripper unit 1700 with
ball screw driven gripper fingers 1702 in a closed position. FIG.
8B shows the gripper unit 1700 with ball screw driven gripper
fingers 1702 in an open position. The downward translation of the
ball screw 1704 causes the gripper fingers 1702 to pivot outwards.
Upward translation of the ball screw 1704 causes the gripper
fingers 1702 to pivot inward. The inward pivoting of the griper
fingers 1702 can cause the gripper fingers 1702 to close about the
specimen container 1700. In one embodiment, the gripper unit 1700
is similar to the gripper unit 1114 with the ball screw assembly
coupled to the body 1116.
[0135] FIGS. 9A-9D show a worm drive assembly for closing gripper
fingers 1802 of a gripper unit 1800 about a specimen container
1804. FIG. 9A shows the gripper unit 1800 with worm gear driven
gripper fingers 1802 in a closed position. When closed about the
specimen container 1804, worm gear driven gripper fingers 1802
clamp the specimen container 1804. FIG. 9B shows the gripper unit
1800 with worm gear driven gripper fingers 1802 in an open position
(e.g., to release specimen container 1804).
[0136] FIG. 9C shows an illustrative worm drive assembly. A worm
drive can include a worm gear 1808 and a worm 1806. The rotation of
the worm 1806 drives rotation of the worm gear 1808. FIG. 9D shows
a worm drive in the context of the gripper unit 1800. The worm 1806
can cause the rotation of multiple worm gears 1808-1814. Each worm
gear may be associated with a gripper finger 1802. As the worm 1806
turns, worm gears 1808-1814 can rotate, causing the gripper fingers
1802 to pivot. Rotation of the worm 1806 in a first direction can
cause the gripper fingers 1802 to pivot inward toward the specimen
container 1804. Rotation of the worm 1806 in a second direction can
cause the gripper fingers 1802 to pivot (e.g., to release the
specimen container 1804).
[0137] In one embodiment, the gripper unit 1800 is similar to the
gripper unit 1114 such that the worm drive assembly can be coupled
to the body 1116. In some embodiments, one or more holes may be
added to allow the gears to be mounted on the gripper fingers.
[0138] In some embodiments, closure of the gripper fingers about a
specimen container is caused by movement of gripper fingers through
a rotating disc with angular slots. FIGS. 10A-10D show a slotted
disc assembly for closing gripper fingers 1902 of a gripper unit
1900. FIG. 10A shows the gripper unit 1900 with slotted disc driven
gripper fingers 1902 in an open position. FIG. 10B shows a section
of the gripper unit viewed from above slotted disc 1904 with
slotted disc driven gripper fingers 1902 in an open position. FIG.
10C shows a gripper unit with slotted disc driven gripper fingers
1902 in a closed position. FIG. 10D shows a section of the gripper
unit viewed from above slotted disc 1904 with slotted disc driven
gripper fingers 1902 in a closed position. As slotted disc 1904
rotates, gripper fingers 1902 are urged along the paths defined by
slots 1906 in slotted disc 1904. Rotation of disc 1906 in a first
direction can cause gripper fingers 1902 to move along slots 1906
inward toward a closed position. Rotation of disc 1906 in a second
direction can cause gripper fingers 1902 to move along slots 1906
outward toward an open position. The spline shape of slots 1906
shown in FIGS. 10A-10D can be advantageous in that the angle under
which force is applied by rotating disc 1904 to gripper finger 1902
is always the same. It will be recognized that other shapes, such
as a linear slot shape, may be used.
[0139] In one embodiment, the gripper unit 1900 is similar to the
gripper unit 1114 such that the slotted disc assembly can be
coupled to the body 1116.
[0140] In some embodiments, closure of the gripper fingers about a
specimen container is caused by rotation of a planetary gear having
a planet gear coupled to each gripper finger 1952 of a gripper unit
1950. FIGS. 11A-11B show a planetary gear assembly for closing
gripper fingers 1952 of the gripper unit 1950. FIG. 11A shows a
gripper unit with planetary gear driven gripper fingers 1952 closed
about a specimen container 1954. FIG. 11B shows a gripper unit with
planetary gear driven gripper fingers 1952 in an open position.
[0141] FIGS. 11C-11D show sections of the gripper unit viewed from
below planetary gear system 1956. A planetary gear system can have
one or more outer gears (i.e., "planet gears"). The planet gears
may revolve around a central gear (i.e., "sun gear"). FIG. 11C
shows a section of the gripper unit with planetary gear driven
gripper fingers 1952 in a closed position corresponding to FIG.
11A. The point of attachment between gripper finger 1952 and a
planetary gear of the planetary gear system 1956 is shown at 1958.
As planet gears 1956 rotate, gripper fingers 1952 rotate to an open
position as shown in FIG. 11D, corresponding to FIG. 11B.
[0142] In one embodiment, the gripper unit 1950 is similar to the
gripper unit 1114 such that the planetary gear assembly can be
coupled to the body 1116.
[0143] Embodiments allow gripping different tube diameters and
lengths with reliable and fast to repair features. The gripper unit
in accordance with various embodiments makes multiple measurements
simultaneously affording a better method of managing the specimen
containers. For example, by determining the diameter, height,
length and the cap color of the specimen container before picking
it up, the embodiments provide faster speed and further qualify
that it's safe to optimally route the specimen containers to other
modules for further processing. In some embodiments, some of the
measurements associated with the specimen container may be used by
a processor to determine the number of specimen containers that may
fit in a container given a fill capacity of the container. Such
information may be used to determine a fill level of the container
so that the container may be emptied, replaced or refilled
accordingly.
II. Removable Specimen Gripper Fingers
[0144] Embodiments of the invention include devices to enable
replacement of gripper fingers without the need of tools or without
the need to demount the entire gripper unit for exchange of gripper
fingers. In some embodiments of the invention, a gripper finger may
comprise means for coupling to a gripper finger release assembly
that can enable a quick exchange of the gripper finger. For
example, a gripper finger may comprise a cavity or a hole for
coupling to a release assembly and to the gripper unit. Note that
in this specification, the term "gripper finger" may imply that the
gripper finger is replaceable or removable and may be used
interchangeably with "removable gripper finger" or "replaceable
gripper finger."
[0145] FIG. 12 depicts a gripper unit 2000 that provides the
capability for quick exchange of gripper fingers, in one embodiment
of the invention.
[0146] The gripper unit 2000 may include a body 2002 and removable
gripper fingers 2004, 2006, 2008. The gripper unit 2000 may be
similar to the gripper unit 1114 and may be coupled to the robot
arm 1002 and the processing unit 1106. It will be understood that
the gripper unit 2000 may be coupled to other units or modules in
the laboratory automation system 1104 for performing the intended
functions. The body 2002 may be coupled to a gripper finger release
assembly 2010 so that the gripper fingers 2004, 2006, 2008 can be
quickly exchanged. It is to be understood that the body 2002 may
include or couple to other components or structures suitable for
performing the intended function of the gripper unit 2000, for
example, as a tube gripper, a recapper or a decapper.
[0147] In some embodiments, the gripper finger release assembly
2010 may include one or more release elements. The release elements
can couple and uncouple the gripper fingers 2004, 2006, 2008 from
the body 2002 without demounting or uncoupling the gripper finger
release assembly 2010 from the body 2002 and without using special
tools. In some embodiments, a sample tube 2012 may be gripped by
the removable gripper fingers 2004, 2006, 2008. In one embodiment,
the sample tube 2012 may have a cylindrical shape with a circular
cross-section. In some embodiments, the sample tube 2012 may have a
cap 2014. The cap 2014 may have a cylindrical shape with a circular
cross-section and a diameter slightly larger than the diameter of
the sample tube 2012 and a length relatively shorter than the
length of the sample tube 2012. It will be understood that other
shapes and sizes of the sample tube 2012 and the cap 2014 are
possible that can be gripped by the gripper unit 2000. Further,
other objects such as caps, secondary test tubes, capillaries,
pipettes may also be gripped by the gripper unit 2000. In some
embodiments, a replaceable jaw may be coupled to one end (gripping
end) of each of the gripper fingers 2004, 2006, 2008 for
accommodating different types of objects such as sample tubes,
caps, capillaries, pipettes, secondary test tubes, etc.
[0148] In some embodiments of the invention, each of the gripper
fingers 2004, 2006 and 2008 may comprise a cavity so that each of
the gripper finger can couple to a release element in the gripper
finger release assembly 2010 to enable a quick exchange of the
gripper finger.
[0149] FIGS. 13A-13C illustrate a release element 2100 according to
a first embodiment of the invention.
[0150] In some embodiments of the invention, the release element
2100 may be part of the gripper finger release assembly 2010 that
may be coupled to the body 2002 of the gripper unit 2000.
[0151] As illustrated in FIG. 13A, the release element 2100 may
include a connection plate (or plate) 2102, a first sliding element
2104, a second sliding element 2106, a cap 2108 and a spring 2110.
Different components of the release element 2100 are further
described with reference to FIG. 13B. In one embodiment, the
release element 2100 may be coupled to a mounting structure 2112,
as illustrated in FIG. 13C. A gripper finger may be coupled to the
first sliding element 2104 and to the mounting structure 2112. In
some embodiments, the first sliding element 2104, the second
sliding element 2106, the cap 2108 and the spring 2110 may have a
circular, radial cross-sections. In one embodiment, the release
element 2100 may be configured to allow the exchange of each of the
gripper fingers 2004, 2006, 2008 without demounting or mounting the
gripper finger release assembly 2010 and without the need to use
tools.
[0152] In some embodiments, the connection plate 2102 may be
coupled to the first sliding element 2104 and the second sliding
element 2106. The connection plate 2102 may be coupled so that the
first and second sliding elements 2104, 2106 may be removed from
the connection plate 2102, or they may be integral with the
connection plate 2102. As shown in FIG. 13A, the connection plate
2102, the first sliding element 2104, and the second sliding
element 2106 may form a U-shape. The connection plate 2102 may be
configured so that the first sliding element 2104 and the second
sliding element 2106 are aligned and connected so that gripper
fingers 2004, 2006, 2008 can be exchanged.
[0153] As illustrated in FIG. 13B, the connection plate 2102 may
have a rectangular cross-section (viewed from its side) and may
have two cavities 2102A, 2102 B. In some embodiments, each of the
cavities 2102A, 2102 B may have a circular cross-section and they
are configured to accommodate and receive a portion of the first
sliding element 2104 and a portion of the second sliding element
2106, respectively. The cavities 2102A, 2102 B may each be of any
suitable length.
[0154] In one embodiment of the invention, the first sliding
element 2104 may be cylindrical in shape with a circular, radial
cross-section. The first sliding element 2104 may also have any
suitable length (e.g., two or more inches in length). The first
sliding element 2104 may also be called a "finger pin" in some
embodiments.
[0155] The first sliding element 2104 may be configured so that a
first end 2104A of the first sliding element 2104 can pass through
a cavity in a removable gripper finger (not shown in FIGS. 13A and
13B) and a cavity in the mounting structure 2112 to secure the
gripper finger to the mounting structure 2112. A diameter of the
first sliding element 2104 including the first end 2104A may be
slightly smaller than a diameter of the cavity in the removable
gripper finger so that the gripper finger can slide on the first
sliding element 2104. A second end 2104B of the first sliding
element 2104 can couple to the connection plate 2102 through the
cavity 2102B. The diameter of the first sliding element 2104
including the second end 2104B can be slightly smaller than the
cavity 2102B so that the first sliding element 2104 can pass
through the cavity 2102B. In one embodiment of the invention, the
first sliding element 2104 is permanently coupled to the connection
plate 2102 via the cavity 2102B.
[0156] In one embodiment of the invention, the second sliding
element 2106 may also be cylindrical in shape and may have a
circular radial cross-section and may be slightly longer than the
first sliding element 2104. The second sliding element 2106 may
also be called a "push screw" in some embodiments. The second
sliding element 2106 may be configured so that a first end 2106A of
the second sliding element 2106 is slightly smaller than the rest
of the second sliding element 2106 and is configured to couple
(temporarily or permanently) to the cap 2108. In some embodiments,
the first end 2106A of the second sliding element 2106 and a second
end 2108B of the cap 2108 may be threaded.
[0157] A second end 2106B of the second sliding element 2106 may be
configured so that it can pass through a cavity 2110A in the spring
2110 and couple to the connection plate 2102 through the cavity
2102A. In one embodiment of the invention, the cap 2108 is
configured as a counterpart to a cavity (not shown) in the mounting
structure 2112 so that the cap 2108 can slide in and out of the
cavity in the mounting structure 2112, when a first end 2108A of
the cap 2108 is pressed to release or couple a gripper finger to
the gripper unit 2000.
[0158] In one embodiment, the second sliding element 2106 has a
round, axial cross section and can pass through the spring 2110. In
one embodiment, the spring 2110 may be in uncompressed state so
that the gripper finger release assembly 2010 is in a closed
position (e.g., normal position) with a gripper finger coupled to
the first sliding element 2104. In the closed position, the spring
2110 may be configured to urge the connection plate 2102 toward the
cap 2108 such that the cap 2108 passes through a cavity in the
mounting structure 2112 coupled to the body 2002. The spring 2110
may be a compression spring or any suitable biasing element for
providing the appropriate force to keep the gripper finger release
assembly 2010 in the closed position.
[0159] The cap 2108 may be cylindrical in shape with a diameter
that exceeds the diameter of the second sliding element. In one
embodiment, the cap 2108 may be configured so that when the cap
2108 is pushed or pressed, the cap 2108 slides into a cavity on the
mounting structure 2112. Pushing the cap 2108 further enables the
first sliding element 2104 to release the gripper finger due to the
movement of the connection plate 2102 away from the mounting
structure 2112.
[0160] A first gripper finger may be secured to the mounting
structure 2112 by coupling to the first sliding element 2104. In
embodiments of the invention, the first gripper finger may be
released by pushing or pressing the cap 2108. The pushing or
pressing the cap 2108 pushes the connection plate 2102 away from
the mounting structure, thus uncoupling the gripper finger from the
first sliding element 2104. After the first gripper finger has been
released, a second gripper finger may be coupled to the first
sliding element 2104 by keeping the cap 2108 pressed and aligning a
cavity in the second gripper finger with the first end 2104A of the
first sliding element 2104 and sliding the second gripper finger on
to the first sliding element 2104. By releasing the cap 2108 pushes
the gripper finger release assembly 2010 in a closed position by
enabling the spring 2110 force the connection plate 2102 towards
the mounting structure 2112 such that the cap 2108 slides out of
the cavity of the mounting structure 2112.
[0161] In embodiments of the invention, the cap 2108 defines the
space for the movement of the spring 2110 and also prevents the
spring 2110 from getting lost.
[0162] FIGS. 14A-14B illustrate the gripper finger release assembly
in a closed position 2200, in one embodiment of the invention.
[0163] As illustrated in FIG. 14A, a cover 2202 may be coupled to
the release element 2100 for covering at least some components of
the release element 2100. The cover 2202 may be in a first position
during the normal operation of the gripper unit and in a second
position during the exchange of the gripper fingers. In one
embodiment, the cover 2202 may be in a closed position (first
position) for the normal operation, as shown in FIG. 14A, and in an
upward position (second position) for exchanging the fingers. The
cover 2202 further protects the release element 2100 from
contamination/pollution and maintains the closed position of the
assembly during normal operation. It will be understood that
various other configurations of the cover 2202 are possible.
[0164] As illustrated in FIG. 14A, cavities 2204, 2206 may be
associated with a connection plate 2208 for a second release
element configured for exchanging the gripper finger 2008.
Similarly, cavities 2210, 2212 may be associated with a cap and a
first end of a first sliding element respectively for a third
release element configured for exchanging the gripper finger 2004.
Note that each release element may have a cover (not shown) which
may be in a first position during the normal operation of the
gripper unit and in a second position during the exchange of the
respective gripper finger.
[0165] In the closed position of the gripper finger release
assembly, the first sliding element 2104 may pass through a first
cavity in the mounting structure 2112 and a cavity in the gripper
finger 2006 to secure the gripper finger 2006 to the mounting
structure 2112. The cap 2108 may be pushed out from the force of
the spring 2110 (not shown in FIG. 14A) through a second cavity in
the mounting structure 2112. An internal, cross-sectional view of
the gripper finger release assembly in the closed position is shown
in FIG. 14B.
[0166] In one embodiment, the gripper finger 2006 may be coupled to
the first sliding element 2104 through a bushing 2214 or any other
suitable component, as illustrated in FIG. 14B. The bushing 2214
may be made of rubber or any such suitable material and may be
configured to allow coupling of the gripper finger 2006 to the
first sliding element 2104.
[0167] FIG. 15 illustrates an inside view of the gripper finger
release assembly in an open position 2300, in one embodiment of the
invention.
[0168] As illustrated in FIG. 15, the first sliding element 2104
may be configured to pass through a cavity 2304 in the gripper
finger 2006 and a cavity 2302 in the mounting structure 2112 to
secure the gripper finger 2006 to the mounting structure 2112. In
order to open the gripper finger release assembly for releasing or
exchanging a gripper finger, the cap 2108 may be pressed until the
head of the cap 2108 is leveled with a surface of the mounting
structure 2112 through a cavity 2306 in the mounting structure
2112. Note that the pressing of the cap 2108 pushes the connection
plate 2102 away from the mounting structure 2112 and keeps the
spring 2110 in a compressed state. This enables the first sliding
element 2104 to slide out of the cavity 2304 in the gripper finger
2006, thus releasing or uncoupling the gripper finger 2006.
[0169] In some embodiments, the cavity 2302 may be substituted for
a bushing, which may be pressed in the mounting structure 2112.
[0170] Referring back to FIG. 14B, as compared to the open position
of the gripper finger release assembly, the first sliding element
2104 is pushed out from the cavity 2304 of the gripper finger 2006.
This allows the uncoupling of the gripper finger 2006 from the
gripper unit. In this position a new gripper finger may be coupled
to the first sliding element 2104 by keeping the cap 2108 pressed
and by sliding the new gripper finger on the first sliding element
2104 through a cavity in the new gripper finger. Once the new
gripper finger is coupled to the first sliding element 2104, the
cap 2108 may be released which enables the spring 2110 to
uncompress and push the cap 2108 out of the cavity 2306 in the
mounting structure 2112 and bring the gripper finger release
assembly to a closed or locked position.
[0171] Embodiments of the invention provide a method to replace a
first gripper finger with a second gripper finger using a release
element, for example, the release element 2100.
[0172] In a first step of the method, the first gripper finger may
be removably coupled to a mounting structure by the release
element. The first gripper finger may comprise a first cavity and
the mounting structure may comprise a second cavity. The release
element may comprise a plate, a first sliding element coupled to
the plate and a second sliding element coupled to the plate. The
first sliding element may be configured to pass through the first
and second cavities to secure the first gripper finger to the
mounting structure. Referring back to FIG. 15, the first gripper
finger may be removably coupled to the mounting structure 2112 by
the release element 2100. For example, the first sliding element
2104 may pass through a first cavity in the first gripper finger
(similar to the cavity 2304) and the cavity 2302 in the mounting
structure 2112.
[0173] In a second step of the method, the first gripper finger may
be released by pressing the second sliding element. For example, by
pressing the cap 2108 presses the second sliding element 2106, thus
enabling the first sliding element 2104 to slide out of the
cavities 2304 and 2302 and release the first gripper finger.
[0174] In a third step of the method, a third cavity on the second
gripper finger may be aligned with the first sliding element after
the first gripper finger has been released. For example, the third
cavity (similar to the cavity 2304) on the second gripper finger
may be aligned with the first sliding element 2104 so that the
first sliding element 2104 can easily pass through it.
[0175] In a fourth step of the method, the second gripper finger
may be removably coupled to the first sliding element by releasing
the second sliding element. For example, by releasing the second
sliding element 2106 (or the cap 2108) enables the spring 2110 to
uncompress and push the second sliding element 2106 (or the cap
2108) out of the cavity 2306 in the mounting structure 2112, thus
coupling the second gripper finger to the first sliding element
2104.
[0176] Embodiments of the invention provide advantages since no
tool is required for exchanging the gripper fingers. The gripper
finger release assembly can be unlocked with only one movement by
using a small force to overcome the force of the spring. Further,
the spring gets no load since bearing of forces is separated from
the closing feature. Embodiments of the invention prevent twisting
of the gripper fingers relative to the gripper unit due to the
inherent configuration of the release element 2100.
[0177] FIG. 16 illustrates a release element 2400 in a second
embodiment of the invention.
[0178] In one embodiment, the release element 2400 may be part of
the gripper finger release assembly 2010. The release element 2400
may comprise a post (or a sliding element) 2402 coupled to a plate
2410. The plate 2410 may be a part of or coupled to a mounting
structure 2412. In one embodiment, the mounting structure 2412 is
part of the body 1116 of the gripper unit 1114.
[0179] The post 2402 may be similar to the first sliding element
2104 (as shown in FIGS. 13A-13B) and may have a cylindrical shape
with a circular cross-section. The post 2402 may be configured to
removably couple to a gripper finger (e.g., one of the gripper
fingers 1118) within a gripper finger slot 2408 and further be
configured to pass through a cavity in the gripper finger and a
cavity in the mounting structure 2412 to secure the gripper finger
to the mounting structure 2412. The cavity in the gripper finger
may be similar to the cavity 2304 of the gripper finger 2006, as
shown in FIG. 15, with a diameter slightly larger than the diameter
of the post 2402 so that the post 2402 can pass through the cavity
of the gripper finger.
[0180] In one embodiment, a lever 2404 may be coupled to the plate
2410 and the post 2402 and configured to control the movement of
the post 2402 within the gripper finger slot 2408. In one
embodiment, the lever 2404 may be configured to enable the post
2402 to release a first gripper finger coupled to the post 2402 by
rotation of the lever 2404. For example, the lever 2404 can be
rotated (e.g., by approximately 90 degrees) and pulled away from
the gripper finger slot 2408 (e.g., to the right or
counterclockwise, in accordance with the illustrative example shown
in FIG. 16) to release the first gripper finger. A groove 2406 in
the mounting structure 2412 may be configured to accommodate the
post 2402 when the post 2402 has been removed from the gripper
finger slot 2408.
[0181] In one embodiment, rotating the lever 2404 in a second
direction (e.g., to the left or clockwise, as shown in the
illustrative example of FIG. 16) may slide the post 2402 into the
gripper finger slot 2408 so that a second gripper finger may be
coupled to the post 2402.
[0182] FIGS. 17A-17C illustrate a release element 2500 in a third
embodiment of the invention.
[0183] In one embodiment, the release element 2500 may be part of
the gripper finger release assembly 2010. The release element 2500
may comprise a post (or a sliding element) 2504 coupled to a plate
2506. A gripper finger 2502 may be removably coupled to the post
2504. The plate 2506 may be a part of or coupled to a mounting
structure 2514. In one embodiment, the mounting structure 2514 is
part of the body 1116 of the gripper unit 1114. A spring 2512 may
be coupled to the mounting structure 2514 configured to be in
contact with the post 2504.
[0184] The post 2402 may be similar to the first sliding element
2104 (as shown in FIGS. 13A-13B) and may have a cylindrical shape
with a circular cross-section. The post 2402 may be configured to
pass through a cavity in the gripper finger 2502 and a cavity in
the mounting structure 2514 to secure the gripper finger 2502 to
the mounting structure 2514. The cavity in the gripper finger 2502
may be similar to the cavity 2304 of the gripper finger 2006, as
shown in FIG. 15, with a diameter slightly larger than the diameter
of the post 2504 so that the post 2504 can pass through the cavity
of the gripper finger 2502.
[0185] In one embodiment, the plate 2506 is configured as a
rotating plate that can be pivoted about an axis defined by a pin
2508 coupled to the plate 2506. The pin 2508 may also be coupled to
the mounting structure 2514 and configured to enable the rotation
of the plate 2506 in a clockwise or a counter clock wise direction
relative to the pin 2508, as discussed with reference to FIGS.
17B-17C.
[0186] As illustrated in FIGS. 17B-17C, in one embodiment, the
plate 2506 may be circular in shape with an opening 2516 relatively
larger than the diameter of the post 2504 in order to allow the
post 2504 pass through the opening 2516 when the plate 2506 is
rotated. It will be understood that any configuration of the plate
2506 and the opening 2516 is possible in order to allow the post
2504 to pass though the opening 2516.
[0187] FIG. 17B illustrates a closed position of the plate 2506, in
which the post 2504 is confined in a cavity 2510 behind the
rotating plate 2506. In this position the gripper finger 2502 may
be coupled to the post 2504 and the spring 2512 may be in a
compressed state.
[0188] FIG. 17C illustrates an open position of the plate 2506, in
which the post 2504 is released through the opening 2516 of the
rotating plate 2506. The spring 2512 urges the post 2504 towards
the opening 2516, thus allowing the post 2504 to be extract from
the cavity 2510. When the post 2504 is extracted, the gripper
finger 2502 can be removed and replaced with another gripper
finger.
[0189] As discussed above, a first gripper finger comprising a
first cavity may be removably coupled to a mounting structure
comprising a second cavity by a release element. The release
element may be the release element 2100, release element 2400 or
the release element 2500. The release element may comprise a plate
and a first sliding element coupled to the plate, and wherein the
first sliding element is configured to pass through the first and
second cavities to secure the first gripper finger to the mounting
structure. The first gripper finger may be released by enabling the
first sliding element to slide out of the first and second
cavities. After the first gripper finger has been released, a third
cavity on a second gripper finger is aligned with the first sliding
element to removably couple the second gripper finger to the first
sliding element.
[0190] Embodiments of the invention provide quick one-handed
exchange of gripper fingers without the need of tools or without
demounting or mounting of the gripper finger release assembly from
the gripper unit. Thus, embodiments allow quick exchange of gripper
fingers, for example, to change the function of the gripper unit,
e.g., as a tube gripper, recapper or a decapper.
[0191] In this section, a number of gripper unit embodiments using
removable specimen gripper fingers are described in detail. It is
understood that any features from these embodiments may be combined
with any of the previously described sensing gripper unit
embodiments described above, as well as strip off element and/or
fill level detection systems and methods described below, without
departing from the scope of the invention. For example, in one
embodiment, the system includes a gripper unit for gripping the
specimen container. The gripper unit comprises a mounting
structure, a plurality of gripper fingers, a plurality of release
elements respectively coupling the gripper fingers in the plurality
of gripper fingers to the mounting structure, and a sensing device.
The sensing device is configured to produce an output. The system
further includes a processor, where the processor is configured to
determine a dimension or a weight of the specimen container based
on the output. As noted above, the sensing device may be a load
cell or a potentiometer.
III. Chute Arrangement with Strip-Off Element
[0192] Another embodiment of the invention provides systems and
methods for a chute arrangement comprising an element for objects,
such as, test tubes, caps, etc. released by a gripper unit such
that the released objects may be collected in a container.
Embodiments may be used for any objects that need to be collected
in a container, such as specimen containers, secondary tubes that
need not be stored, caps, capillary waste, pipette waste, etc.
[0193] A gripper unit according to an embodiment of the invention
may utilize plurality of gripper fingers to grip an object. In
embodiments of the invention, at least one gripper finger in the
plurality of gripper fingers may separate (e.g., strip off) from a
sticky object so that the at least one gripper finger is not stuck
to the object and the object is released from the gripper finger.
An element can be used to surround the object to restrain (hold
back) the object as the gripper fingers release the object.
[0194] FIG. 18A illustrates a typical gripper unit operable to grip
a specimen container.
[0195] Typically, a gripper unit 2650 may be operable to grip a
specimen container 2654 using gripper fingers 2652 to discard the
specimen container 2654 into a waste container. The specimen
container 2654 may be a test tube containing patient samples. Under
normal conditions, the gripper unit 2650 may release the specimen
container 2654 by opening the gripper fingers 2652. However, in
some cases, a substance 2656 may be stuck to an outside surface of
the specimen container 2654. The substance 2656 may be deposited
due to contamination from aliquotting or glue from a label stuck on
the surface of the specimen container 2654. Due to the presence of
the substance 2656, the gripper fingers 2652 may get stuck to the
specimen container 2654 during the process of discarding the
specimen container 2654. As a result, when the gripper unit 2650
opens its gripper fingers 2652 to release the specimen container
2654, the specimen container 2654 may be left dangling because it
is attached to the gripper finger. This may increase the processing
time to discard the specimen containers as human intervention may
be required to remove the stuck specimen container 2654. Further,
contamination may be transported by the gripper fingers 2652 to
other specimen containers, thus, further spreading the
contamination.
[0196] FIG. 18B illustrates a prior art robotic gripper 2660 that
may be used as a strip-off element for caps.
[0197] The robotic gripper 2660 comprises a strip-off element 2662
for caps using gripper fingers 2664. A similar robotic gripper is
used in Beckman Automate.TM. 2500 series as a decapper for
decapping or removing caps from specimen containers, such as,
sample tubes. In such a system, if there is contamination on a
sample tube, the contamination may be transferred to the body of
the strip-off element 2660 (e.g., the cylinder). Since the
strip-off element 2662 is attached to the body of the robotic
gripper 2660, it may not be easily cleaned and the contamination
may be transferred to other specimen containers.
[0198] Another embodiment of the invention provides for an element
that is detached from the gripper unit, thus, can be easily
replaced or removed for cleaning, etc. The element may be part of a
chute arrangement that can be mounted right above a waste container
so the contamination does not get transferred to other components
of the automation system. Embodiments may be used for any object
that needs to be collected in a container, such as discarded
specimen samples (e.g., waste tubes), secondary tubes that need not
be stored, 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).
[0199] In one embodiment of the invention, the robot arm 1002 may
be operable to grip a specimen container (e.g., a sample tube)
using the gripper unit 1114 from a specimen carrier (e.g., a tube
rack) and drop it through the chute arrangement 1122 into a waste
container that may be part of the container unit 1128. This is
further explained with reference to FIG. 19.
[0200] FIG. 19 illustrates certain elements of an exemplary system
3000 comprising a chute arrangement, in one embodiment of the
invention.
[0201] 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 grip an object such as a specimen container
3014 using the gripper fingers 3004 and may discard the specimen
container 3014 into a waste container 3016. The waste container
3016 may be part of the container unit 1128. Further, in some
embodiments, the gripper fingers 3004 may be removably coupled to
the body of the gripper unit 3004 such that one or more of the
gripper fingers 3004 may be exchanged with a new gripper finger
using one of the release elements (e.g., release elements 2100,
2400, 2500) that may be coupled to the body of the gripper unit
3002.
[0202] In one embodiment of the invention, a chute arrangement 3012
may include a top chute 3006 in the form of an element 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. In one embodiment, the gripper unit 3002 may
be similar to the gripper unit 1114 and may be communicatively
coupled to the processing unit 1106. The processor 1108 may control
the gripper unit 3002 using code stored in the memory 1110. In some
embodiments, the processor 1108 may further be able to determine
characteristics associated with the specimen container 3014 and/or
the specimen inside the specimen container 3014 based on outputs
from one or more sensors (e.g., sensor unit 1120) coupled to the
gripper unit 3002.
[0203] In some embodiments, a sensor unit 3018 may be in proximity
to the chute arrangement 3012, as shown in FIG. 19. The sensor unit
3018 may include one or more sensors and may be part of the sensor
unit 1120. For example, the sensor unit 3018 may include an
ultrasonic sensor, an optical sensor, a motion sensor or any such
suitable sensor. In some embodiments, the sensor unit 3018 may be
configured to detect the presence of an object, e.g., the specimen
container 3014 passing through the chute arrangement 3012 and
generate an output. In some embodiments, detection of a falling
object through the chute arrangement 3012 may be used to keep a
count of the number of objects (e.g., tubes, caps, etc.) that can
be collected in the waste container 3016 by the processor 1108
based on the output from the sensor unit 3018. In one embodiment,
the sensor unit 3018 may be configured to detect different fill
levels of objects in the waste container 3016.
[0204] The gripper unit 3002 may be configured to grip the specimen
container 3014 using the gripper fingers 3004. In embodiments of
the invention, the chute arrangement 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 chute
arrangement 3012 may be configured to allow un-gripped objects to
fall through the chute by means of gravity. If the specimen
container 3014 is not sticky (i.e., no substance 1056), the
specimen container 3014 may fall into the waste container 3016 when
it is released by the gripper fingers 3004. However, as explained
above, the specimen container 3014 may stick to the gripper fingers
3004. In embodiments of the invention, the top chute 3006 can be an
element and can separate the specimen container 3014 from the
gripper fingers 3004, when the gripper fingers 3004 move outwardly
to release the specimen container 3014. The top chute 3006 may
restrain the specimen container 3014 from moving with the gripper
fingers 3004 as they move outwardly away from the specimen
container 3014. This allows the specimen container 3014 to separate
from the gripper fingers 3004 so that it can pass down through the
chute arrangement 3012.
[0205] The adapter unit 3008 may be configured as a spacer unit to
provide a height adjustment for mounting the chute arrangement 3012
on a platform. One end of the adapter unit 3008 may be coupled to
the top chute 3006 and another end of the adapter unit 3008 may be
coupled to the bottom chute 3010. 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. In case a cap of
the specimen container 3014 is partially or entirely removed from
the specimen container 3014 before the specimen container 3014 is
released from the gripper fingers 3004, a potential splash of the
sample specimen (e.g., fluid) can be confined by the top chute 3006
and/or the adapter unit 3008. The chute arrangement 3012 may be
able to accommodate specimen containers of any suitable length so
that the specimen container does not interrupt the acoustic, light,
or other signal used for detecting the falling specimen container,
when the specimen container 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 lengths of
different objects that are intended to be passing through the chute
arrangement 3012.
[0206] The bottom chute 3010 may be configured to provide multiple
functions. The bottom chute 3010 may include a mechanism for
mounting on a platform to provide support or stability to the chute
arrangement 3012. For example, one end of the bottom chute 3010 may
comprise mounting tabs for mounting on a platform and another end
of the bottom chute 3010 may couple to the adapter unit 3008 or
directly to the top chute 3006. In one embodiment, the bottom chute
3010 may be configured to be in a close proximity of the sensor
unit 3018 so that the sensor unit 3018 can detect a falling object
passing through the bottom chute 3010. For example, an opening on
the bottom chute 3010 may be in a line of sight of the sensor unit
3018 so that an ultrasonic signal transmitted by the sensor unit
3018 can reflect from a surface of an object passing through the
bottom chute 3010 and bounce back to the sensor unit 3018. The
sensor unit 3018 may be communicatively coupled to the processing
unit 1106 so that a count of the falling objects can be stored
and/or updated in the memory 1110 by the processor 1108. In one
embodiment, when the sensor unit 3018 does not detect an object
passing through the bottom chute 3010, a beam emitted by the sensor
unit 3018 may get deflected downwards into the waste container 3016
by an inclined surface of the bottom chute 3010 and may help
determine a fill level of the waste container 3016.
[0207] In FIG. 19, the bottom chute 3010 has wider dimensions than
the top chute 3006. The increased size of the bottom chute 3010, in
conjunction with the sensor unit 3018, can provide for the
capability of detecting falling objects. However, it is to be noted
that the bottom chute 3010 may have any suitable design as long as
it can interface with the top chute 3006, with or without the
adapter unit 3008.
[0208] In embodiments of the invention, the top chute 3006 enables
the waste tube 3014 to strip off from the gripper fingers 3004, as
further explained with reference to FIGS. 20A-20B.
[0209] FIGS. 20A-20B are close up, perspective views of a top chute
in the form of an element.
[0210] As illustrated in FIG. 20A, the top chute 3006 includes a
plurality of slots 3102. In one embodiment, each of the plurality
of slots is parallel to a longitudinal axis of the top chute 3006.
In embodiments of the invention, the gripper fingers 3004 may
generally enter the plurality of slots 3102 from above for at least
partially inserting the specimen container 3014 gripped by at least
two of the gripper fingers 3004. In one embodiment, the gripper
fingers 3004 may open laterally to release the gripped specimen
container 3014. A geometric dimension of each of the plurality of
slots 3102 may be smaller than an overall length, width or height
of the specimen container 3014 such that the specimen container
3014 is unable to pass through the slots 3102 when released by the
gripper fingers 3004. In one embodiment, the geometric dimension of
each of the plurality of slots may be a width of the slot so that
each of the gripper fingers 3004 may pass through the slot but not
the object. Under normal conditions, the specimen container 3014
may drop down the chute arrangement 3012 into the waste container
3016 when the specimen container 3014 is released from the gripper
fingers 3004, as shown in FIG. 19. However, if there is
contamination on the specimen container 3014, the specimen
container 3014 may stick to the gripper fingers 3004. Embodiments
provide a stripping feature in the top chute 3006 such that the
gripper fingers 3004 can be moved by the gripper unit 3002 to
extend outwardly through the slots 3102 so that the specimen
container 3014 can be released and separated from the gripper
fingers.
[0211] FIG. 20B illustrates open gripper fingers 3004 that have
opened outwardly outside the slots 3102 of the top chute 3006. The
gripper fingers 3004 do not touch the sample container 3014 and are
completely separated from it.
[0212] The slots 3102 may be configured such that the gripper
fingers 3004 may pass through the slots 3102. If the specimen
container 3014 sticks to the gripper fingers 3004 due to some
contamination (e.g., substance 2656) during the movement of the
opening of the gripper fingers 3004, the element of the top chute
3006 retains the specimen container 3014 within it so that the
specimen container 3014 is released from the gripper fingers 3004
and passes down through the chute arrangement 3012. Because slots
3102 are smaller in dimensions (e.g., narrower) than the specimen
container 3014, the specimen container 3014 does not pass through
the slots 3102 when the gripper fingers 3004 pass through the slots
and is restrained by the element. The element can be made of a
material sufficiently strong to restrain the specimen container
3014 if the specimen container 3014 sticks to the gripper fingers
3004 due to contamination on the specimen container 3014. Some
non-limiting examples of the material for the element are metal
(e.g., steel or aluminum), plastic, Teflon, etc. Stabilizing bars
3104 on the surface of the top chute 3006 may help provide further
stabilization.
[0213] The specimen container 3014 may be collected in a container,
e.g., the waste container 3016 or for further processing. The
substance 2656 may get transported with the specimen container 3014
into the waste container 3016 instead of sticking to the gripper
fingers 3004. This may avoid having contamination from the
substance 2656 transferred to the other objects that may come in
contact with the gripper fingers 3004.
[0214] FIG. 21 illustrates a top chute arrangement with a square
shaped radial cross-section, or a square shaped profile, according
to one embodiment of the invention.
[0215] A top chute arrangement 3200 may comprise an element 3202
and an adapter unit 3204, both with a square shaped profile. The
element 3202 may comprise an element body 3202A comprising a
central axial bore 3202B, a first end 3202C and a second end 3202D.
For example, the gripper unit 3002 may insert the specimen
container 3014 held by the gripper fingers 3004 into the element
3202 from top for discarding it. In various embodiments of the
invention, the element 3202 may be configured to have dimensions
that may allow different types of objects (e.g., different types of
tubes, caps, etc.) to be surrounded by the element body 3202A so
that the element body 3202A can restrain the object when the object
is released by the gripper fingers. The top chute arrangement 3200
may have any suitable profile that would allow a correct alignment
of the element 3202 and the gripper unit 3002 to allow the gripper
fingers 3004 to properly enter the plurality of slots 3206. In one
embodiment, the top chute arrangement 3200 is part of the chute
arrangement 1122.
[0216] As shown in FIG. 21, the element body 3202A has a square
shaped profile. In one embodiment, the element body 3202A may
comprise four walls where each wall may comprise a slot. In some
embodiments, the element body 3202A may comprise a plurality of
stabilizing bars 3202E for providing stabilization or support to
the element 3202. As illustrated in FIG. 21, there is one
stabilizing bar on each side of the slot, which runs longitudinally
along the element body 3202A from the first end 3202C to the second
end 3202D.
[0217] In one embodiment, the second end 3202D of the element body
3202A may have slightly larger dimensions than the rest of the
element body 3202A. In one embodiment, the second end 3202D may be
configured to support the coupling of the stabilizing bars 3202E to
the element body 3202 A. The stabilizing bars 3202 may be
integrally formed with the main body of the element, or could be
separate parts that are attached to the main body of the element.
The second end 3202D may further be configured to couple to one end
of the adapter unit 3204. The element body 3202A may comprise of a
material with sufficient strength to restrain a specimen container
from moving with the gripper fingers when the gripper fingers are
moving away from the specimen container through the slots 3206. The
number of slots 3206 may be same as the number of gripper fingers
and configured in shape and size such that the gripper fingers may
pass through the slots 3206 but the specimen container stays
confined within the element 3202. In one embodiment, the slots 3206
are parallel to a longitudinal axis of the central axial bore
3202B.
[0218] In one embodiment, each slot in the plurality of slots 3206
may have a rectangular cross-section and may have an open end 3206A
and a closed end 3206B. The open end 3206A may coincide with the
first end 3202C of the element body 3202A to enable the gripper
fingers to insert a gripped object into the central axial bore
3202B from above. The closed end 3206B may be at a distance
approximately half way down the entire length of the element body
3202A. In some embodiments, the length and width of each slot may
depend upon a number of factors such as the dimensions (e.g.,
length of the element, width of each wall, etc.) of the element
body 3202, the dimensions (e.g., length, width, thickness, etc.) of
the gripper finger passing through each slot, the dimensions of
each object that may be surrounded by the element body 3202A for
dropping through the top chute arrangement 3200, material of the
element 3202, etc.
[0219] In one embodiment, the adapter unit 3204 has a square shaped
profile. However, any suitable shape is possible. The square shaped
profile of the adapter unit 3204 may provide for easy alignment
with the element 3202. The adapter unit 3204 or other portion of
the element 3202 having a square cross-sectional profile can be
used to ensure that each time the top chute arrangement 3200 is
installed, the plurality of slots 3206 are positioned to receive
the gripper fingers. The square shaped profile of the element 3202
provides a benefit over a cylindrical shape since a cylindrical
shaped chute may be rotated when replaced such that the gripper
fingers are not aligned with the slots. In some embodiments, a
cylindrical shape profile with specific alignment features may be
used. In one embodiment, these features are preferably located at
the second end 3202D of the element body 3202A and may e.g.
interface with the adapter unit 3204 in such a way that an
unintentional rotation or misplacement of the element 3202 that
would lead to a mis-alignment of the slots 3206 in relation to the
gripper fingers 3004, is avoided.
[0220] In one embodiment, the adapter unit 3204 is part of the
element 3202. The adapter unit 3204 may further be configured to
couple to a bottom chute for forming a chute arrangement that may
be used to drop off waste objects into a waste container, e.g., the
waste container 3016. For example, referring back to FIG. 19, one
end of the bottom chute 3010 which connects to the adapter unit
3008 may be configured to have a square shaped profile so that the
bottom chute 3010 may be coupled to the adapter unit 3204 for
forming a chute arrangement. Further, the chute arrangement may be
coupled to a platform, as described with reference to FIG. 22.
[0221] FIG. 22 illustrates a perspective view of the placement of a
chute arrangement 3300 according to one embodiment of the
invention.
[0222] As illustrated in FIG. 22, a top chute 3302 is coupled to a
bottom chute 3306 via an adapter unit 3304. In one embodiment, the
top chute 3302 may be attached directly to the bottom chute 3306
without the adapter unit 3304 or any other intermediary unit. In
another embodiment, the adapter unit 3304 may be a part of the
bottom chute 3306. Top chute 3302 may be easily removed or replaced
for cleaning or other maintenance.
[0223] In one embodiment of the invention, the top chute 3302 may
have a square shaped profile similar to the top chute 3202 of FIG.
21. Similarly, the adapter unit 3304 may have a square shaped
profile similar to the adapter unit 3204 that provides an easy
alignment with the top chute 3302. Further, the adapter unit 3304
or other portion of the top chute 3302 may be inserted into an
opening, such as an opening in a deck 3308, for support or
stability. The bottom chute 3306 may comprise a plurality of
mounting tabs for mounting on a deckbase 3310. However, it is to be
noted that any mechanism may be used to connect the bottom chute
3306 to the deckbase 3310 or any other stabilizing platform. In one
embodiment, the top chute 3302 may be attached directly to the
bottom chute 3306 without the optional adapter unit 3304 or any
other intermediary unit. In another embodiment, the adapter unit
3304 may be a part of the bottom chute 3306. The adapter unit 3304
may have a profile that provides an easy alignment with the top
chute 3302 (e.g., square shaped or cylindrical profile to match
with the top chute 3302).
[0224] In one embodiment, the deck 3308 and the deckbase 3310 are
part of the laboratory automation system 1104 (e.g., in a storage
unit). In one embodiment, the deck 3308 may hold a plurality of
specimen carrier racks holding a plurality of specimen carriers
carrying multiple specimen containers. In some embodiments, the
deck 3308 may hold other means of supplying waste objects through
the chute arrangement 3300.
[0225] In one embodiment, the adapter unit 3304 may be configured
to compensate for the distance between the top chute 3302 and the
bottom chute 3306 that results from the presence of the deck base
3310. In some embodiments, the bottom chute 3306 is in close
proximity to an ultrasonic sensor 3312 such that the ultrasonic
signals emitted from the ultrasonic sensor 3312 are directed
towards an opening or side hole in the bottom chute 3306 to detect
an object passing through the chute arrangement 3300. In one
embodiment, an optical sensor may be used in place of the
ultrasonic sensor 3312 for short range detection of the passing
objects. The optical sensor may be mounted on the deck base 3310
such that an object falling through the chute arrangement 3300 is
in its line of sight. The optical sensor may detect change in light
when a sample container passes through the chute arrangement 3300.
In some embodiments, the optical sensor may be implemented as a
light barrier or a light curtain comprising multiple light barriers
in parallel. The ultrasonic sensor and/or the optical sensor may be
part of the sensor unit 1120. The chute arrangement 3300 may be
part of a specimen output system, as described with reference to
FIG. 23.
[0226] FIG. 23 illustrates overview of an exemplary specimen output
system according to one embodiment of the invention.
[0227] In one embodiment, a specimen output system 3400 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,
plasma, etc. An output robot 3402 may be used to transport the
specimen containers from various areas of a laboratory system, such
as input, distribution, centrifuge, decapper, aliquotter, output,
analyzer, sorting, recapping, and secondary tube lift areas. The
specimen containers may be stored in a single tube carrier rack
3404. A plurality of such racks may be placed in the deck 3308. The
output robot 3402 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 3404 for discarding into a waste container
3406. Even though the exemplary system 3400 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.
[0228] In one embodiment, the waste container 3406 may include a
height 3408, length 3410 and a width 3412 that may be used to
determine a fill capacity of the waste container 3406. For example,
the height 3408, length 3410 and the width 3412 and any other
geometric information related to the waste container 3416 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 capacity
of the waste container 3406.
[0229] Embodiments may be used to help the specimen container pass
through a chute arrangement into the waste container 3406 when
released by the gripper unit (not shown). In one embodiment, the
chute arrangement includes one or more of the top chute 3302,
adapter unit 3304 and the bottom chute 3306. The bottom chute 3306
may be mounted on the deckbase 3310 to provide support or stability
(as shown in FIG. 22). The adapter unit 3304 may be configured to
compensate for the distance between the top chute 3302 and the
bottom chute 3306 caused by the deck base 3310. Further, it will be
understood that other feeders or supply mechanisms may be used to
feed discarded objects through the chute arrangement 3012. For
examples, bowl feeders or step feeders may be used to feed
individual objects such as caps through the chute arrangement 3012
directed towards the waste container 3406.
[0230] Embodiments provide for a number of advantages. For example,
by not attaching the waste container 3406 to the chute arrangement
or the deckbase 3310, the waste container 3406 may be removed for
emptying or replaced with another container.
[0231] In some embodiments, the specimen output system 3400 may be
part of the laboratory automation system 1104. The output robot
3402 may utilize the robot arm 1002 for gripping an object using
the gripper unit 1114 from the single tube carrier rack 3404 and
dropping it into the waste container 3406 through the chute
arrangement comprising one or more of the top chute 3302, adapter
unit 3304 and the bottom chute 3306. In one embodiment, the
processing unit 1106 may be in communication with the output robot
3402 to control the output robot 3402 to start and stop the
specimen container discarding process.
[0232] FIG. 24 illustrates a flow chart for a method of releasing
an object through a chute arrangement, in one embodiment of the
invention.
[0233] In step 3502, an object is gripped using a plurality of
gripper fingers in a gripper unit. Referring back to FIG. 19, the
gripper unit 3002 may grip the specimen container 3014 using the
gripper fingers 3004 (e.g., from the single tube carrier rack 3404
as shown in FIG. 23) for discarding it into the waste container
3016. The gripper unit 3002 may be part of the output robot
3402.
[0234] In step 3504, the object is inserted into a chute
arrangement using the gripper unit. For example, the gripper unit
3002 may insert the specimen container 3014 into the chute
arrangement 3012. The chute arrangement 3012 may comprise the top
chute 3006 in the form of an element and the bottom chute 3010
coupled to the top chute 3006 through the optional adapter unit
3008. As shown in FIGS. 20A-20B, the specimen container 3014 may be
inserted into the top chute 3006 from above by the gripper unit
3002 using the gripper fingers 3004.
[0235] In step 3506, the object is released by the plurality of
gripper fingers by causing the gripper fingers to extend outward
while the object is within an element of the chute arrangement. As
shown in FIG. 20B, the specimen container 3014 may be released by
the gripper fingers 3004 by causing the gripper fingers 3004 to
extend outward while the specimen container 3014 is within the
element 3006 of the chute arrangement 3012. In embodiments of the
invention, the element 3006 helps separate the specimen container
3014 from the gripper fingers 3004, when the gripper fingers 3004
release the specimen container 3014 and pass through the plurality
of slots 3102.
[0236] In step 3508, the object passes through the chute
arrangement into a waste container placed under the chute
arrangement. As shown in FIG. 19, the specimen container 3014
passes through the chute arrangement 3012 into the waste container
3016 when released by the gripper fingers 3004. The waste container
3016 is not attached to the chute arrangement 3012, thus can be
easily replaced or emptied as needed.
IV. Container Fill Level Detection
[0237] Referring back to FIG. 2, the gripper unit 1114 may grip a
waste object using the gripper fingers 1118 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 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 and transport it to another work unit or
module in the laboratory automation system 1104 for further
processing. In one embodiment, the container unit 1128 may include
one or more waste containers to collect or store disposable or
waste objects such as test tubes, test tube caps, capillaries,
secondary test tubes, pipettes etc.
[0238] Referring back to FIG. 19, the gripper unit 3002 may be
configured to grip objects, such as specimen containers, caps,
etc., using gripper fingers 3004 to automatically discard into the
waste container 3016. In embodiments of the invention, the waste
container 3016 may be configured to collect the objects dropped
through the chute arrangement 3012, the feeder unit 1130 or via any
other suitable mechanism. The sensor unit 3018 may be configured to
detect an object, e.g., the specimen container 3014, passing
through the chute arrangement 3012 and provide a corresponding
output to the processor 1108 relating to the presence of the object
through the chute arrangement 3012. The sensor unit 3018 may also
be configured to detect a fill level of the waste container 3016
and provide a corresponding output to the processor 1108 for
generating an estimate of the number of objects that can further
fit in the waste container 3016.
[0239] 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.
[0240] FIG. 25 illustrates an ultrasonic sensor arrangement 4200 in
accordance with embodiments of the invention.
[0241] 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).
[0242] In one embodiment, the deflector chute 4204 is similar to
the bottom chute 3010 of the chute arrangement 3012 (in FIG. 19).
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.
[0243] 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.
[0244] 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.
[0245] 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.
[0246] 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.
[0247] 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.
[0248] FIG. 26 illustrates an exemplary ultrasonic sensor
arrangement 4300 using two ultrasonic sensors, in one embodiment of
the invention.
[0249] 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 3310
through an opening 4310. The output robot 3402 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 3310 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.
[0250] 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.
[0251] FIG. 27 illustrates an exemplary sensor arrangement 4400
using one ultrasonic sensor and one optical sensor, in one
embodiment.
[0252] 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 3310 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.
[0253] 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. 28 and FIGS. 29A-29C.
[0254] FIG. 28 illustrates a method 4500 for detecting the fill
level of a container in one embodiment.
[0255] 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. 23, a maximum fill level "H" the
container 3406 may be determined based on the height 3408, length
3410 and the width 3412 of the container 3406 as well as one or
more known geometric dimensions of the object. In one embodiment,
the geometric dimensions of the object may be determined as
discussed previously with reference to FIG. 3. 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.
[0256] In step 4504, a passing object directed to the container is
detected using a sensor unit. Referring back to FIG. 25, 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.
[0257] 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.
[0258] In step 4508, a fill level H.sub.1 of the container is
measured using the sensor unit. Referring back to FIG. 25, 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.
[0259] 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, as explained above, 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.
[0260] As shown in FIG. 29A, 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.
[0261] 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
3402 (as shown in FIG. 23) to determine how may more waste tubes
may be dropped (e.g., using the gripper unit 3002) into the
container 3406. 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.
[0262] 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,
[0263] N.sub.count=number of counted objects,
[0264] W.sub.count=a first weight factor for counted objects,
[0265] N.sub.meas=number of objects estimated from measurement
and
[0266] W.sub.meas=a second weight factor for estimation from
measurement.
[0267] 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)
[0268] 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
[0269] 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.
[0270] As illustrated in FIG. 29B, 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.
[0271] 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.
[0272] 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.
[0273] 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. 29C, 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.
[0274] 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.
[0275] 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. 29A-29C. Handling of
the consumable objects is further discussed with reference to FIG.
30 and FIGS. 31A-31C.
[0276] FIG. 30 illustrates a method 4700 for detecting the fill
level of a container with consumable objects, in one
embodiment.
[0277] 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. 31A,
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.
[0278] As shown in FIG. 31A, 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. 29A-29C. Alternatively, a
light barrier located close to the top of the container (as shown
in FIG. 31A) 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.
[0279] 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.
[0280] 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.
[0281] 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. 31B, the (partial) fill level H.sub.1
may be reduced to a level 4804 as objects are removed from the
consumable container 4800.
[0282] 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.
[0283] 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.
[0284] In step 4714, it is determined if the fill level H.sub.1 is
zero. If the corrected estimated 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. 31C, a level 4806
represents a zero fill level H.sub.1.
[0285] 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
generate 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.
[0286] In one embodiment, a plurality of containers may be used, as
discussed with reference to FIG. 13.
[0287] FIG. 32 illustrates an exemplary specimen output system
4900.
[0288] As illustrated in the figure, the deck 3308 may be coupled
to an output frame 4906 with a plurality of containers 4904 located
underneath the deck 3308. 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. Referring back to FIGS. 19 and 23, the output
robot 3402 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 3402 using the
gripper unit 3002 and transported to another unit for further
processing. A system 4902 may be configured to control the output
robot 3402 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.
[0289] FIG. 33 illustrates an arrangement 5000 for a bin frame 5006
with a door 5004.
[0290] A container 5002 may be positioned to collect an object
dropped through the chute arrangement 3012, as shown in FIG. 19.
The bottom part of the chute arrangement 3012 may be mounted on the
deckbase 3310. The ultrasonic sensor 3018 may be configured to
detect a passing object through the chute arrangement 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 3402) 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 arrangement 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. 34 and 35.
[0291] 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. 34.
[0292] In step 5102, an operator removes the waste container to
empty out the disposable or waste objects. Referring back to FIG.
33, 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 3402, 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.
[0293] 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. 32). 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.
[0294] 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. 28, 29A-29C.
[0295] 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.
[0296] 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.
[0297] 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.
[0298] 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.
[0299] 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.
[0300] 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. 35.
[0301] To remove a consumable container for refilling by opening a
door, steps 5102 and 5104 are followed, as discussed with reference
to FIG. 34.
[0302] 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 500.
[0303] 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. 28. In
another embodiment, a simple light barrier may be used to detect
the level.
[0304] In step 5206, it is determined if the consumables were
filled to a defined maximum level.
[0305] In step 5208, an alert message may be sent to the operator
if the consumables were not filled to a desired maximum level.
[0306] In step 5210, a consumable counter may be set to a defined
maximum value.
[0307] 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. 30, 31A-31C.
[0308] 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.
[0309] 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.
[0310] A number of specific embodiments that can determine a fill
level of objects in a container are described in this section.
Embodiments of the invention may include various combinations of
the features of such systems with features in the above-described
systems that utilize a strip off element and corresponding chute
arrangement, as well as systems that utilize the sensing gripper
unit embodiments and/or replaceable gripper finger embodiments. For
example, in some embodiment, the system comprises an element
comprising a tubular body comprising a central axial bore running
the length of said body with a first open end and a second open
end, the first end including two or more slots parallel to the axis
of the central axial bore. The system also comprises a container
for holding objects passing through the tubular body, and a sensor
unit configured to generate a first output by detecting a fill
level of the container. The system further comprises a processor
configured to determine different levels of the objects in the
container as the objects fill the container or are removed from the
container based on at least the first output. Other details
regarding features of such combinations are provided above.
V. Computer Architecture
[0311] The various participants and elements described herein with
reference to FIG. 2 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.
[0312] Examples of such subsystems or components are shown in FIG.
36. The subsystems shown in FIG. 36 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.
[0313] Embodiments of the technology are not limited to the
above-described embodiments. Specific details regarding some of the
above-described aspects are provided above. The specific details of
the specific aspects may be combined in any suitable manner without
departing from the spirit and scope of embodiments of the
technology. For example, back end processing, data analysis, data
collection, and other processes may all be combined in some
embodiments of the technology. However, other embodiments of the
technology may be directed to specific embodiments relating to each
individual aspect, or specific combinations of these individual
aspects.
[0314] 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
[0315] 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.
[0316] 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.
[0317] 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.
[0318] A recitation of "a", "an" or "the" is intended to mean "one
or more" unless specifically indicated to the contrary.
[0319] 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.
* * * * *