U.S. patent application number 15/434968 was filed with the patent office on 2017-09-07 for laboratory automated instruments, systems, and methods.
The applicant listed for this patent is GEN-PROBE INCORPORATED. Invention is credited to Gary D. LAIR, Matthias MERTEN, George T. WALKER.
Application Number | 20170254827 15/434968 |
Document ID | / |
Family ID | 58213342 |
Filed Date | 2017-09-07 |
United States Patent
Application |
20170254827 |
Kind Code |
A1 |
WALKER; George T. ; et
al. |
September 7, 2017 |
LABORATORY AUTOMATED INSTRUMENTS, SYSTEMS, AND METHODS
Abstract
A laboratory automated system can include a host conveyor
assembly configured to transport a plurality of carriers and
receptacles coupled thereto between at least a sample processing
instrument and at least one assay instrument. The system includes
an intermediate conveyor assembly configured to transport a
plurality of carriers and receptacles coupled thereto from within
sample processing instrument to the host conveyor assembly. The
system also includes an intermediate conveyor assembly for each
assay instrument configured to transport a plurality of carriers
from host conveyor assembly to a respective processing position
within the assay instrument. The intermediate conveyor assembly
coupled to the assay instrument can include a buffer conveyor
subassembly configured to receive carriers from the host conveyor
assembly, and a spur conveyor assembly configured to transport a
carrier to the processing position of the assay instrument.
Inventors: |
WALKER; George T.; (San
Diego, CA) ; MERTEN; Matthias; (San Diego, CA)
; LAIR; Gary D.; (San Diego, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GEN-PROBE INCORPORATED |
San Diego |
CA |
US |
|
|
Family ID: |
58213342 |
Appl. No.: |
15/434968 |
Filed: |
February 16, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62332831 |
May 6, 2016 |
|
|
|
62297348 |
Feb 19, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N 35/04 20130101;
G01N 35/1011 20130101; G01N 2035/0406 20130101; G01N 2035/00801
20130101; G01N 2035/047 20130101; G01N 35/00732 20130101; G01N
2035/0462 20130101; C12Q 1/6806 20130101; G01N 2035/00782 20130101;
G01N 2035/0467 20130101; G01N 35/1065 20130101; G01N 2035/0472
20130101; G01N 2035/00742 20130101; G01N 35/00871 20130101 |
International
Class: |
G01N 35/10 20060101
G01N035/10; G01N 35/04 20060101 G01N035/04; C12Q 1/68 20060101
C12Q001/68; G01N 35/00 20060101 G01N035/00 |
Claims
1. An automated sample processing system comprising: a first
instrument comprising a first automated pipettor configured to
aspirate at least a portion of a sample from a first sample
containing receptacle and dispense the portion of the first sample
into a first processing receptacle; a second instrument comprising
a second automated pipettor configured to aspirate at least
portions of samples from processing receptacles containing samples
at a first processing position within the second instrument and
dispense at least portions of samples into assay receptacles, the
second instrument being further configured to perform first assays
on the portions of the samples contained within assay receptacles;
a first conveyor assembly configured to transport a first carrier
coupled to the first processing receptacle containing the portion
of the first sample dispensed by the first automated pipettor from
the first instrument to a position outside the first instrument; a
second conveyor assembly configured to receive the first carrier
coupled to the first processing receptacle from the first conveyor
assembly at the position outside the first instrument, and to
transport the first carrier to a first position outside the second
instrument; a third conveyor assembly configured to (i) receive the
first carrier from the second conveyor assembly at the first
position outside the second instrument, (ii) transport the first
carrier to the first processing position within the second
instrument at which the second automated pipettor of the second
instrument aspirates at least a portion of the first sample from
the first processing receptacle for subsequently dispensing the
portion of the first sample into an assay receptacle, (iii) after
the second automated pipettor of the second instrument aspirates at
least a portion of the first sample from the first processing
receptacle, transport the first carrier coupled to the first
processing receptacle from the first processing position to a
second position outside the second instrument, and (iv) transfer
the first carrier at the second position outside the second
instrument to the second conveyor assembly.
2. The automated sample processing system of claim 1, wherein the
second instrument is configured to perform first assays by
subjecting samples contained within assay receptacles to nucleic
acid amplification reaction conditions.
3. The automated sample processing system of claim 1, wherein the
first instrument is further configured to (a) couple the first
processing receptacle with the first carrier, or (b) decap and cap
at least one of the first sample containing receptacle and the
first processing receptacle.
4. The automated sample processing system of claim 1, wherein the
first instrument further comprises (a) an input bay configured to
manually receive the first sample containing receptacle, or (b) an
input bay configured to automatically receive the first sample
containing receptacle.
5. (canceled)
6. The automated sample processing system of claim 1, further
comprising a third instrument comprising a third automated pipettor
configured to aspirate at least portions of samples from processing
receptacles containing samples at a second processing position
within the third instrument and dispense the portions of samples
into second assay receptacles, the third instrument being further
configured to perform second assays on samples contained within
assay receptacles.
7. The automated sample processing system of claim 6, wherein the
first assays are different than the second assays.
8. The automated sample processing system of claim 6, wherein: the
third instrument is configured to perform the second assays by
subjecting samples contained within assay receptacles to nucleic
acid amplification reaction conditions; the second instrument is
configured to perform first assays by subjecting samples contained
within assay receptacles to nucleic acid amplification reaction
conditions, the subjecting samples contained within assay
receptacles to nucleic acid amplification reaction conditions of
the first assay comprises adding a first reagent to samples
contained within assay receptacles; and the subjecting samples
contained within assay receptacles to nucleic acid amplification
reaction conditions of the second assay comprises adding a second
reagent, different than the first reagent, to samples contained
within assay receptacles.
9. (canceled)
10. The automated sample processing system of claim 6, wherein the
first assays are configured to determine the presence of a first
analyte, and wherein the second assays are configured to determine
the presence of a second analyte different than the first
analyte.
11. The automated sample processing system of claim 6, wherein the
first assays are the same as the second assays.
12. The automated sample processing system of claim 6, further
comprising a fourth conveyor assembly configured to (i) receive a
second carrier coupled to a second processing receptacle from the
second conveyor assembly at a first position outside the third
instrument, (ii) transport the second carrier to the second
processing position within the third instrument at which the third
automated pipettor of the third instrument aspirates at least a
portion of a second sample from the second processing receptacle
for subsequently dispensing the portion of the second sample into a
second assay receptacle, and (iii) after the third automated
pipettor of the third instrument aspirates the portion of the
second sample from the second processing receptacle, transport the
second carrier from the second processing position to a second
position outside the third instrument; wherein the first automated
pipettor of the first instrument is further configured to aspirate
at least a portion of the second sample from the second sample
containing receptacle and dispense the portion of the second sample
into the second processing receptacle; wherein the first conveyor
assembly is further configured to transport the second carrier
coupled to the second processing receptacle containing the portion
of the second sample dispensed by the first automated pipettor from
the first instrument to the position outside the first instrument;
and wherein the second conveyor assembly is further configured to
receive the second carrier coupled to the second processing
receptacle from the first conveyor assembly at the position outside
the first instrument, and transport the second carrier to the first
position outside the third instrument.
13. The automated sample processing system of claim 12, wherein the
first instrument comprises a writer configured to transfer a first
identifier to at least one of the first carrier and the first
processing receptacle, and to transfer a second identifier to at
least one of the second carrier and the second processing
receptacle.
14. (canceled)
15. (canceled)
16. The automated sample processing system of claim 13, wherein:
the writer is configured to transfer the first identifier to the
first carrier and the second identifier to the second carrier; the
first carrier comprises a first RFID tag; the second carrier
comprises a second RFID tag; and the writer comprises an RFID
writer configured to transmit the first identifier to the first
RFID tag and the second identifier to the second RFID tag.
17. The automated sample processing system of claim 13, wherein:
the writer is configured to transfer the first identifier to the
first carrier and the second identifier to the second carrier; the
second conveyor system comprises: a first portion configured to
transport carriers from the position outside the first instrument
to the first position outside the second instrument; a second
portion configured to transport carriers from the first position
outside the second instrument to the second position outside the
second instrument; and a diverter configured to transfer the first
carrier from the first portion of the second conveyor assembly to
the third conveyor assembly based on the first identifier, and
configured to transfer the second carrier from the first portion of
the second conveyor assembly to the second portion of the second
conveyor assembly based on the second identifier; the automated
sample processing system further comprises a control system
configured to transmit a control signal to the diverter; the
diverter is configured to transfer the first carrier from the first
portion of the second conveyor assembly to the third conveyor
assembly based on the control signal, and configured to transfer
the second carrier from the first portion of the second conveyor
assembly to the second portion of the second conveyor assembly
based on the control signal; the second conveyor assembly further
comprises a sensor configured to detect the first identifier of the
first carrier and the second identifier of the second carrier, and
to transmit a sensor signal to the control system based on the
detected first identifier and the detected second identifier; and
the control system is configured to adjust the control signal
transmitted to the diverter based on the sensor signal received
from the sensor.
18. (canceled)
19. The automated sample processing system of claim 17, wherein the
sensor of the second conveyor assembly comprises an RFID antenna or
an image sensor.
20. (canceled)
21. The automated sample processing system claim 13, wherein: the
writer is configured to transfer the first identifier to the first
carrier and the second identifier to the second carrier; and the
third conveyor assembly comprises a sensor configured to detect the
first identifier of the first carrier positioned at the first
processing position; and the second instrument is configured to
start aspirating the portion of the first sample from the first
processing receptacle containing the portion of the first sample at
the first processing position within the second instrument based on
the detected first identifier.
22. (canceled)
23. (canceled)
24. The automated sample processing system of claim 13, wherein:
the writer is configured to transfer the first identifier to the
first carrier and the second identifier to the second carrier; the
second conveyor system further comprises: a first portion
configured to transport carriers from the second position outside
the second instrument to the first position outside the third
instrument; a second portion configured to transport carriers from
the first position outside the third instrument to the second
position outside the third instrument; and a diverter configured to
transfer the second carrier from the first portion of the second
conveyor assembly to the fourth conveyor assembly based on the
second identifier of the second carrier, and configured to transfer
the first carrier from the first portion of the second conveyor
assembly to the second portion of the second conveyor assembly
based on the first identifier; the automated sample processing
system further comprises a control system configured to transmit a
control signal to the diverter; the diverter is configured to
transfer the second carrier from the first portion of the second
conveyor assembly to the fourth conveyor assembly based on the
control signal, and configured to transfer the first carrier from
the first portion of the second conveyor assembly to the second
portion of the second conveyor assembly based on the control
signal; the second conveyor assembly further comprises a sensor
configured to detect the first identifier of the first carrier and
the second identifier of the second carrier, and to transmit a
second sensor signal to the control system based on the detected
first identifier and the detected second identifier; and the
control system is configured to adjust the control signal
transmitted to the diverter based on the second sensor signal
received from the sensor of the second conveyor assembly.
25. (canceled)
26. (canceled)
27. (canceled)
28. The automated sample processing system of claim 13, wherein:
the fourth conveyor assembly comprises a sensor configured to
detect the second identifier of the second carrier positioned at
the second processing position; and the third instrument is
configured to start aspirating the portion of the second sample
from the second processing receptacle containing the second sample
at the second processing position within the third instrument based
on the detected second identifier.
29. (canceled)
30. (canceled)
31. (canceled)
32. The automated sample processing system of claim 1, wherein the
third conveyor assembly comprises: a first conveyor subassembly
comprising an input portion configured to transport the first
carrier from the second conveyor assembly to a first transfer
position, and an output portion configured to transport the first
carrier from a second transfer position to the second position
outside the second instrument; and a second conveyor subassembly
configured to transport the first carrier between a third transfer
position and the first processing position within the instrument,
and a diverter configured to transport the first carrier from the
first transfer position to the third transfer position while
simultaneously transporting another carrier from the third transfer
position to the second transfer position.
33. The automated sample processing system of claim 32, wherein the
second conveyor subassembly comprises (a) a gripper configured to
secure the first carrier to the first processing receptacle as a
distal end of the second automated pipettor is withdrawn from the
first processing receptacle, or (b) a movable track configured to
transport the first carrier between the third transfer position and
the first processing position within the instrument.
34. (canceled)
35. The automated sample processing system of claim 1, wherein the
first carrier comprises a puck.
36. The automated sample processing system of claim 1, wherein: the
first instrument further comprises a first housing; the first
automated pipettor is positioned in the first housing; the second
instrument further comprises a second housing; and the second
automated pipettor is positioned in the second housing.
37. (canceled)
38. (canceled)
39. An automated sample processing system comprising: a first
conveyor assembly configured to transport a first carrier coupled
to a first processing receptacle containing a first sample, and a
second carrier coupled to a second processing receptacle containing
a second sample; a second conveyor assembly configured to (i)
receive the first carrier from the first conveyor assembly; (ii)
transport the first carrier to a first processing position; and
(iii) return the first carrier to the first conveyor assembly; a
first instrument comprising a first automated pipettor configured
to aspirate at least a portion of the first sample from the first
processing receptacle at the first processing position and dispense
the portion of the first sample into a first assay receptacle,
wherein the first processing position is within the first
instrument, and wherein the first instrument is further configured
to perform a first assay on the first sample contained within the
first assay receptacle to determine the presence of a first analyte
in the first sample; a third conveyor assembly configured to (i)
receive the second carrier from the first conveyor assembly; (ii)
transport the second carrier to a second processing position; and
(iii) return the second carrier to the first conveyor assembly; and
a second instrument comprising a second automated pipettor
configured to aspirate at least a portion of the second sample from
the second processing receptacle at the second processing position
and dispense the portion of the second sample into a second assay
receptacle, wherein the second processing position is within the
second instrument, and wherein the second instrument is further
configured to perform a second assay on the second sample contained
within the second assay receptacle to determine the presence of a
second analyte in the second sample.
40. The automated sample processing system of claim 39, wherein the
first assay comprises subjecting the first sample contained within
the first assay receptacle to nucleic acid amplification reaction
conditions.
41. The automated sample processing system of claim 39, wherein the
first assay is different than the second assay.
42. The automated sample processing system of claim 39, wherein the
second assay comprises subjecting the second sample contained
within the second assay receptacle to nucleic acid amplification
reaction conditions.
43. The automated sample processing system of claim 39, wherein the
first analyte and the second analyte are the same analytes.
44. The automated sample processing system of claim 39, wherein the
first analyte and the second analyte are different analytes.
45. The automated sample processing system of claim 39, wherein: at
least one of the first processing receptacle and the first carrier
comprises a first identifier; at least one of the second processing
receptacle and the second carrier comprises a second identifier;
and the first conveyor system comprises: a first portion configured
to transport the first carrier and the second carrier to a first
position upstream from the second conveyor system; a second portion
configured to transport the first carrier and the second carrier to
a second position upstream from the third conveyor system; and a
first diverter configured to transfer the first carrier from the
first portion of the first conveyor assembly to the second conveyor
assembly based on the first identifier, and configured to transfer
the second carrier from the first portion of the first conveyor
assembly to the second portion of the first conveyor assembly based
on the second identifier.
46. The automated sample processing system of claim 45, further
comprising a control system configured to transmit a first control
signal to the first diverter; wherein the first diverter is
configured to transfer the first carrier from the first portion of
the first conveyor assembly to the second conveyor assembly based
on the first control signal, and configured to transfer the second
carrier from the first portion of the first conveyor assembly to
the second portion of the first conveyor assembly based on the
first control signal; wherein the first conveyor assembly further
comprises: a first sensor configured to (i) detect the first
identifier when the first carrier is at the first position upstream
from the second conveyor system, (ii) detect the second identifier
when the second carrier is at the first position upstream from the
second conveyor system, and (iii) transmit a first sensor signal to
the control system based on the detected first identifier and the
detected second identifier; a second sensor configured to (i)
detect the first identifier when the first carrier is at the second
position upstream from the third conveyor system, (ii) detect the
second identifier when the second carrier is at the second position
upstream from the third conveyor system, and (iii) transmit a
second sensor signal to the control system based on the detected
first identifier and the detected second identifier; a third
portion configured to transport the first carrier and the second
carrier to a third position downstream from the second instrument;
and a second diverter configured to transfer the first carrier from
the second portion of the first conveyor assembly to the third
portion of the first conveyor assembly based on the first
identifier; transfer the second carrier from the second portion of
the first conveyor assembly to the third conveyor assembly based on
the second identifier; transfer the second carrier from the second
portion of the first conveyor assembly to the third conveyor
assembly based on the second control signal; and transfer the first
carrier from the second portion of the first conveyor assembly to
the third portion of the first conveyor assembly based on the
second control signal; and wherein the control system is configured
to adjust the first control signal transmitted to the first
diverter based on the first sensor signal received from the first
sensor; transmit a second control signal to the second diverter;
and adjust the second control signal transmitted to the second
diverter based on the second sensor signal received from the second
sensor.
47. (canceled)
48. (canceled)
49. The automated sample processing system claim 46, wherein: the
second conveyor assembly further comprises a third sensor
configured to detect the first identifier of the first carrier
positioned at the first processing position; the first instrument
is configured to start aspirating the portion of the first sample
from the first processing receptacle at the first processing
position based on the detected first identifier; the third conveyor
assembly further comprises a fourth sensor configured to detect the
second identifier of the second carrier positioned at the second
processing position; and the second instrument is configured to
start aspirating the portion of the second sample from the second
processing receptacle at the second processing position based on
the detected second identifier.
50-175. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Nos. 62/332,831, filed May 6, 2016 and 62/297,348,
filed Feb. 19, 2016, the contents of each of which applications is
hereby incorporated by reference herein in its entirety.
FIELD
[0002] Embodiments of this disclosure relate to laboratory
automated instruments, systems, and methods for processing a
sample.
BACKGROUND
[0003] Laboratory automated instruments and systems can have
automated conveyor assemblies that transport samples among various
positions within a laboratory. For example, the samples can be
contained in receptacles, and the receptacles can be coupled to
carriers (e.g., pucks). To transport the carriers and, in turn, the
receptacles containing the samples, the carriers are placed on the
conveyor assembly, and the conveyor assembly transports the
carriers and the receptacles coupled to the carriers among the
various positions within the laboratory.
SUMMARY
[0004] In some embodiments, an automated sample processing system
includes a first instrument that includes a first automated
pipettor configured to aspirate at least a portion of a sample from
a first sample containing receptacle and dispense the portion of
the first sample into a first processing receptacle. The automated
sample processing system also includes a second instrument includes
a second automated pipettor configured to aspirate at least
portions of samples from processing receptacles containing samples
at a first processing position within the second instrument and
dispense at least portions of samples into assay receptacles. The
second instrument is further configured to perform first assays on
the portions of the samples contained within assay receptacles. The
automated sample processing system also includes a first conveyor
assembly configured to transport a first carrier coupled to the
first processing receptacle containing the portion of the first
sample dispensed by the first automated pipettor from the first
instrument to a position outside the first instrument. The
automated sample processing system also includes a second conveyor
assembly configured to receive the first carrier coupled to the
first processing receptacle from the first conveyor assembly at the
position outside the first instrument, and to transport the first
carrier to a first position outside the second instrument.
[0005] The automated sample processing system also includes a third
conveyor assembly. The third conveyor assembly is configured to
receive the first carrier from the second conveyor assembly at the
first position outside the second instrument. The third conveyor
assembly is also configured to transport the first carrier to the
first processing position within the second instrument at which the
second automated pipettor of the second instrument aspirates at
least a portion of the first sample from the first processing
receptacle for subsequently dispensing the portion of the first
sample into an assay receptacle. The third conveyor assembly is
also configured to, after the second automated pipettor of the
second instrument aspirates at least a portion of the first sample
from the first processing receptacle, transport the first carrier
coupled to the first processing receptacle from the first
processing position to a second position outside the second
instrument. The third conveyor assembly is also configured to
transfer the first carrier at the second position outside the
second instrument to the second conveyor assembly.
[0006] The second instrument can be configured to perform first
assays by subjecting samples contained within assay receptacles to
nucleic acid amplification reaction conditions. The first
instrument can be further configured to couple the first processing
receptacle with the first carrier. The first instrument can further
include an input bay configured to manually receive the first
sample containing receptacle. The first instrument can further
include an input bay configured to automatically receive the first
sample containing receptacle.
[0007] The automated sample processing system can further include a
third instrument that includes a third automated pipettor
configured to aspirate at least portions of samples from processing
receptacles containing samples at a second processing position
within the third instrument and dispense the portions of samples
into second assay receptacles. The third instrument is further
configured to perform second assays on samples contained within
assay receptacles.
[0008] The first assays can be different than the second assays.
The third instrument can be configured to perform the second assays
by subjecting samples contained within assay receptacles to nucleic
acid amplification reaction conditions. Subjecting samples
contained within assay receptacles to nucleic acid amplification
reaction conditions of the first assay can include adding a first
reagent to samples contained within assay receptacles, and
subjecting samples contained within assay receptacles to nucleic
acid amplification reaction conditions of the second assay can
include adding a second reagent, different than the first reagent,
to samples contained within assay receptacles. The first assays can
be configured to determine the presence of a first analyte, and the
second assays can be configured to determine the presence of a
second analyte different than the first analyte.
[0009] The first assays can be the same as the second assays.
[0010] The automated sample processing system can further include a
fourth conveyor assembly configured to receive a second carrier
coupled to a second processing receptacle from the second conveyor
assembly at a first position outside the third instrument. The
fourth conveyor assembly is further configured to transport the
second carrier to the second processing position within the third
instrument at which the third automated pipettor of the third
instrument aspirates at least a portion of a second sample from the
second processing receptacle for subsequently dispensing the
portion of the second sample into a second assay receptacle. And
the fourth conveyor assembly is further configured to, after the
third automated pipettor of the third instrument aspirates the
portion of the second sample from the second processing receptacle,
transport the second carrier from the second processing position to
a second position outside the third instrument. The first automated
pipettor of the first instrument is further configured to aspirate
at least a portion of the second sample from the second sample
containing receptacle and dispense the portion of the second sample
into the second processing receptacle. The first conveyor assembly
is further configured to transport the second carrier coupled to
the second processing receptacle containing the portion of the
second sample dispensed by the first automated pipettor from the
first instrument to the position outside the first instrument. The
second conveyor assembly is further configured to receive the
second carrier coupled to the second processing receptacle from the
first conveyor assembly at the position outside the first
instrument, and transport the second carrier to the first position
outside the third instrument.
[0011] The first instrument cam include a writer configured to
transfer a first identifier to at least one of the first carrier
and the first processing receptacle, and to transfer a second
identifier to at least one of the second carrier and the second
processing receptacle. The writer can be a printer configured to
print the first identifier on at least one of the first carrier and
the first processing receptacle, and to print the second identifier
on at least one of the second carrier and the second processing
receptacle. The writer can be configured to transfer the first
identifier to the first carrier and the second identifier to the
second carrier. The first carrier can include a first RFID tag, and
the second carrier can include a second RFID tag. The writer can
include an RFID writer configured to transmit the first identifier
to the first RFID tag and the second identifier to the second RFID
tag.
[0012] The second conveyor system can include a first portion
configured to transport carriers from the position outside the
first instrument to the first position outside the second
instrument. The second conveyor system can also include a second
portion configured to transport carriers from the first position
outside the second instrument to the second position outside the
second instrument. And the second conveyor system can include a
diverter configured to transfer the first carrier from the first
portion of the second conveyor assembly to the third conveyor
assembly based on the first identifier. The divert is also
configured to transfer the second carrier from the first portion of
the second conveyor assembly to the second portion of the second
conveyor assembly based on the second identifier.
[0013] The automated sample processing system can further include a
control system configured to transmit a control signal to the
diverter. The diverter can be configured to transfer the first
carrier from the first portion of the second conveyor assembly to
the third conveyor assembly based on the control signal. The
diverter can be also configured to transfer the second carrier from
the first portion of the second conveyor assembly to the second
portion of the second conveyor assembly based on the control
signal. The second conveyor assembly can further include a sensor
configured to detect the first identifier of the first carrier and
the second identifier of the second carrier, and to transmit a
sensor signal to the control system based on the detected first
identifier and the detected second identifier. The control system
is configured to adjust the control signal transmitted to the
diverter based on the sensor signal received from the sensor. The
sensor of the second conveyor assembly can include an RFID antenna.
The sensor of the second conveyor assembly can also be an image
sensor.
[0014] The third conveyor assembly can include a sensor configured
to detect the first identifier of the first carrier positioned at
the first processing position. The second instrument can be
configured to start aspirating the portion of the first sample from
the first processing receptacle containing the portion of the first
sample at the first processing position within the second
instrument based on the detected first identifier. The sensor of
the third conveyor assembly can include an RFID antenna. The sensor
of the third conveyor assembly can also be an image sensor.
[0015] The second conveyor system can further include a first
portion configured to transport carriers from the second position
outside the second instrument to the first position outside the
third instrument, and a second portion configured to transport
carriers from the first position outside the third instrument to
the second position outside the third instrument. The second
conveyor system can further include a diverter configured to
transfer the second carrier from the first portion of the second
conveyor assembly to the fourth conveyor assembly based on the
second identifier of the second carrier. The divert can also be
configured to transfer the first carrier from the first portion of
the second conveyor assembly to the second portion of the second
conveyor assembly based on the first identifier.
[0016] The automated sample processing system can also include a
control system configured to transmit a control signal to the
diverter. The diverter can be configured to transfer the second
carrier from the first portion of the second conveyor assembly to
the fourth conveyor assembly based on the control signal, and
configured to transfer the first carrier from the first portion of
the second conveyor assembly to the second portion of the second
conveyor assembly based on the control signal. The second conveyor
assembly further includes a sensor configured to detect the first
identifier of the first carrier and the second identifier of the
second carrier, and to transmit a second sensor signal to the
control system based on the detected first identifier and the
detected second identifier. The control system can be configured to
adjust the control signal transmitted to the diverter based on the
second sensor signal received from the sensor of the second
conveyor assembly. The sensor of the second conveyor assembly
includes an RFID antenna. The sensor of the second conveyor
assembly can also be an image sensor.
[0017] The fourth conveyor assembly can include a sensor configured
to detect the second identifier of the second carrier positioned at
the second processing position. And the third instrument can be
configured to start aspirating the portion of the second sample
from the second processing receptacle containing the second sample
at the second processing position within the third instrument based
on the detected second identifier. The sensor of the fourth
conveyor assembly can include an RFID antenna. The sensor of the
fourth conveyor assembly can also be an image sensor.
[0018] The third instrument can further include a housing defining
a substantially enclosed volume, and the third automated pipettor
can be positioned in the volume.
[0019] The third conveyor assembly can include a first conveyor
subassembly that includes an input portion configured to transport
the first carrier from the second conveyor assembly to a first
transfer position. The first conveyor subassembly can also include
an output portion configured to transport the first carrier from a
second transfer position to the second position outside the second
instrument. The third conveyor assembly can also include a second
conveyor subassembly configured to transport the first carrier
between a third transfer position and the first processing position
within the instrument. The third conveyor assembly can also include
a diverter configured to transport the first carrier from the first
transfer position to the third transfer position while
simultaneously transporting another carrier from the third transfer
position to the second transfer position. The second conveyor
subassembly can include a gripper configured to secure the first
carrier to the first processing receptacle as a distal end of the
second automated pipettor is withdrawn from the first processing
receptacle. The second conveyor subassembly can also include a
movable track configured to transport the first carrier between the
third transfer position and the first processing position within
the instrument.
[0020] The first carrier can be a puck.
[0021] The first instrument can further include a first housing,
and the first automated pipettor is positioned in the first
housing. The second instrument can further include a second
housing, and the second automated pipettor is positioned in the
second housing.
[0022] The first instrument can further include a sample processing
station configured to decap and cap at least one of the first
sample containing receptacle and the first processing
receptacle.
[0023] In some embodiments, an automated sample processing system
includes a first conveyor assembly configured to transport a first
carrier coupled to a first processing receptacle containing a first
sample, and a second carrier coupled to a second processing
receptacle containing a second sample. The automated sample
processing system includes a second conveyor assembly configured to
receive the first carrier from the first conveyor assembly,
transport the first carrier to a first processing position, and
return the first carrier to the first conveyor assembly. The
automated sample processing system also includes a first instrument
that includes a first automated pipettor configured to aspirate at
least a portion of the first sample from the first processing
receptacle at the first processing position and dispense the
portion of the first sample into a first assay receptacle. The
first processing position is within the first instrument. And the
first instrument is further configured to perform a first assay on
the first sample contained within the first assay receptacle to
determine the presence of a first analyte in the first sample. The
automated sample processing system includes a third conveyor
assembly configured to receive the second carrier from the first
conveyor assembly, transport the second carrier to a second
processing position, and return the second carrier to the first
conveyor assembly. The automated sample processing system includes
a second instrument that includes a second automated pipettor
configured to aspirate at least a portion of the second sample from
the second processing receptacle at the second processing position
and dispense the portion of the second sample into a second assay
receptacle. The second processing position is within the second
instrument. And the second instrument is further configured to
perform a second assay on the second sample contained within the
second assay receptacle to determine the presence of a second
analyte in the second sample.
[0024] The first assay can include subjecting the first sample
contained within the first assay receptacle to nucleic acid
amplification reaction conditions. The first assay can be different
than the second assay.
[0025] The second assay can include subjecting the second sample
contained within the second assay receptacle to nucleic acid
amplification reaction conditions.
[0026] The first analyte and the second analyte can be the same
analytes, or the first analyte and the second analyte can be
different analytes.
[0027] At least one of the first processing receptacle and the
first carrier can include a first identifier, and at least one of
the second processing receptacle and the second carrier can include
a second identifier. The first conveyor system can also include a
first portion configured to transport the first carrier and the
second carrier to a first position upstream from the second
conveyor system. The first conveyor system can also include a
second portion configured to transport the first carrier and the
second carrier to a second position upstream from the third
conveyor system. And the first conveyor system can include a first
diverter configured to transfer the first carrier from the first
portion of the first conveyor assembly to the second conveyor
assembly based on the first identifier. The diverter is also
configured to transfer the second carrier from the first portion of
the first conveyor assembly to the second portion of the first
conveyor assembly based on the second identifier. The automated
sample processing system can also include a control system
configured to transmit a first control signal to the first
diverter. The first diverter is configured to transfer the first
carrier from the first portion of the first conveyor assembly to
the second conveyor assembly based on the first control signal, and
the first diverter configured to transfer the second carrier from
the first portion of the first conveyor assembly to the second
portion of the first conveyor assembly based on the first control
signal. The first conveyor assembly further includes a first sensor
configured to detect the first identifier when the first carrier is
at the first position upstream from the second conveyor system,
detect the second identifier when the second carrier is at the
first position upstream from the second conveyor system, and
transmit a first sensor signal to the control system based on the
detected first identifier and the detected second identifier. The
control system is also configured to adjust the first control
signal transmitted to the first diverter based on the first sensor
signal received from the first sensor.
[0028] The first conveyor system can further include a third
portion configured to transport the first carrier and the second
carrier to a third position downstream from the second instrument.
The first conveyor system can further include a second diverter
configured to transfer the first carrier from the second portion of
the first conveyor assembly to the third portion of the first
conveyor assembly based on the first identifier. The second
diverter is also configured to transfer the second carrier from the
second portion of the first conveyor assembly to the third conveyor
assembly based on the second identifier.
[0029] The control system can be further configured to transmit a
second control signal to the second diverter. The second diverter
is configured to transfer the second carrier from the second
portion of the first conveyor assembly to the third conveyor
assembly based on the second control signal, and configured to
transfer the first carrier from the second portion of the first
conveyor assembly to the third portion of the first conveyor
assembly based on the second control signal. The first conveyor
assembly can further include a second sensor configured to detect
the first identifier when the first carrier is at second position
upstream from the third conveyor system, detect the second
identifier when the second carrier is at the second position
upstream from the third conveyor system, and transmit a second
sensor signal to the control system based on the detected first
identifier and the detected second identifier. The control system
can also be configured to adjust the second control signal
transmitted to the second diverter based on the second sensor
signal received from the second sensor.
[0030] The second conveyor assembly can further include a third
sensor configured to detect the first identifier of the first
carrier positioned at the first processing position. The first
instrument is configured to start aspirating the portion of the
first sample from the first processing receptacle at the first
processing position based on the detected first identifier.
[0031] The third conveyor assembly can further include a fourth
sensor configured to detect the second identifier of the second
carrier positioned at the second processing position, and wherein
the second instrument is configured to start aspirating the portion
of the second sample from the second processing receptacle at the
second processing position based on the detected second
identifier.
[0032] In some embodiments, a conveyor assembly transports a
plurality of carriers coupled to respective processing receptacles
from a host conveyor assembly outside an instrument to a processing
position within the instrument. The conveyor assembly includes a
buffer conveyor subassembly configured to transport the plurality
of carriers coupled to the respective receptacles from the host
conveyor assembly to a first transfer position and configured to
transport the plurality of carriers coupled to the respective
receptacles from a second transfer position to the host conveyor
assembly. The conveyor assembly also includes a spur conveyor
subassembly configured to transport the plurality of carriers
coupled to the respective receptacles from a third transfer
position to the processing position within the instrument. The spur
conveyor subassembly includes a diverter configured to transport
one of the plurality of carriers coupled to one of the respective
receptacles from the first transfer position to the third transfer
position while simultaneously transporting another one of the
plurality of carriers coupled to another one of the respective
receptacles from the third transfer position to the second transfer
position.
[0033] The buffer conveyor subassembly can be mounted to an outer
surface of the instrument. The third transfer position can be
outside of the instrument. The spur conveyor subassembly can
further include a cover that encloses a portion of a path within
the instrument between the third transfer position and the
processing position. The cover can define an opening configured to
allow a distal end of a pipettor of the instrument to pass. The
distal end of the pipettor can include a disposable tip. The cover
can have a substantially inverted U-shape.
[0034] The spur conveyor subassembly can further include a sensor
configured to detect an identifier of one of the plurality of
carriers positioned at the processing position of the instrument.
The sensor can include an RFID reader.
[0035] The buffer conveyor subassembly can include a single movable
track. A portion of the diverter can overlap the single movable
track forming an input portion and an output portion of the buffer
conveyor subassembly. The input portion of the buffer conveyor
subassembly can have a length sufficient to queue a plurality of
carriers. The instrument can be configured to aspirate at least
portions of samples from processing receptacles coupled to carriers
at the processing position and to dispense the portions of the
samples into cavities defined by an assay receptacle. The length of
the input portion of the buffer conveyor subassembly can be
sufficient to queue a number of carriers at least equal to a number
of cavities defined by the assay receptacle.
[0036] The diverter can define a first concave recess and a second
concave recess. The first concave recess is configured to receive a
carrier at the first transfer position, and the second concave
recess is configured to receive a carrier at the third transfer
position. The diverter can further define a third concave recess.
The first, second, and third concave recess of the diverter can be
equally spaced about a periphery of the diverter.
[0037] The diverter can be configured to rotate about an axis. The
diverter can be configured to rotate about the axis in only one
direction, or the diverter can be configured to rotate about the
axis in two directions. The conveyor assembly can further include a
base and a drive assembly coupled to the base and configured to
rotate the diverter. The diverter can be rotatably coupled to the
base.
[0038] The spur conveyor can define a single path along which the
plurality of carriers coupled to the respective receptacles are
transported. The spur conveyor further can include a portion
defining a recess configured to receive a portion a receptacle
coupled a carrier positioned at the processing position within the
instrument.
[0039] In some embodiments, the spur conveyor subassembly can
further include a movable gripper configured to grasp one of the
plurality carriers at the third transfer position and transport the
one of the plurality carriers to the processing position within the
instrument. The gripper can include at least two movable prongs
configured to apply pressure to the carrier grasped by the gripper.
Each of the at least two movable prongs can include a portion
having a protrusion configured to mate with a groove defined by the
carrier grasped by the gripper such that as a distal end of a
pipettor of the instrument is removed from a respective processing
receptacle of the carrier grasped by the gripper. The gripper can
hold the carrier to the spur conveyor subassembly. The at least two
movable prongs can be further configured to contact a receptacle
coupled to the carrier grasped by the gripper.
[0040] In other embodiments, the spur conveyor subassembly includes
a movable track configured to transport one of the plurality
carriers between the third transfer position the processing
position within the instrument.
[0041] In some embodiments, a sample processing method includes
verifying that an identifier of a first carrier detected at a first
position on a host conveyor assembly is associated with a first
sample on which a first assay is scheduled to be performed with a
first instrument. The method also includes diverting the first
carrier from the host conveyor assembly to a first intermediate
conveyor assembly, and transporting the first carrier to a first
processing position within the first instrument using the first
intermediate conveyor assembly. The method also includes verifying
that an identifier of the first carrier detected at the first
processing position is associated with the first sample on which
the first assay is scheduled to be performed with the first
instrument. The method also includes, at the first processing
position, transferring at least a portion of the first sample from
a first processing receptacle coupled to the first carrier to a
first assay receptacle using a first automated pipettor of the
first instrument. The method also includes performing the first
assay by subjecting the portion of the first sample in the first
assay receptacle to nucleic acid amplification reaction conditions
using the first instrument. And the method includes transporting
the first carrier from the first processing position to the host
conveyor assembly using the first intermediate conveyor
assembly.
[0042] The method can also include verifying that an identifier of
a second carrier detected at the first position on the host
conveyor assembly is associated with a second sample on which the
first assay is scheduled to be performed with the first instrument.
The method can also include diverting the second carrier from the
host conveyor assembly to the first intermediate conveyor assembly.
The method can also include transporting the second carrier to the
first processing position within the first instrument using the
intermediate conveyor assembly, and verifying that an identifier of
the second carrier detected at the first processing position is
associated with the second sample on which the first assay is
scheduled to be performed with the first instrument. The method can
also include, at the first processing position, transferring at
least a portion of the second sample from a second processing
receptacle coupled to the second carrier to the first assay
receptacle using the first automated pipettor. The method can also
include performing the first assay by subjecting the portion of the
second sample in the first assay receptacle to nucleic acid
amplification reaction conditions using the first instrument, and
transporting the second carrier from the first processing position
to the host conveyor assembly using the intermediate conveyor
assembly.
[0043] Transporting the second carrier to the first processing
position within the first instrument using the intermediate
conveyor assembly can occur after the transporting the first
carrier from the first processing position to the host conveyor
assembly using the first intermediate conveyor assembly.
Transporting the second carrier to the first processing position
within the first instrument using the intermediate conveyor
assembly can also occur concurrently with the transporting the
first carrier from the first processing position to the host
conveyor assembly using the first intermediate conveyor
assembly.
[0044] The method can also include determining whether an
identifier of a second carrier detected at the first position on
the host conveyor assembly is associated with a second sample on
which the first assay is scheduled to be performed with a first
instrument. The method can also include bypassing the second
carrier past the intermediate conveyor assembly to a second
position on the host conveyor assembly when the identifier of the
second carrier detected at the first position on the host conveyor
assembly is not associated with the second sample on which the
first assay will be performed. The method can also include
determining whether an identifier of the second carrier detected at
the second position on the host conveyor assembly is associated
with a third sample on which a second assay is scheduled to be
performed with a second instrument. The method can also include
diverting the second carrier from the host conveyor assembly to a
second intermediate conveyor assembly. The method can also include
transporting the second carrier to a second processing position
within the second instrument using the second intermediate conveyor
assembly, and determining whether an identifier of the second
carrier detected at the second processing position is associated
with the third sample on which the second assay is scheduled to be
performed with the first instrument. The method can also include,
at the second processing position, transferring at least a portion
of the third sample from a second processing receptacle coupled to
the second carrier to a second assay receptacle using a second
automated pipettor of the second instrument. The method can also
include performing the second assay by subjecting the portion of
the third sample in the second assay receptacle to nucleic acid
amplification reaction conditions using the second instrument. The
method can also include transporting the second carrier coupled to
the second processing receptacle from the second processing
position to the host conveyor assembly using the intermediate
conveyor assembly.
[0045] The second assay can be different than the first assay.
Performing the first assay can include subjecting a respective
portion of a sample in an assay receptacle to nucleic acid
amplification reaction conditions that promotes a polymerase chain
reaction, and performing the second assay can include subjecting a
respective portion of a sample in an assay receptacle to nucleic
acid amplification reaction conditions that promotes a
transcription-based amplification reaction.
[0046] The second assay can be the same as the first assay.
Performing the first assay can include subjecting a respective
portion of a sample in an assay receptacle to nucleic acid
amplification reaction conditions that promotes a polymerase chain
reaction, and performing the second assay includes subjecting a
respective portion of a sample in an assay receptacle to nucleic
acid amplification reaction conditions that promotes a polymerase
chain reaction.
[0047] The first assay can include subjecting a respective portion
of a sample in an assay receptacle to nucleic acid amplification
reaction conditions that promotes a transcription-based
amplification reaction, and performing the second assay can
includes subjecting a respective portion of a sample in an assay
receptacle to nucleic acid amplification reaction conditions that
promotes a transcription-based amplification reaction.
[0048] The method can also include, before the transporting the
second carrier to the first processing position within the first
instrument using the intermediate conveyor assembly, queuing a
predetermined number of carriers on the intermediate conveyor
assembly. The predetermined number can correspond to a number of
sample receiving cavities defined by the first assay
receptacle.
[0049] In some embodiments, an automated sample processing method
includes aspirating at least a portion of a first sample from a
first sample containing receptacle using a first automated pipettor
of a first instrument, and dispensing the portion of the first
sample into a first processing receptacle using the automated
pipettor of the first instrument. The method can also include
transporting a first carrier coupled to the first processing
receptacle containing the first sample from a position inside the
first instrument to a host conveyor assembly using a first
intermediate conveyor assembly, and transporting the first carrier
from the host conveyor assembly to a first processing position
within a second instrument using a second intermediate conveyor
assembly. The method can also include aspirating at least a portion
of the first sample from the first processing containing receptacle
at the first processing position using a second automated pipettor
of the second instrument, and dispensing the portion of the first
sample into a first assay receptacle using the second automated
pipettor of the second instrument. The method can also include
performing a first assay on the portion of the first sample in the
first assay receptacle using the second instrument, and
transporting the first carrier from the first processing position
to the host conveyor assembly using the second intermediate
conveyor assembly.
[0050] Performing the first assay can include subjecting the
portion of the first sample in the first assay receptacle to
nucleic acid amplification reaction conditions.
[0051] The method can also include coupling the first processing
receptacle with the first carrier using the first instrument. The
method can also include manually inserting the first sample
containing receptacle into an input bay of the first instrument, or
automatically inserting the first sample containing receptacle into
an input bay of the first instrument.
[0052] The method can also include aspirating at least a portion of
a second sample from a second sample containing receptacle using
the first automated pipettor of the first instrument, and
dispensing the portion of the second sample into a second
processing receptacle using the first automated pipettor of the
first instrument. The method can also include transporting a second
carrier coupled to the second processing receptacle containing the
second sample from the position inside the first instrument to the
host conveyor assembly using the first intermediate conveyor
assembly, and transporting the second carrier from the host
conveyor assembly to a second processing position within a third
instrument using a third intermediate conveyor assembly. The method
can also include aspirating at least a portion of the second sample
from the second processing receptacle at the second processing
position using a third automated pipettor of the third instrument,
and dispensing the portion of the second sample into a second assay
receptacle using the third automated pipettor of the instrument.
The method can also include performing a second assay on the
portion of the second sample in the second assay receptacle using
the third instrument, and transporting the second carrier from the
second processing position to the host conveyor assembly using the
third intermediate conveyor assembly.
[0053] The first assay can be different than the second assay. The
first assay can be configured to determine the presence of a first
analyte, and the second assay is configured to determine the
presence of a second analyte different than the first analyte.
[0054] The first assay can be the same as the second assay. The
first assay can be configured to determine the presence of a first
analyte, and the second assay can be configured to determine the
presence of the first analyte.
[0055] Performing the second assay can include subjecting the
portion of the second sample in the second assay receptacle to
nucleic acid amplification reaction conditions.
[0056] The method can also include transporting the first carrier
coupled to the first processing receptacle on the host conveyor
assembly such that the first carrier bypasses the second processing
position within the third instrument. The method can also include
transporting the second carrier coupled to the second processing
receptacle on the host conveyor assembly such that the second
carrier bypasses the first processing position within the second
instrument.
[0057] The method can also include decapping at least one of the
first sample containing receptacle and the first processing at a
sample processing station of the first instrument, and capping the
at least one of the first sample containing receptacle and the
first processing at the sample processing station of the first
instrument.
[0058] In some embodiments, an automated sample processing method
includes transporting a first carrier coupled to a first processing
receptacle containing a first sample from a host conveyor assembly
to a first processing position within a first instrument using a
first intermediate conveyor assembly. The method also includes
aspirating at least a portion of the first sample from the first
processing containing receptacle at the first processing position
using a first automated pipettor of the first instrument. The
method also includes dispensing the portion of the first sample
into a first assay receptacle using the first automated pipettor of
the first instrument. The method also includes performing a first
assay on the portion of the first sample in the first assay
receptacle using the first instrument. The method also includes
transporting the first carrier from the first processing position
to the host conveyor assembly using the first intermediate conveyor
assembly, and transporting a second carrier coupled to a second
processing receptacle containing a second sample from the host
conveyor assembly to a second processing position within a second
instrument using a second intermediate conveyor assembly. The
method also includes aspirating at least a portion of the second
sample from the second processing receptacle at the second
processing position using a second automated pipettor of the second
instrument, and dispensing the portion of the second sample into a
second assay receptacle using the second automated pipettor of the
second instrument. The method also includes performing a second
assay on the portion of the second sample in the second assay
receptacle using the second instrument, transporting the second
carrier from the second processing position to the host conveyor
assembly using the second intermediate conveyor assembly.
[0059] Performing the first assay can include subjecting the
portion of the first sample in the first assay receptacle to
nucleic acid amplification reaction conditions.
[0060] The first assay can be different than the second assay, or
the first assay can be the same as the second assay.
[0061] Performing the second assay can include subjecting the
portion of the second sample in the second assay receptacle to
nucleic acid amplification reaction conditions.
[0062] The method can also include transporting the first carrier
coupled to the first processing receptacle on the host conveyor
assembly such that the first carrier bypasses the second processing
position within the second instrument. The method can also include
transporting the second carrier coupled to the second processing
receptacle on the host conveyor assembly such that the second
carrier bypasses the first processing position within the first
instrument.
[0063] In some embodiments, an automated conveyor assembly
transports carriers coupled to processing receptacles from (i)
another conveyor assembly that transports carriers to (ii) a
processing position within an instrument. The automated conveyor
assembly includes a gripper configured to selectively grasp a
carrier and move between (i) a first position and (ii) the
processing position in the instrument. The automated conveyor
assembly includes a diverter defining a recess configured to
receive a carrier. The diverter being rotatable between (i) a first
position at which the recess is aligned with the other conveyor
assembly and (ii) a second position at which the recess is aligned
with the first position of the gripper.
[0064] The diverter can further define a second recess aligned with
the first position of the gripper when the diverter is at the first
position. The second recess can be aligned with the other conveyor
assembly when the diverter is at the second position.
[0065] The diverter can further define a third recess and is
movable between the first position, the second position, and a
third position at which the first recess is aligned with the other
conveyor assembly, the second recess is aligned with the other
conveyor assembly, and the third recess is aligned with the first
position of the gripper.
[0066] The first recess, the second recess, and the third recess
can be spaced equally about an axis about which the diverter
rotates.
[0067] The gripper can include at least two movable prongs
configured to apply pressure to the carrier grasped by the gripper.
Each of the at least two movable prongs can include a portion
having a protrusion configured to mate with a groove defined by the
carrier grasped by the gripper such that, as a distal end of a
pipettor of the instrument is removed from a respective processing
receptacle of the carrier grasped by the gripper, the gripper holds
the carrier to the automated conveyor assembly. Each of the at
least two movable prongs can include a portion shaped to closely
correspond to a respective portion of a perimeter of the carrier.
Each of the at least two movable prongs can include a portion that,
when the gripper is grasping the carrier, overlaps in a vertical
direction at least a respective portion of the carrier.
[0068] The first position of the gripper can be outside the
instrument.
[0069] The automated conveyor assembly can further include a cover
that encloses a portion of a path between the first position of the
gripper and the processing position in the instrument. The cover
can define an opening configured to allow a distal end of a
pipettor of the instrument to pass.
[0070] In some embodiments, a diverter transports carriers between
a first automated conveyor assembly path and a second automated
conveyor assembly path. The diverter includes a first recess
configured to receive a first carrier and a second recess spaced
apart from the first recess and configured to receive a second
carrier. The diverter is rotatable between (i) a first position at
which the first recess is aligned with the first automated conveyor
assembly path and the second recess is aligned with the second
automated conveyor assembly path, and (ii) a second position at
which the first recess is aligned with the second automated
conveyor assembly path and the second recess is aligned with the
first automated conveyor assembly path. The diverter transport the
first carrier from the first automated conveyor assembly path to
the second automated conveyor assembly path while simultaneously
transporting the second carrier from second automated conveyor
assembly path to the first automated conveyor assembly path.
[0071] The first automated conveyor assembly path is perpendicular
to the second automated conveyor assembly path.
[0072] The diverter can further include a third recess configured
to receive a third carrier. At the first position of the diverter,
the third recess can be aligned with the first automated conveyor
assembly path, and at the second position of the diverter, the
third recess can be aligned with the first automated conveyor
assembly path.
[0073] The diverter can have a circular outer periphery defining
the first recess and the second recess. The first recess can be
spaced from the second recess by about 120 degrees about an axis
about which the diverter rotates.
[0074] In some embodiments, a method of transporting carriers to a
processing position within an instrument includes transporting,
using an automated conveyor assembly, a carrier from a first
position to the processing position within the instrument. The
method also includes grasping the carrier with a gripper and
inserting a distal end of an automated pipettor into a receptacle
coupled to the carrier. The method also includes aspirating, using
the automated pipettor, at least a portion of a sample in the
receptacle, and removing the distal end of the automated pipettor
from the receptacle coupled to the carrier while the gripper is
grasping the carrier.
[0075] Transporting the carrier from the first position to the
processing position can include moving the gripper while the
gripper is grasping the carrier.
[0076] The gripper can include at least two movable prongs, and
grasping the carrier with the gripper can include moving the at
least two movable prongs together to apply pressure to the carrier
to secure the carrier to the gripper.
[0077] Transporting the carrier from the first position to the
processing position includes transporting the carrier using a
movable track.
[0078] The method can also include, after removing the distal end
of the automated pipettor from the receptacle coupled to the
carrier, transporting the carrier from processing position within
the instrument to the first position using the automated conveyor
assembly.
[0079] The first position can be outside the instrument.
[0080] In some embodiments, a method of transporting carriers
includes receiving a first carrier in a first recess of a diverter
from a first automated conveyor assembly, and receiving in a second
carrier in a second recess of the diverter from a second automated
conveyor assembly. The method also includes rotating the diverter,
while the first carrier is received within the first recess and the
second carrier is received within the second recess, such that the
first carrier is aligned with the second automated conveyor
assembly and the second carrier is aligned with the first automated
conveyor assembly path. The first carrier is transported from the
first automated conveyor assembly to the second automated conveyor
assembly simultaneously with the second carrier being transported
from the second automated conveyor assembly to the first automated
conveyor assembly.
[0081] The first automated conveyor can define a first path that is
perpendicular to a second path defined by the second automated
conveyor assembly path. The diverter can have a circular outer
periphery defining the first recess and the second recess. The
first recess can be spaced from the second recess by about 120
degrees about an axis about which the diverter rotates.
[0082] The method can also include transporting, after rotating the
divert, the first carrier to a processing position within an
instrument using the second automated conveyor assembly. Receiving
the first carrier in the first recess of the diverter can occur
outside the instrument. The instrument can be an assay
instrument.
[0083] In some embodiments, a carrier for transporting a receptacle
using a conveyor assembly includes a main body having a top end
portion and a bottom end portion. The top end portion defines a
recess configured to receive a portion of the receptacle. The
carrier also includes a first groove defined in an outer periphery
of the main body. The first groove is configured to mate with
corresponding protrusion of the conveyor assembly as the carrier is
transported by the conveyor assembly. The carrier also includes a
second groove separate from the first groove and defined in the
outer periphery of the main body. The second groove is configured
to mate with a protrusion of a movable gripper of the conveyor
assembly. The main body can be cylindrical or non-cylindrical. The
recess can be cylindrical.
[0084] The carrier can also include a plurality of movable
retaining members positioned within the recess. The retaining
members define an interior recess portion configured to receive the
portion of the receptacle. The plurality of movable retaining
members can form an annulus that defines the interior recess
portion. Each of the plurality of movable retaining members can
include a tapered surface configured to self-align the portion of
the receptacle with a center of the recess when the portion of the
receptacle is being inserted in the interior recess portion. Each
of the plurality of movable retaining members can be biased toward
a center of the interior recess portion such that each retaining
member applies a force to the portion of the receptacle inserted in
the interior recess portion that secures the receptacle to the
carrier. The carrier can also include a biasing device configured
to bias each of the plurality of retaining members toward the
center of the interior recess portion. The biasing device can be a
garter spring, and each of the plurality of retaining members can
define a periphery groove configured to receive the garter spring.
Each of the plurality of movable retaining members can have a
radial stroke such that the inner recess portion varies in size to
accommodate receptacles of at least two different sizes.
[0085] The lower end portion of the main body can define a second
recess configured to receive a transponder. The transponder can be
an RFID tag. The second recess can include a first portion shaped
to receive a first type of transponder and a second portion shaped
to receive a second type of transponder different than the first
type. The first portion of the second recess can be cylindrical,
and the second portion of the second recess can be rectangular. A
center of the first portion of the second recess and a center of
the second portion of the second recess can be coaxial.
[0086] Further features and advantages of the embodiments, as well
as the structure and operational of various embodiments, are
described in detail below with reference to the accompanying
drawings. It is noted that the invention is not limited to the
specific embodiments described herein. Such embodiments are
presented herein for illustrative purposes only. Additional
embodiments will be apparent to persons skilled in the relevant
art(s) based on the teachings contained herein.
DESCRIPTION OF THE DRAWINGS
[0087] The accompanying drawings, which are incorporated herein and
form a part of the specification, illustrate the embodiments and,
together with the description, further serve to explain the
principles of the embodiments and to enable a person skilled in the
relevant art(s) to make and use the embodiments.
[0088] FIG. 1 is a schematic block diagram of a laboratory
automated system according to an embodiment.
[0089] FIG. 2 is a schematic plan view of a laboratory automated
system including a sample processing instrument, a host conveyor
assembly, intermediate conveyor assemblies, and assay instruments,
according to an embodiment.
[0090] FIG. 3 is a rear view of an assay instrument and an
intermediate conveyor assembly according to an embodiment.
[0091] FIG. 4 is a cross-sectional plan view of an assay instrument
and an intermediate conveyor assembly, according to an
embodiment.
[0092] FIG. 5 is a perspective view of a spur conveyor subassembly
of an intermediate conveyor assembly, according to an
embodiment.
[0093] FIG. 6 is a plan view of a buffer conveyor subassembly and a
spur conveyor subassembly of an intermediate conveyor assembly,
according to an embodiment.
[0094] FIG. 7 is a cross-sectional side view of an assay instrument
and an intermediate conveyor assembly, according to an
embodiment.
[0095] FIG. 8 is a perspective view of a pipettor of an assay
instrument, a spur conveyor subassembly of an intermediate conveyor
assembly, and a processing receptacle, according to an
embodiment.
[0096] FIG. 9 is a perspective view of a host conveyor assembly
operatively coupled to intermediate conveyor assemblies and assay
instruments, according to an embodiment.
[0097] FIG. 10 is a perspective view of an assay instrument, an
intermediate conveyor assembly, and a host conveyor assembly,
according to an embodiment.
[0098] FIG. 11 is a schematic system diagram of a host conveyor
assembly, an intermediate conveyor assembly, and an assay
instrument, according to an embodiment.
[0099] FIG. 12 is a schematic system diagram of a host conveyor
assembly, an intermediate conveyor assembly, and an assay
instrument, according to another embodiment.
[0100] FIG. 13 is a schematic system diagram of a host conveyor
assembly, an intermediate conveyor assembly, and an assay
instrument, according to yet another embodiment.
[0101] FIG. 14 is a schematic system diagram of a sample processing
instrument, a host conveyor assembly, intermediate conveyor
assemblies, and assay instruments, according to an embodiment.
[0102] FIG. 15 is a schematic diagram of a controller of an
intermediate conveyor assembly coupled to a buffer conveyor
subassembly and a spur conveyor subassembly of the intermediate
conveyor assembly, according to an embodiment.
[0103] FIG. 16 is a block diagram of a laboratory automated method,
according to an embodiment.
[0104] FIG. 17 is a perspective view of a carrier and a receptacle
according to an embodiment.
[0105] FIG. 18 is a cross-sectional view of the carrier and
receptacle of FIG. 17 according to an embodiment.
[0106] FIG. 19 is a perspective view of a capping and decapping
mechanism, according to an embodiment.
[0107] FIG. 20 is a perspective view of a capping and decapping
mechanism, according to an embodiment.
[0108] FIG. 21 is a perspective view of a receptacle gripper
according to an embodiment.
[0109] FIG. 22 is a cross-sectional view of a spur conveyor
subassembly of an intermediate conveyor assembly, according to an
embodiment.
[0110] FIG. 23 is a cross-sectional view of a gripper of a spur
conveyor subassembly at a subassembly at a processing position,
according to an embodiment.
[0111] FIG. 24 is a perspective view of a diverter and a gripper
(in an open configuration) of a spur conveyor subassembly,
according to an embodiment.
[0112] FIG. 25 perspective view of a diverter and a gripper (in a
closed configuration) of a spur conveyor subassembly, according to
an embodiment.
[0113] FIG. 26 is a cross-sectional view of a carrier, a
receptacle, and a gripper in a closed configuration, according to
an embodiment.
[0114] FIG. 27 is a top perspective view of a sample carrier
showing a new design.
[0115] FIG. 28 is a bottom perspective view thereof.
[0116] FIG. 29 is a front view thereof, the rear view being the
same.
[0117] FIG. 30 is a left side view thereof, the right side view
being the same.
[0118] FIG. 31 is a top view thereof.
[0119] FIG. 32 is a bottom view thereof.
[0120] FIG. 33 is a top perspective view of another sample carrier
showing our new design.
[0121] FIG. 34 is a bottom perspective view thereof.
[0122] FIG. 35 is a top view thereof.
[0123] FIG. 36 is a bottom view thereof.
[0124] FIG. 37 is a front view of another sample carrier showing a
new design, the rear, right, and left side views being the
same.
[0125] The features and advantages of the embodiments will become
more apparent from the detailed description set forth below when
taken in conjunction with the drawings, in which like reference
characters identify corresponding elements throughout.
DETAILED DESCRIPTION
[0126] The present disclosure will now be described in detail with
reference to embodiments thereof as illustrated in the accompanying
drawings. References to "one embodiment," "an embodiment," "some
embodiments," "an exemplary embodiment," "for example," "an
example," "exemplary," etc., indicate that the embodiment described
may include a particular feature, structure, or characteristic, but
every embodiment may not necessarily include the particular
feature, structure, or characteristic. Moreover, such phrases are
not necessarily referring to the same embodiment. Further, when a
particular feature, structure, or characteristic is described in
connection with an embodiment, it is submitted that it is within
the knowledge of one skilled in the art to affect such feature,
structure, or characteristic in connection with other embodiments
whether or not explicitly described.
[0127] As used herein, "a" or "an" means "at least one" or "one or
more."
[0128] As used herein, a "sample" refers to any material to be
analyzed, regardless of the source. The material may be in its
native form or any stage of processing (e.g., the material may be
chemically altered or it may be one or more components of a sample
that have been separated and/or purified from one or more other
components of the sample). A sample may be obtained from any
source, including, but not limited to, an animal, environmental,
food, industrial or water source. Animal samples include, but are
not limited to, peripheral blood, plasma, serum, bone marrow,
urine, bile, mucus, phlegm, saliva, cerebrospinal fluid, stool,
biopsy tissue including lymph nodes, respiratory tissue or
exudates, gastrointestinal tissue, cervical swab samples, semen or
other body or cellular fluids, tissues, or secretions. Samples can
be diluted or contained within a receptacle containing diluents,
transport media, preservative solution, or other fluids. As such,
the term "sample" is intended to encompass samples contained within
a diluent, transport media, and/or preservative or other fluid
intended to hold a sample.
[0129] As used herein, a "sample containing receptacle" refers to
any type of fluid container, including, for example, a tube, vial,
cuvette, cartridge, microtiter plate, etc., that contains a sample
in its native form or at any stage of processing.
[0130] As used herein, a "processing receptacle" refers to any type
of fluid container, including, for example, a tube, vial, cuvette,
cartridge, microtiter plate, etc., that is configured to contain a
sample at a point during processing. Exemplary processing
receptacles include Aptima.RTM. collection and transport tubes
(Hologic, Inc., Bedford, Mass.).
[0131] As used herein, an "assay receptacle" refers to any type of
fluid container, including, for example, a tube, vial, cuvette,
cartridge, microtiter plate, etc., that is configured to contain a
sample at a point while performing an assay. In some embodiments,
an assay receptacle is formed with a material that can tolerate
high temperatures (e.g., between 35.degree. C.-90.degree. C.)
without deforming or leaching chemicals into a contained sample.
Exemplary processing receptacles include multiple-tube units (MTUs)
that each define a plurality of cavities for receiving samples, for
example, MTUs used with Panther.RTM. systems sold by Hologic, Inc.,
Bedford, Mass.
[0132] As used herein, an "assay instrument" refers to any
instrument capable of analyzing a sample and rendering a result.
Any instrument capable of performing a hybridization assay, a
molecular assay including a nucleic acid based amplification assay,
a sequencing assay, an immunoassay, or chemistry assay on a sample
is included in this definition of an assay instrument. In some
embodiments, an assay can be carried out directly on a sample
without any sample processing, but other samples require processing
before carrying out an assay. Samples requiring some form of sample
processing before subjecting the samples to the steps of an assay
include, in some embodiments, cell samples, tissue samples, stool
samples, mucus samples, semen samples, cerebrospinal fluid samples,
blood samples, bone marrow samples, serum samples, urine samples,
bile samples, respiratory samples, sputum samples, and exosome
samples, among others. Exemplary assay instruments include the
Tigris.RTM. and Panther.RTM. systems sold by Hologic, Inc.,
Bedford, Mass.
[0133] As used herein, a "sample processing instrument" refers to
an instrument capable of performing a processing step on a sample
contained within a receptacle before performing an assay on the
sample, and is not capable of analyzing a sample and/or rendering a
result. For example, an instrument that transfers a sample from one
receptacle to another receptacle, but does not perform an assay on
the sample, is a sample processing instrument. An exemplary sample
processing instrument is the Tomcat.RTM. system sold by Hologic,
Inc., Bedford, Mass.
[0134] As used herein, a "robotic arm" refers to an
electromechanical device that translates a payload (e.g., a
pipettor, a receptacle gripper (such as a pick-and-place claw), a
camera, a sensor, a capper/decapper, etc.) in the X, Y, and/or Z
directions. In an embodiment, a robotic arm can move in the X, Y,
and Z directions.
1. Exemplary Embodiments of Laboratory Automated Systems
[0135] FIG. 1 schematically illustrates a laboratory automated
system 100 according to an embodiment. System 100 includes a host
conveyor assembly 102 configured to transport a plurality of
carriers and receptacles coupled thereto (described further below)
between at least one sample processing instrument 104 (for example,
one sample processing instrument 104 as shown in FIG. 1, or two or
more sample processing instruments 104) and at least one assay
instrument (for example, three assay instruments 108a, 108b, and
108c as shown in FIG. 1, collectively referred to as assay
instruments 108 or individually and generically as assay instrument
108). In other embodiments, system 100 includes more than one
sample processing instrument 104 and more than or less than three
assay instruments 108.
[0136] System 100 can also include an intermediate conveyor
assembly 106 configured to transport a plurality of carriers and
receptacles coupled thereto from within sample processing
instrument 104 to host conveyor assembly 102. In some embodiments,
intermediate conveyor assembly 106 is also configured to transport
a plurality of carriers from host conveyor assembly 102 to within
sample processing instrument 104.
[0137] System 100 also includes an intermediate conveyor assembly
for each of assay instruments 108 (for example, intermediate
conveyor assemblies 133a, 133b, and 133c, collectively referred to
as intermediate conveyor assemblies 133 or generically and
individually as intermediate conveyor assembly 133). Intermediate
conveyor assemblies 133 are configured to transport a plurality of
carriers from host conveyor assembly 102 to respective processing
positions within respective assay instrument 108a, 108b, and
108c.
[0138] In some embodiments, intermediate assay conveyor assemblies
133 each include a buffer conveyor assembly (buffer conveyor
subassemblies 114a, 114b, and 114c as shown in FIG. 1, collectively
referred to as buffer conveyor subassemblies 114 or generically and
individually as buffer subassembly 114) and a spur conveyor
assembly (spur conveyor subassemblies 116a, 116b, and 116c in FIGS.
1 and 2, collectively referred to as spur conveyor subassemblies
116 or generically and individually referred to as spur subassembly
116). Each buffer conveyor subassembly 114 is configured to receive
carriers from host conveyor assembly 102 and transport the carriers
to an intermediate position upstream from the processing position
of the respective assay instrument 108. Spur conveyor subassembly
116 is configured to receive a carrier from buffer conveyor
subassembly 114 and transport the carrier to the processing
position of the respective assay instrument 108. The respective
assay instrument 108 can process a sample contained within a
receptacle coupled to the carrier at the processing position as
explained further below. Spur conveyor subassembly 116 is also
configured to transport the carrier from the processing position
back to buffer conveyor subassembly 114. Buffer conveyor
subassembly 114 is also configured to transport the carriers
received from spur conveyor subassembly 116 back to host conveyor
assembly 102.
[0139] After receiving carriers from a buffer conveyor subassembly
of one intermediate conveyor assembly, host conveyor assembly 102
transport the carriers to other position within system 100, for
example, to another assay instrument 108, to another sample
processing instrument 104, or to any other instrument operatively
coupled to host conveyor assembly 102.
[0140] FIG. 2 illustrates a schematic plan view of system 100
according to an embodiment. As shown in FIG. 2, system 100 includes
one sample processing instrument 104, an intermediate conveyor
assembly 106, a host conveyor assembly 102, three intermediate
conveyor assemblies 133a-133c, and three assay instruments
108a-108c. In other embodiments, system 100 can include more than
one sample processing instrument 104, or system 100 can omit sample
processing instrument 104. In other embodiments, system 100 can
include less than three or more than three assay instruments 108,
or system 100 can omit assay instruments 108. Embodiments of each
of these components of system 100 are described further below.
[0141] A. Exemplary Embodiments of Sample Processing Instruments
104
[0142] In some embodiments, sample processing instrument 104 is an
instrument according to any one of the embodiments described in
U.S. Patent Application Publication No. 2013/0065797, published on
Mar. 14, 2013. For example, sample processing instrument 104 can
include a sample processing station 107, an input bay 109
configured to movably and manually receive one or more input racks
111, an output bay 113 configured to movably receive one or more
output racks 115, one or more robotic arms 117, one or more
receptacle grippers 119, one or more pipettors 121, one or more
incubators 123, and a controller. In some embodiments, receptacle
gripper 119 is coupled to robotic arm 117 and configured to
transport sample containing receptacles 105 and processing
receptacles 103 within sample processing instrument 104, for
example, between input racks 111, a sample processing station 107,
output racks 115, and intermediate conveyor assembly 106. Each of
these components of sample processing instrument 104 can be
enclosed by an instrument housing. Sample containing receptacles
105 contain a sample, for example, an animal sample such as a
liquid based cytology (LBC) specimen.
[0143] In some embodiments, processing receptacles 103 within
instrument 104 are configured to be used in at least one of assay
instruments 108.
[0144] In some embodiments, sample pipettor 121 is configured to
transfer samples from sample containing receptacles 105 (e.g.,
liquid based cytology (LBC) specimen collection containers), to
processing receptacles 103 (e.g., Aptima.RTM. collection and
transport tubes available from Hologic, Inc., Bedford, Mass.).
[0145] In some embodiments, sample processing station 107 is
configured to hold sample containing receptacles 105 and processing
receptacles 103, perform barcode reading, barcode positioning,
sample mixing, and capping/decapping of sample containing
receptacles 105 and processing receptacles 103. In some
embodiments, sample processing station 107 includes a
capping/decapping mechanism configured to cap and decap
receptacles, for example, sample containing receptacles 105 or
processing receptacles 103. FIGS. 19 and 20 illustrate a
capping/decapping mechanism 201 according to an embodiment.
Capping/decapping mechanism 201 can be configured to cap and decap
two or more different types of containers having a different shape
and/or different shaped cap. Capping/decapping mechanism 201 can
include a chuck 203 that is configured to selectively grasp a cap
of a receptacle, for example, a sample containing receptacle 105 or
a processing receptacle 103. As shown in FIGS. 19 and 20, chuck 203
can include a plurality of prongs that are configured to move
radially inward to grasp a cap of either a sample containing
receptacle 105 or a processing receptacle 103, and radially outward
to release the cap. In some embodiments, capping/decapping
mechanism 201 rotates to rotate the grasped cap relative to the
main body of a sample containing receptacle 105 or a processing
receptacle 103, thereby capping or decapping a sample containing
receptacle 105 or a processing receptacle 103. In other
embodiments, capping/decapping mechanism 201, while grasping the
cap, remains stationary, and sample processing station 107 rotates
the main body of a sample containing receptacle 105 or a processing
receptacle 103 relative to the grasped cap thereby capping or
decapping a sample containing receptacle 105 or a processing
receptacle 103.
[0146] In some embodiments, sample processing instrument 104
includes one or more incubators 123. Incubators 123 can be
configured to incubate samples directly within processing
receptacles 103. For example, LBC samples such as biological
samples collected in a SurePath.RTM. (Becton Dickinson, Inc.,
Franklin Lakes, N.J.) sample containing receptacle 105 often
require processing, such as reagent addition and heated incubation
using incubators 123, before conducting a molecular assay. In other
embodiments, LBC sample types such as those collected in a
ThinPrep.RTM. (Hologic, Inc., Bedford, Mass.) sample containing
receptacle may not require further processing such as incubation
using incubators 123.
[0147] In some embodiments, sample processing instrument 104 also
includes a controller that is configured to manage and process
device-wide activities by delegating specific tasks to instrument
sub-components or modules. Exemplary system activities include
capping/decapping collection and processing receptacles, vortexing,
moving collection and processing receptacles, pipetting, waste
reservoir monitoring, monitoring consumable inventory, monitoring
sample queues, maintaining run logs, monitoring process controls,
monitoring system alarms, etc.
[0148] In some embodiments, sample processing instrument 104
includes a software user interface. In one embodiment, the user
interface incorporates an integrated touch screen for operator
input, instrument control, status monitoring, and displaying sample
tracking information. In some embodiments, sample processing
instrument 104 includes data input devices. For example, sample
processing instrument 104 can include USB ports, for example, for
updating system configuration files, downloading sample tracking
data and run logs, and connecting additional user interface devices
such as a mouse or keyboard.
[0149] In some embodiments, sample processing instrument 104
includes a hardware user interface so that a user can access
various areas of sample processing instrument 104, for example, the
sample input bay 109, the output bay 113, and the consumable areas.
In one embodiment, sample processing instrument 104 includes two or
more cabinets or drawers on the front of the automated instrument
to access these areas.
[0150] Sample processing instrument 104 can also include output bay
113 configured to movably receive, for example, slidably receive,
and hold one or more output racks 115. The output racks can act as
input queues for assay instruments not coupled to host conveyor
assembly 102.
[0151] Sample processing instrument 104 can also include input bay
109 that is configured to movably receive, for example, slidably
receive, and hold one or more input racks 111.
[0152] In some embodiments, sample processing instrument 104 is
configured to handle a variety of sample types, including samples
collected in different shaped collection receptacles. In one such
embodiment, input bay 109 is configured to hold multiple types of
sample input racks 111. For example, in one embodiment, input bay
109 is configured to hold sample input racks 111 containing
ThinPrep.RTM. and/or SurePath.RTM. sample containing receptacles
105, respectively. In another embodiment, each sample input rack
111 is configured to hold a single type of specimen such that if
two input racks 111 are in input bay 109, one input rack 111 may
contain only ThinPrep.RTM. sample containing receptacles 105, and
the other input rack may contain only SurePath.RTM. sample
containing receptacles 105. In another embodiment, each input rack
111 received within input bay 109 of sample processing instrument
104 is configured to hold two or more different shaped receptacles
105. For example, each input rack can be configured to hold two or
more different shaped sample containing receptacles 105, for
example, ThinPrep.RTM. and SurePath.RTM. sample containing
receptacles 105, respectively. In such embodiments, the input rack
111 can be configured to hold SurePath.RTM. sample containing
receptacles 105 (including the corresponding processing receptacles
103 in some embodiments) on one side, and ThinPrep.RTM. sample
containing receptacles 105 (including the corresponding processing
receptacles 103 in some embodiments) on the opposite side. In use,
such a input rack 111 can hold SurePath.RTM. sample containing
receptacles 105, and then if flipped upside down, the same input
rack 111 can hold ThinPrep.RTM. sample containing receptacles 105.
In some embodiments, processing receptacles 103 held by the input
rack 111 in input bay 109 do not contain a sample. In some
embodiments, each input rack received within input bay 109 of
sample processing instrument 104 is configured to hold both a
sample containing receptacle 105 and a processing receptacle 103
that is configured differently than the sample containing
receptacle 105. In such embodiments, input rack 111 can be
configured to hold multiple pairs of sample containing receptacles
105 and processing receptacles 103, such that sample containing
receptacles 105 and processing receptacles 103 are incorporated in
a one-to-one ratio and in an alternating fashion as shown in FIG.
1. In such embodiments, the user, after verifying instrument
consumable levels, can begin sample processing by simply inserting
input rack 111 holding pairs of sample containing receptacles 105
and processing receptacles 103 into input bay 109 of the automated
instrument 104.
[0153] In some embodiments, receptacle gripper 119 and robotic arm
117 of processing instrument 104 are configured to couple
receptacles 103 with respective carriers 101. And in some
embodiments, receptacle gripper 119 and robotic arm 117 are
configured to place receptacles 103 and the corresponding coupled
carriers 101 onto intermediate conveyor assembly 106.
[0154] In some embodiments, receptacle gripper 119 and robotic arm
117 are configured to place receptacles 103 onto output racks 115.
Once processing receptacles 103 are placed on output rack 115, a
user can retrieve output rack 115 to run assay(s) on the contents
of the processing receptacles 103 using an assay instrument
(coupled or uncoupled to host conveyor assembly 102). In some
embodiments, output rack 115 is configured to be operable in an
assay instrument 108 that performs the assay, for example, an assay
instrument configured to perform molecular assays. For example, in
some embodiments, output rack 115 of processing instrument 104
functions as an input rack for an assay instrument 108. In such
embodiments, the user removes rack 115 holding processed samples in
processing receptacles 103 from the automated processing instrument
104, and inserts rack 115 in the input bay of an automated assay
instrument 108, for example, a molecular assay instrument that
performs a desired assay. In other embodiments, processing
receptacles 103 in output rack 115 are manually transferred to an
input rack configured to be operable in an automated assay
instrument 108, for example, a molecular assay instrument that
performs a desired assay.
[0155] In some embodiments, processing instrument 104 places
matching machine readable labels (such as barcodes) on both a
paired sample containing receptacle 105 and processing receptacle
103. In some embodiments, sample processing instrument 104 includes
an onboard barcode reader 127 configured to read barcodes on sample
containing receptacle 105 or processing receptacle 103 placed in
sample processing station 107.
[0156] In some embodiments, sample processing instrument 104
includes one or more robotic arms 117 configured to translate in
the X, Y, and Z planes within the automated instrument. In some
embodiments, one robotic arm includes receptacle gripper 119 and is
configured to transport sample containing receptacles 105 and
processing receptacles 103 within sample processing instrument 104,
for example, between input racks 111, sample processing station
107, output racks 115, and intermediate conveyor assembly 106. For
example, sample processing instrument 104 can include one robotic
arm 117 and one receptacle gripper 119 configured to transport
sample containing receptacles 105 and processing receptacles 103.
In other embodiments, sample processing instrument 104 includes
more than one robotic arm 117 and more than one receptacle gripper
119 configured to transport sample containing receptacles 105 and
processing receptacles 103 within the housing of instrument 104. In
some embodiments, robotic arm 117 is any one of the robotic arm
embodiments described in U.S. application Ser. No. 13/608,876,
filed Sep. 10, 2012.
[0157] In some embodiments, robotic arm 117, which includes gripper
119, also includes a pipettor 121 configured to aspirate and
dispense sample material. In some embodiments, pipettor 121 is an
air-based pipettor configured to aspirate a sample from sample
containing receptacles 105 or a reagent from a reagent containing
receptacle and dispense the sample or reagent into a processing
receptacle 103.
[0158] In some embodiments, processing instrument 104 includes at
least two separate robotic arms 117. One robotic arm 117 can
include pipettor 121 for transferring samples, and the other
robotic arm 117 can include gripper 119 for transporting sample
containing receptacles 105 and processing receptacles 103.
[0159] In some embodiments, receptacle gripper 130 is configured to
pick-and-place sample containing receptacles 105 and processing
receptacles 103 within sample processing instrument 104.
[0160] In some embodiments, samples are transferred from sample
containing receptacles 105 to processing receptacles 103 in a
serial fashion. For example, pipettor 121 is configured to take an
aliquot of a sample from one sample containing receptacle 105 and
transfer the aliquot to a processing receptacle 103. Thereafter
pipettor 121 is configured to take another aliquot of a different
sample from a different sample containing receptacle 105 and
transfer the aliquot to another, different processing receptacle
103. An exemplary process for transferring and processing the
sample, for example, at sample processing station 107, is described
in detail below.
[0161] In some embodiments, sample processing instrument 104 is
configured to add a reagent to a sample and/or incubate the sample
as part of the sample processing.
[0162] In some embodiments, a receptacle gripper 119 of robotic arm
117 will transport processing receptacles 103 to incubator 123, for
example, after completion of processing in sample processing
station 107. After incubation is complete, receptacle gripper 119
of robotic arm 117 will transport processing receptacles 103 from
incubator 123 to a carrier 101 positioned within instrument 104 or
to an output rack 115.
[0163] In some embodiments, receptacle gripper 119 performs all
pick and place duties required by sample processing instrument 104.
In some embodiments, receptacle gripper 119 is programmed, by way
of the controller, to perform one or more of the following steps:
(1) transport processing receptacles 103 and sample containing
receptacles 105 between, for example, input racks 111 and sample
processing station 107, (2) transport sample containing receptacles
105 from sample processing station 107 to input racks 111, (3)
transport processing receptacles 103 from processing station 107 to
incubator 123, (4) transport processing receptacles 103 from
processing station 107 to be coupled with carriers 101, and (5)
transport processing receptacles 103 from the one or more
incubators 123 to be coupled with carriers 101. In some
embodiments, sample processing instrument 104 uses multiple
receptacle grippers 117 to perform the above steps, which can
maximize throughput and permits uninterrupted processing in sample
processing station 107.
[0164] FIG. 21 illustrates a receptacle gripper 119 of robotic arm
117 of processing instrument 104 according to one embodiment. As
shown in FIG. 21, receptacle gripper 119 includes a chuck 302 that
is configured to selectively grasp a portion, for example a cap, of
a sample containing receptacle 105 or a processing receptacle 103.
Chuck 302 can include a plurality of prongs 304 (for example, three
prongs 304 as shown in FIG. 21) that are configured to move
radially inward to grasp a cap of either a sample containing
receptacle 105 or a processing receptacle 103, and radially outward
to release the sample containing receptacle 105 or a processing
receptacle 103.
[0165] Ensuring sample identification accuracy is another problem
encountered when automating a sample processing process. For
example, as the sample is prepared it is transferred between a
sample containing receptacle 105 and a processing receptacle 103.
Therefore, it is important to ensure that the sample in processing
receptacle 103 is correlated with the sample in sample containing
receptacle 105 so that the sample is processed according to the
proper protocol and that the correlation of that sample with the
donor patient is maintained. Accordingly, in some embodiments,
system 100 tracks the identification of each sample throughout
processing, including processing within instrument 104, following
the sample as it is transferred from sample containing receptacle
105 to processing receptacle 103 and subsequent handling by host
conveyor assembly 102 and processing by one or more assay
instruments 108. One exemplary method of tracking this information
within system 100, including within instrument 104, is to utilize
matching barcodes on both sample containing receptacle 105 and
processing receptacle 103. This process maintains sample-to-result
positive identification tracking. In some embodiments, a user, for
example, a laboratory, prints one barcode containing patient
identification and applies it to sample containing receptacle 105.
Processing receptacle 103, in turn, contains no label, a blank
label, or a different label. Sample processing instrument 104, for
example, using barcode reader 127, then reads the barcode of sample
containing receptacle 105, transfers (for example, using a writer
131) information from the read barcode, for example, an identifier,
to at least one of processing receptacle 103 or the corresponding
carrier 101 coupled to the processing receptacle 103.
[0166] In some embodiments, writer 131 is a printer that prints the
same barcode as contained on sample containing receptacle 105 (with
optional additional metadata in the form of barcode prefixes,
suffixes, or similar metadata) and applies the barcode to
processing receptacle 103 and/or carrier 101. In some embodiments,
the printer is any one of the printer embodiments described in U.S.
application Ser. No. 14/919,467, filed Oct. 21, 2015. In some
embodiments, sample processing instrument 104 reads the barcode of
sample containing receptacle 105, and writer 131 creates the same
barcode (with optional additional metadata in the form of barcode
prefixes, suffixes, or similar metadata) directly on processing
receptacle 103 and/or carrier 101, for example, by way of printing,
imprint, burning, thermal transfer, or another method. Also in some
embodiments, a different bar code is printed on processing
receptacle 103 or carrier 101 containing additional metadata (e.g.,
time, volume, type, reagents, errors, etc.) related to the
processing of the corresponding sample.
[0167] In some embodiments, writer 131 is an RFID writer configured
to transfer information, including for example, an identifier, to
an RFID tag on processing receptacle 103, carrier 101, or both. In
such embodiments, the RFID tag on processing receptacle 103 or
carrier 101 can be passive (e.g., a microchip attached to an
antenna) or active (e.g., active transponders or beacons) RFID
tags. Exemplary passive RFID tags can operate at low, high, or
ultra-high frequency. Low frequency passive RFID tags can operate,
for example, at 124 kHz, 125 kHz, or 135 kHz. High frequency
passive RFID tags can operate, for example, at 13.56 MHz. And
ultra-high frequency passive RFID tags can operate, for example, at
a range from 860 MHz to 960 MHz. In some embodiments, the passive
RFID tag operates at 2.45 GHz. In some embodiments, RFID writer 131
transfers information obtained from the barcode on sample
containing receptacle 105 (with optional additional metadata in the
form of barcode prefixes, suffixes, or similar metadata) to the
RFID tag on receptacle 103 and/or carrier 101. Also in some
embodiments, RFID writer 131 transfers information different than
information found on the barcode on sample containing receptacle
105 (e.g., time, volume, type, reagents, errors, etc.) related to
the processing of the corresponding sample within instrument
104.
[0168] In some embodiments, writer 131 includes both an RFID writer
module and a printer module as described above.
[0169] In some embodiments, instrument 104 does not include writer
131. Instead, instrument 104 includes an RFID reader configured to
read information, for example, an identifier, from an RFID tag on
either carrier 101 or processing receptacle 103. Automated sample
processing instrument 104 reads both the barcode on sample
containing receptacle 105 creates an association between (1) the
sample containing receptacle 105 from which a sample was taken and
(2) the read identifier of the RFID tag on the carrier 101 or
receptacle 103 in which a portion of the sample was dispensed. This
association information is then transferred to a laboratory
information system via a network connection (e.g., LAN, Ethernet,
WiFi, Bluetooth.RTM., ZigBee.RTM., RS232, USB, RF, IR,
Firewire.RTM., Thunderbolt.RTM., eSATA, or other network
connection).
[0170] As explained below, when system 100 encounters carriers 101
and processing receptacles 103 with information, for example, an
identifier, associated with various positions within system 100,
system 100 handles carriers 101 and processes receptacles 103
accordingly.
[0171] In some embodiment, receptacle gripper 119 retrieves sample
containing receptacle 105 and processing receptacle 103 from input
rack 111. Both receptacles 103 and 105 are transported to sample
processing station 107 where, for example, the barcodes of
receptacles 103 or 105 passed through a field of view of barcode
reader 127 to be read and verified to be a corresponding pair. In
such an embodiment, processing receptacle 103 can be transported to
the writer 131, for example, a printer or RFID writer, by
receptacle gripper 119 of robotic arm 117 to print a barcode or
transfer information to an RFID tag on processing receptacle 103
before receptacle 103 is transported to sample processing station
107. The barcode printed on, or otherwise applied, or information
transferred to processing receptacle 103 may be identical to the
information on the barcode on corresponding sample containing
receptacle 105, or it may be a different barcode. In some
embodiments, a different bar code is printed on or different
information is transferred to processing receptacle 103 that
encodes additional metadata relevant to the processing of that
particular sample.
[0172] In some embodiment, once processing has been completed,
gripper 119 of robotic arm 117 transports processing receptacle 103
to a carrier 101, and transports sample containing receptacle 105
back to input rack 111. For example, if carrier 101 is a puck
defining a recess, gripper 119 can insert a portion of processing
receptacle 103 into the recess defined by the carrier 101, thereby
coupling processing receptacle 103 to carrier 101. Then in some
embodiments, gripper 119 or another device (e.g., another robotic
arm or conveyor assembly) transports receptacle 103 and the
respective carrier 101 to intermediate conveyor assembly 106.
[0173] In some embodiments, the automated processing instrument 104
is a high-throughput, random access sample processing instrument
104 capable of simultaneously processing multiple different sample
types. As indicated, the instrument automatically processes samples
according to a rule set that balances throughput with
time-to-next-result, which is particularly relevant when the
instrument is processing different types of samples that require
different routines and reagents. For example, in one embodiment,
instrument 104 is designed to process up to about 540 samples that
do not require incubation, or up to about 360 samples that require
reagent addition and heated incubation within a single eight hour
shift. Included in this time is instrument setup, run preparation,
sample processing, clean up and instrument power down. For purposes
of this discussion, a "run" is defined as the processing of up to
about sixty samples, for example, LCB specimens, from start to
finish. In other embodiments, a run can include processing more or
less than sixty samples, depending on the number of available input
lanes in the input bay 109 and output lanes in the output bay of
the machine. For example, a run could refer to the processing of up
to about ninety-six samples, for example, LCB specimens, from start
to finish. In one embodiment, a run refers to processing a
collection of samples that occupy a defined portion or all of the
available input lanes of the input bay 109 or that occupy a defined
portion or all of the available output lanes of the output bay.
[0174] In some embodiments, instrument 104 is configured to perform
one or more of the following processes (for example, when
processing a ThinPrep.RTM. sample):
1. Using robotic arm 117 having receptacle gripper 119, pick sample
containing receptacle 105 from input rack 111 and place in a
corresponding container holster on a carousel in processing station
107; 2. Read a barcode on sample containing receptacle 105 using
barcode reader 127; 3. Orbital mix the sample in sample containing
receptacle 105 using processing station 107; 4. If necessary, using
robotic arm 117 having receptacle gripper 119, pick corresponding
processing receptacle 103 from input rack 111 and place in the
printer for printing a barcode (or other machine readable label) on
processing receptacle 103; 5. Using robotic arm 117 having
receptacle gripper 119, pick corresponding processing receptacle
103 from the printer and place in a processing receptacle holster
on a carousel in processing station 107; 6. Uncap the sample
containing receptacle 105 using a capping/decapping mechanism 201
at the sample processing station 107; 7. Using pipettor 121,
aspirate at least a portion of a sample from sample containing
receptacle 105; 8. Recap sample containing receptacle 105 using a
capping/decapping mechanism 201; 9. Uncap the processing receptacle
103 using a capping/decapping mechanism 201 at the sample
processing station 107; 10. Using pipettor 121, dispense the
aspirated portion of the sample into processing receptacle 103; 11.
Recap the processing receptacle 103 using the capping/decapping
mechanism 201 at the sample processing station 107; 12. Using
robotic arm 117 with receptacle gripper 119, transport sample
containing receptacle 105 to input rack 111; 13. Using robotic arm
117 with receptacle gripper 119, couple processing receptacle 103
with a carrier 101 (for example, by inserting a portion of
processing receptacle 103 within a recess defined by carrier 101);
and 14. Using robotic arm 117 with receptacle gripper 119,
transport processing receptacle 103 coupled to carrier 101 to
intermediate conveyor assembly 106. 15. Alternatively, using
robotic arm 117 with receptacle gripper 119, transport processing
receptacle 103 to output rack 115.
[0175] In some embodiments, processing instrument 104 is configured
to perform one or more of the following processes (for example,
when processing a SurePath.RTM. sample):
1. Using robotic arm 117 having receptacle gripper 119, pick sample
containing receptacle 105 from input rack 111 and place in a
corresponding container holster on a carousel in processing station
107; 2. Read a barcode on sample containing receptacle 105 using
barcode reader 127; 3. Orbital mix the sample in sample containing
receptacle 105 using processing station 107; 4. If necessary, using
robotic arm 117 having receptacle gripper 119, pick corresponding
processing receptacle 103 from input rack 111 and place in the
printer for printing a barcode (or other machine readable label) on
processing receptacle 103; 5. Using robotic arm 117 having
receptacle gripper 119, pick corresponding processing receptacle
103 from the printer and place in a processing receptacle holster
on a carousel in processing station 107; 6. Uncap the sample
containing receptacle 105 using a capping/decapping mechanism 201
at the sample processing station 107; 7. Using pipettor 121,
aspirate a predetermined amount of a sample processing reagent
(e.g., Fast Express reagent, available from Hologic, Inc., Bedford,
Mass.) from a reagent containing receptacle within instrument 104;
8. Using pipettor 121, aspirate at least a portion of a sample from
sample containing receptacle 105; 9. Recap sample containing
receptacle 105 using a capping/decapping mechanism 201; 10. Uncap
the processing receptacle 103 using a capping/decapping mechanism
201 at the sample processing station 107; 11. Using pipettor 121,
dispense the aspirated portion of the sample into processing
receptacle 103; 12. Recap the processing receptacle 103 using the
capping/decapping mechanism 201 at the sample processing station
107; 13. Using robotic arm 117 with receptacle gripper 119,
transport sample containing receptacle 105 to input rack 111; 14.
Optionally, mixing processing receptacle 103; 15. Using robotic arm
117 with receptacle gripper 119, transport processing receptacle
103 to output rack 115, or incubator 123 for incubation; 16. If
processing receptacle 103 is positioned in incubator 123, using
robotic arm 117 with receptacle gripper 119, either transport
processing receptacle 103 from incubator 123 to output rack 115
after incubation or couple processing receptacle 103 with a carrier
101 (for example, by inserting a portion of processing receptacle
103 within a recess defined by carrier 101); and 16. If receptacle
103 is coupled to carrier 101, using robotic arm 117 with
receptacle gripper 119, transport processing receptacle 103 coupled
to carrier 101 to intermediate conveyor assembly 106.
[0176] In some embodiments, one or more of the above processes can
occur simultaneously. The above automated protocols are provided by
way of example only such that modifications of the number of steps,
what happens in each step, and the number of processes occurring in
a particular order or simultaneously may be changed or altered
without affecting the subject matter of this disclosure. One of
skill in the art would appreciate that the processing time required
to process each sample has a direct effect on the number of samples
that can be prepared in a given time period. Manipulation of the
processing time may have a detrimental impact on processing
accuracy and can increase the risk of contamination, though a
variety of sample processing times are contemplated with the caveat
that downtime between sample processing is kept to a minimum.
[0177] B. Exemplary Embodiments of Intermediate Conveyor Assembly
106
[0178] As shown in FIG. 2, intermediate conveyor assembly 106 is
configured to transport a plurality of carriers 101 from a position
136 to a position 135. In some embodiments, position 136 is within
a housing of sample processing instrument 104, and position 135 is
outside the housing of processing instrument 104. Intermediate
conveyor assembly 106 is configured to transport carriers 101 that
are each coupled a processing receptacle 103. In some embodiments,
processing receptacles 103 coupled to carriers 101 each contain a
sample portion dispensed by an automated pipettor 121 of sample
processing instrument 104 and processed according to any one of the
above identified processes of sample processing instrument 104.
[0179] In some embodiments, intermediate conveyor assembly 106
defines a single path along which carriers 101 move as shown in
FIG. 2. In other embodiments, intermediate conveyor assembly 106
defines two or more paths along which carriers 101 move. In some
embodiments, intermediate conveyor assembly 106 includes a movable
track that defines the path along which carriers 101 move. In some
track embodiments, the track can be a unitary belt or a plurality
of links coupled to form a belt. In such track embodiments,
carriers 101 sit on the track(s) and move as the track(s) move, for
example, in the direction of the annotated arrow in FIG. 2. In
other embodiments (not shown), intermediate conveyor assembly 106
includes a movable gripper that defines the path along which
carriers 101 move. For example, the gripper can grasp a carrier 101
or a processing receptacle 103 coupled to carrier 101 and move in
the direction of the annotated arrow in FIG. 2.
[0180] Intermediate conveyor assembly 106 is configured to transfer
carriers 101 to host conveyor assembly 102. For example, in some
embodiments, intermediate conveyor assembly 106 includes a diverter
140 configured to transfer a carrier 101 located at position 135 to
host conveyor assembly 102. In some embodiments, diverter 140 is a
rotatable disc that defines one or more recesses (for example,
three recesses as shown in FIG. 2) configured to receive a carrier
101 at position 135. As diverter 140 rotates, carrier 101 received
within the recess defined by diverter 140 is transferred to host
conveyor assembly 102. In some embodiments, diverter 140 is
configured to rotate in one direction or in two directions about an
axis of rotation.
[0181] C. Exemplary Embodiments of Host Conveyor Assembly 102
[0182] Host conveyor assembly 102 is configured to transport a
plurality of carriers 101 along a path. In some embodiments, this
path transports carriers 101 between positions adjacent processing
instrument 104 and assay instruments 108a-108c. The path defined by
host conveyor assembly 102 can have various shapes based on the
placement of processing instrument 104 and assay instruments
108a-108c. For example, as shown in FIG. 2, the path defined by
host conveyor assembly 102 is substantially rectangular. But in
other embodiments, the path defined by host conveyor assembly 102
can have non-rectangular shapes such as an L-shape or a circular
shape. As shown in FIG. 2, host conveyor assembly 102 includes a
first portion 118 configured to transport carriers 101 in a first
direction as indicated by the annotated arrows, and a second
portion 120 configured to transport carriers 101 in a second
direction, opposite the direction of first portion 118, as
indicated by the annotated arrows pointing in the opposite
direction. In some embodiments, first portion 118 and second
portion 120 are linear as shown in FIG. 2.
[0183] In some embodiments, the first portion 118 includes one or
more movable tracks that define the path along which carriers 101
move in the first direction. In some embodiments, the first portion
118 includes a single track that defines the path along which
carriers 101 move. In some track embodiments, the track(s) of first
portion 118 can be unitary belts or a plurality of links coupled to
form one or more belts. In such track embodiments, carriers 101 sit
on the track(s) of first portion 118 and move as the track(s) move.
In other embodiments, host conveyor assembly 102 includes a movable
gripper that defines the path along which carriers 101 move along
first portion 118.
[0184] In some embodiments, the second portion 120 includes one or
more movable tracks that define the path along which carriers 101
move in the first direction. In some embodiments, the second
portion 120 includes a single track that defines the path along
which carriers 101 move. In some track embodiments, the track(s) of
second portion 120 can be unitary belts or a plurality of links
coupled to form one or more belts. In such track embodiments,
carriers 101 sit on the track(s) of second portion 120 and move as
the track(s) move. In other embodiments, host conveyor assembly 102
includes a movable gripper that defines the path along which
carriers 101 move along second portion 120.
[0185] Host conveyor assembly 102 can include one or more drive
assemblies (not shown in FIG. 2) configured to move the drive
elements (for example, movable tracks or grippers) of first and
second portions 118 and 120 of host conveyor assembly 102. In some
embodiments, a single drive assembly moves both the drive elements
of first and second portions 118 and 120 of host conveyor assembly
102.
[0186] In some embodiments, host conveyor includes a diverter 122
configured to transfer carriers 101 from first portion 118 to
second portion 120. In some embodiments, diverter 122 is a
rotatable disc that defines one or more recesses (for example, one
recess as shown in FIG. 2) configured to receive a carrier 101 on
the first portion 118 of host conveyor assembly 102. As diverter
122 rotates, the carrier 101 received within the recess defined by
diverter 122 is transferred to second portion 120 of host conveyor
assembly 102. In some embodiments, diverter 140 is configured to
rotate in one direction or in two directions about an axis of
rotation. In some embodiments, host conveyor assembly 102 includes
a sensor 126 configured to detect the presence of a carrier 101 at
a position in which the carrier 101 is received within the recess
of diverter 122. In some embodiments, diverter 122 is operably
coupled to sensor 126 such that when a carrier 101 is detected to
be within the recess defined by diverter 122, rotation of diverter
122 is actuated and the carrier 101 is transferred to second
portion 120 of host conveyor assembly 102. In some embodiments,
diverter 122 is located at a terminal end portion of first portion
118, and at a beginning end portion of second portion 120. In other
embodiments, diverter 122 is positioned at non-terminal or
beginning ends of first and second portions 118 and 120 of host
conveyor assembly 102.
[0187] In some embodiments, host conveyor assembly 102 includes
another diverter 124 configured to transfer carriers 101 from
second portion 120 to first portion 118. In some embodiments,
diverter 124 is a rotatable disc that defines one or more recesses
(for example, one recess as shown in FIG. 2) configured to receive
a carrier 101 on the second portion 120 of host conveyor assembly
102. As diverter 124 rotates, the carrier 101 received within the
recess defined by diverter 124 is transferred to first portion 118
of host conveyor assembly 102. In some embodiments, diverter 124 is
configured to rotate in one direction or in two directions about an
axis of rotation. In some embodiments, host conveyor assembly 102
includes a sensor 128 configured to detect the presence of a
carrier 101 at a position in which the carrier 101 is received
within the recess of diverter 124. In some embodiments, diverter
124 is operably coupled to sensor 128 such that when a carrier 101
is detected to be within the recess defined by diverter 122,
rotation of diverter 124 is actuated and carrier 101 is transferred
to first portion 118 of host conveyor assembly 102. In some
embodiments, diverter 124 is located at a terminal end portion of
second portion 120, and at a beginning end portion of first portion
118 of host conveyor assembly 102. In other embodiments, diverter
124 is positioned at non-terminal or beginning ends of second and
first portions 120 and 118 of host conveyor assembly 102.
[0188] In some embodiments, one or more of assay instruments 108
and intermediate assay conveyor assemblies 133 are operatively
coupled to first portion 118 of host conveyor assembly 102 (assay
instruments 108a and 108b, and intermediate conveyor assemblies
133a and 133b as shown in FIG. 2), and one or more assay
instruments 108 and respective intermediate conveyor assemblies 133
(assay instrument 108c and intermediate conveyor assembly 133c as
shown in FIG. 2) are operative coupled to second portion 120 of
host conveyor assembly 102, as shown in FIG. 2. In other
embodiments (not shown in FIG. 2), none of assay instruments 108
and respective intermediate conveyor assemblies 133 are coupled to
one of first and second portions 118 and 120 of host conveyor
assembly 102.
[0189] In some embodiments, host conveyor assembly 102 is
configured to transport carriers 101 to positions (for example,
positions 141a, 141b, and 141c as shown in FIG. 2, collectively
referred to as positions 141 or generically and individually as
position 141) outside and adjacent respective assay instruments
108. In other embodiments (not shown), position 141 is inside the
housing of respective assay instrument 108.
[0190] In some embodiments, at position 141, host conveyor assembly
102 is configured to transport a carrier 101 such that carrier 101
either bypasses respective assay instrument 108 or is transported
to intermediate conveyor assembly 133. For example, referring to
FIG. 2, host conveyor assembly 102 can be configured to transport a
carrier 101 such that it bypasses respective assay instrument
108--the carrier 101 is never received by intermediate conveyor
assembly 133--and is transported to a downstream portion 145 of
host conveyor assembly 102 that transports the carrier 101 to a
position (for example, downstream positions 141b, 141c, and 141a)
adjacent another assay instrument 108 operatively coupled to host
conveyor assembly 102. As for another example, host conveyor
assembly 102 can be configured to transport a carrier 101 such that
it bypasses both assay instruments 108a and 108b--the carrier 101
is never received by intermediate assay conveyor assemblies 133a
and 133b--and is transported to a position (for example, position
141c) adjacent assay instrument 108c. Or at position 141, host
conveyor assembly 102 is configured to transport carrier 101 to
intermediate conveyor assembly 133 such that carrier 101 is
transported to assay instrument 108.
[0191] In some embodiments, host conveyor assembly 102 includes a
diverter (for example, diverters 142a, 142b, and 142c, collectively
referred to as diverters 142 or individually and generically
referred to as diverter 142) adjacent position 141 and a respective
intermediate conveyor assembly 133. Diverter 142 is configured to
selectively transport a carrier 101 (one at a time in some
embodiments) from a portion (first portion 118 or second portion
120) of host conveyor assembly 102 to intermediate conveyor
assembly 133 (for example, intermediate assay conveyor assemblies
133a, 133b, or 133c) based on information (e.g., an identifier) on
the carrier 101, the processing receptacle 103 coupled to the
carrier 101, or both the carrier 101 and receptacle 103. In some
embodiments, diverter 142 is also configured to alternatively and
selectively transfer a carrier 101 (one at a time in some
embodiments) from position 141 on host conveyor assembly 102 to
downstream portion 145 of host conveyor assembly 102 such that the
carrier 101 bypasses the respective intermediate conveyor assembly
133 based on an information (e.g., an identifier) on the carrier
101, the processing receptacle 103 coupled to the carrier 101, or
both the carrier 101 and receptacle 103.
[0192] In some embodiments, diverter 142 is a rotatable disc that
defines one or more recesses (for example, one recess as shown in
FIG. 2) configured to receive a carrier 101 at position 141 on an
upstream portion of host conveyor assembly 102. As diverter 142
rotates, the carrier 101 received within the recess defined by
diverter 142 is transferred to either intermediate conveyor
assembly 133 (for example, if diverter 142 rotates counter
clockwise) or to downstream portion 145 of host conveyor assembly
102 (for example, if diverter 142 rotates clockwise) such that the
carrier bypasses the respective intermediate conveyor assembly 133
based on information (e.g., an identifier) on the carrier 101, the
processing receptacle 103 coupled to the respective carrier 101, or
both. For example, an upstream portion of host conveyor assembly
102 transports a carrier 101 such that it is received within a
recess defined by diverter 142 at position 141. Then based on
information (e.g., an identifier) on the carrier 101, the
processing receptacle 103 coupled to the respective carrier 101, or
both, diverter 142 rotates to a position that aligns the recess in
which carrier 101 is received with either (1) downstream portion
145 of host conveyor assembly 102 (such that the carrier bypasses
intermediate conveyor assembly 133 and assay instrument 108) or (2)
a portion of intermediate conveyor assembly 133a such that the
carrier can be subsequently transported to a processing position of
assay instrument 108. In some embodiments, diverter 142 is
configured to rotate in one direction or in two directions about an
axis of rotation.
[0193] In some embodiments, host conveyor assembly 102 includes a
sensor (for example, sensors 144a, 144b, and 144c, collectively
referred to as sensors 144 or individually and generically as
sensor 144) configured to read the information (e.g., an
identifier) on the carrier 101, the processing receptacle 103
coupled to the respective carrier 101, or both. Sensor 144 can be
positioned upstream from diverter 142. Diverter 142 is operatively
coupled to sensor 144 such that diverter 142 selectively transfers
a carrier 101 from an upstream portion of host conveyor assembly
102 to either (1) an intermediate conveyor assembly 133 or (2) a
downstream portion 145 of host conveyor assembly 102 that bypasses
intermediate conveyor assembly 133 and assay instrument 108 based
on the information (e.g., an identifier) on the carrier 101, the
processing receptacle 103 coupled to the respective carrier 101, or
both read by sensor 144.
[0194] In some embodiments, system 100 includes a control system
(not shown in FIG. 2) configured to transmit a control signal to
diverter 142. Diverter 142 is configured to transfer the carrier
101 from the upstream portion of host conveyor assembly 102 to
either (1) an intermediate conveyor assembly 133 or (2) a
downstream portion 145 of host conveyor assembly 102 that bypasses
intermediate conveyor assembly 133 and assay instrument 108 based
on the control signal received from the control system. And sensor
144 can be configured to transmit a signal to the control system
based on the read information (e.g., an identifier) of the carrier
101, the processing receptacle 103 coupled to the respective
carrier 101, or both. The control system also can be configured to
adjust the control signal transmitted to diverter 142 based on the
sensor signal received from sensor 144 to control whether the
carrier 101 is transported from an upstream portion of host
conveyor assembly 102 to either (1) an intermediate conveyor
assembly 133 or (2) a downstream portion 145 of host conveyor
assembly 102 that bypasses intermediate conveyor assembly 133 and
assay instrument 108.
[0195] In some embodiments, at least one of the carrier 101 and the
respective processing receptacle 103 includes an RFID tag that
transmits an identifier, and sensor 144 is an RFID antenna
configured to detect the identifier transmitted by the RFID tag on
the at least one of carrier 101 and processing receptacle 103. In
other embodiments, at least one of the carrier 101 and the
respective processing receptacle 103 includes a machine readable
label, for example, a barcode, that includes an identifier, and
sensor 144 is an image sensor, for example, a barcode reader,
configured to detect the label on the at least one of carrier 101
and processing receptacle 103.
[0196] In some embodiments, each of sensors 144a, 144b, and 144c
are the same type of sensor, and in other embodiments at least two
of sensors 144a, 144b, and 144c are different types of sensors.
[0197] In some embodiments, the path defined by host conveyor
assembly 102 is substantially enclosed by a cover (not shown). The
cover can help prevent contamination of samples within receptacles
103 coupled to carriers 101 being transported on host conveyor
assembly 102.
[0198] D. Exemplary Embodiments of Intermediate Conveyor Assemblies
133
[0199] Intermediate conveyor assembly 133 is configured to receive
carriers 101 at position 141 on host conveyor assembly 102 and
transport the carriers to a respective processing position (for
example, processing positions 154a, 154b, 154c, collectively
referred to as processing positions 154 or individually referred to
as processing position 154) of the assay instrument 108. In some
embodiments, position 154 is within a housing of the respective
assay instrument 108. In some embodiments, assay instrument 108
includes an automated pipettor configured to aspirate at least a
portion of a sample from a processing receptacle 103 coupled to a
carrier 101 positioned at processing position 154. Automated
pipettor 158 can also be configured to subsequently dispense the
aspirated portion of the first sample from the processing
receptacle 103 at processing position 154 into an assay receptacle
160. Automated pipettor 158 and assay instrument 108 are described
further below.
[0200] In some embodiments, intermediate conveyor assembly 133 is
also configured to transport a carrier 101 from processing position
154 to another position outside the housing of assay instrument 108
(for example, positions 167a, 167b, and 167c, collectively referred
to as positions 167 or individually referred to as position 167).
In other embodiments, intermediate conveyor assembly 133 is
configured to transport a carrier 101 from processing position 154
to another position inside the housing of assay instrument 108. In
some embodiments, intermediate conveyor assembly 133 is configured
to transport a carrier 101, after being positioned at processing
position 154, back to host conveyor assembly 102. For example,
intermediate conveyor assembly 133 can be configured to transport a
carrier 101 at a position outside of the housing of assay
instrument 108 (for example, position 167 in FIG. 2), to host
conveyor assembly 102.
[0201] In some embodiments, each of intermediate conveyor
assemblies 133a-133c is configured similarly (e.g., similar
components, shape, size, and path along which carriers 101 are
transported) as shown in FIG. 2. In other embodiments, at least two
of intermediate conveyor assemblies 133a-133c are configured
differently (e.g., different components, shape, size, or path along
which carriers 101 are transported).
[0202] In some embodiments, intermediate conveyor assembly 133
includes a buffer conveyor subassembly 114 and a spur conveyor
subassembly 116. FIGS. 3-10 illustrate embodiments of buffer
conveyor subassembly 114 and a spur conveyor subassembly 116, and
are referenced collectively below in describing embodiments of
buffer conveyor subassembly 114 and a spur conveyor subassembly
116.
[0203] Buffer conveyor subassembly 114 can include an input portion
146 configured to receive a carrier 101 from host conveyor assembly
102 (for example, by diverter 142) and transport the carrier 101 to
a position 147. Buffer conveyor subassembly 114 can also include an
output portion 162 configured to receive a carrier 101 at a
position 163 from spur conveyor subassembly 116 and transport the
carrier 101 to a position 167. In some embodiments, position 147,
position 163, and position 167 are each outside the housing of
assay instrument 108. In other embodiments, at least one of
position 147, position 163, and position 167 are outside the
housing of assay instrument 108. In some embodiments (not shown),
position 147 is collocated with position 163--position 147 and
position 163 are the same position.
[0204] Spur conveyor subassembly 116 is configured to transport a
carrier 101 between a position 153 and the processing position 154
within the housing of assay instrument 108. In some embodiments,
position 153 is substantially outside the housing of assay
instrument 108, as best seen in FIG. 2 and FIG. 6. In other
embodiments (not shown), position 153 is inside the housing of
assay instrument 108. In some embodiments, as shown, spur conveyor
subassembly 116 is configured to receive only one carrier 101 at a
time. In other embodiments (not shown), spur conveyor subassembly
116 is configured to receive more than one carrier 101 at a
time.
[0205] Spur conveyor subassembly 116 can include a diverter 150
configured to transport a carrier 101 from position 147 on buffer
conveyor subassembly 114 to position 153 on spur conveyor
subassembly 116. And in some embodiments, diverter 150 is
configured to transport a carrier 101 from position 147 to position
153 while simultaneously transporting another carrier 101 from
position 153 to position 163 on buffer conveyor subassembly 114.
Simultaneously transporting one carrier 101 from position 147 to
position 153 while transporting another carrier 101 from position
153 to position 163 can increase throughput of spur conveyor
subassembly 116 and, in turn, assay instrument 108.
[0206] Diverter 150 can define a plurality of recesses for
receiving and transporting carriers 101. For example, as best seen
in FIGS. 5 and 6, diverter 150 can define three recesses 155, each
configured to closely receive a carrier 101. In other embodiments,
diverter 150 defines more than or less than three recesses 155. For
example, diverter 150 can define one recess 155 or five recesses
155. In some embodiments, as illustrated, diverter 150 has a
circular periphery with three concave, circular recesses 155.
Recesses 155 can be evenly spaced around the periphery of diverter
150, as best seen in FIGS. 4 and 5. For example, if diverter 150
has three recesses 155, the recesses can be positioned about 120
degrees apart (about a center point of diverter 150).
[0207] In some embodiments, recesses 155 are positioned on diverter
150 such that when one recess 155 is aligned with position 147 on
buffer conveyor subassembly 114, one recess 155 is aligned with
position 153 spur conveyor subassembly 116, and one recess 155 is
aligned with position 163 of buffer conveyor subassembly 114. Such
a configuration allows diverter 150 to receive one carrier 101 at
position 147 simultaneously with either (1) receiving or releasing
another carrier 101 at position 153 or (2) releasing another
carrier 101 at position 163. Accordingly, diverter 150 can
transport a carrier 101 from position 147 to position 153 while
simultaneously transporting another carrier 101 from position 153
to position 163.
[0208] As best seen in FIGS. 4 and 5, diverter 150 is configured to
rotate about an axis of rotation. In some embodiments, diverter 150
is configured to rotate in one direction or in two directions.
[0209] Spur conveyor subassembly 116 can include a drive assembly
202 that is operatively coupled to diverter 150 to selectively
rotate diverter 150 about the axis of rotation. Drive assembly 202
can include a motor that is operatively coupled to an axle coupled
to diverter 150 via, for example, one or more of gears, pulleys,
and belts that drive the axle coupled to diverter 150. For example,
referencing FIG. 22, drive assembly 202 can include a motor 325
that rotates a drive shaft 326 operatively coupled to motor 325. As
shown in FIG. 22, drive shaft 326 is substantially vertical in some
embodiments. Drive shaft 326 can include a pulley 328 operatively
coupled to a drive belt 330. As shown in FIG. 22, drive belt 330 is
substantially horizontal in some embodiments. Drive belt 330 is
operative coupled to a pulley 332 fixedly connected to a rotating
shaft 334. Rotating shaft 334 is substantially vertical, as shown
in FIG. 22 in some embodiments. And diverter 150 is fixedly coupled
to shaft 334. The motor of drive assembly 202 is selectively
activated to rotate shaft 326 and pulley 328, which in turn rotates
belt 330. As belt 330 rotates, pulley 332 and shaft 334 rotate,
which in turn rotates diverter 150.
[0210] In some embodiments, as best seen in FIG. 7, drive assembly
202 is positioned between a housing panel 168 of instrument 108 and
a track of buffer conveyor subassembly 114. In some embodiments,
the motor of drive assembly 202 is coupled to a mounting bracket
204 of spur conveyor subassembly 116. Mounting bracket 204
positions the motor of drive assembly 202 below diverter 150 in
some embodiments as shown in FIGS. 5 and 7. As best seen in FIG.
22, mounting bracket 204 can enclose substantially the entire drive
assembly 202 in some embodiments.
[0211] In some embodiments as best seen in FIGS. 3, 4, 6, 7, 9, and
10, buffer conveyor subassembly 114 includes a single movable
track, and diverter 150 of spur conveyor subassembly 116 dissects
the single movable track of buffer conveyor subassembly 114 into
input portion 146 and output portion 162. In such embodiments, a
portion of diverter 150 overlaps in a vertical direction at least a
portion of the single movable track of buffer conveyor subassembly
114 input portion 146. In such embodiments, the single movable
track of buffer conveyor subassembly 114 transports a carrier 101
received from host conveyor assembly 102 in the direction of the
annotated arrows in FIGS. 2 and 10 along input portion 146, and
diverter 150 stops the carrier 101 at position 147 if position 147
is unoccupied by another carrier 101. If position 147 is already
occupied by a carrier 101, the subsequent carrier 101 being
transported by input portion 146 is stopped by the carrier 101 at
position 147.
[0212] In some embodiments, input portion 146 of buffer conveyor
subassembly 114 has a length sufficient to queue a plurality of
carriers 101 between diverter 150 and diverter 142a on host
conveyor assembly 102. For example, in some embodiments, input
portion 146 has a length sufficient to queue at least five carriers
101, for example, at least fifteen carriers 101.
[0213] In some embodiments in which buffer conveyor subassembly 114
includes a single movable track, buffer conveyor subassembly 114
includes a pair of rotating axles 174 and 176 around which the
movable track moves. In such embodiments, buffer conveyor
subassembly 114 can include a drive assembly 172 that powers the
movable track. For example, drive assembly 172 can be operatively
coupled to one of the axles 174 and 176, for example, axle 174 as
shown in FIG. 4. Drive assembly 172 can include a motor that is
operatively coupled to axle 174 via, for example, one or more of
gears, pulleys, and belts that drive axle 174 and, in turn, the
movable track. In some embodiments, drive assembly 172 is
positioned between a housing panel 168 of instrument 108 and the
track of buffer conveyor subassembly 114 as best seen in FIG.
4.
[0214] In some embodiments, buffer conveyor subassembly 114 is
mounted to an outer surface of housing panel 168 of assay
instrument 108 as best seen in FIG. 3. In some embodiments, housing
panel 168 is a rear housing panel of assay instrument 108 on a side
opposite of a manual input bay of assay instrument 108. In such
embodiments, the path along which carriers 101 are transported
along buffer conveyor subassembly 114, which includes position 147,
163, and 167, is outside the housing of assay instrument 108. In
some embodiments, as best seen in FIGS. 3 and 4, the path defined
by buffer conveyor subassembly 114 is substantially parallel to
housing panel 168 to which the buffer conveyor subassembly 114 is
mounted. Buffer conveyor subassembly 114 can include a pair of
mounting brackets 178 configured to secure buffer conveyor
subassembly 114 to an outer surface of housing panel 168. In some
embodiments, the path defined by buffer conveyor subassembly 114 is
substantially parallel to the path defined by an adjacent portion
of host conveyor assembly 102.
[0215] Buffer conveyor subassembly 114 can also include a carrier
alignment bracket 180 in some embodiments, as best seen in FIG. 4.
Alignment bracket 180 is shaped to push a carrier 101 to position
147 as the carrier 101 is transported by buffer conveyor
subassembly 114 towards diverter 150. For example, the alignment
bracket 180 can have a surface that is at an obtuse angle relative
to the path defined by buffer conveyor subassembly 114 along which
carriers 101 are transported. As the carrier 101 contacts this
surface, the carrier 101 is pushed toward position 147 on buffer
conveyor subassembly 114.
[0216] In some embodiments, buffer conveyor subassembly 114 also
includes a sensor 148 configured to detect the presence of a
carrier 101 at position 147 and/or read information (for example,
an identifier) from a carrier 101, a receptacle 103 coupled to the
carrier 101, or both the carrier and the receptacle 103. In some
embodiments, diverter 150 is operably coupled to sensor 148 such
that when a carrier 101 is detected to be at position 147 (and
within a recess 155 defined by diverter 150), rotation of diverter
150 is actuated, and the carrier 101 is transported to position 153
on a portion 184 of spur conveyor subassembly 116. In some
embodiments, sensor 148 is positioned on alignment bracket 180 or
any other position near diverter 150. Sensor 148 can be an optical
sensor or an RFID antenna.
[0217] Turning back to spur conveyor subassembly 116, subassembly
116 receives a carrier 101 from diverter 150 at position 153. Spur
conveyor subassembly 116 is configured to transport the carrier 101
between position 153 and the processing position 154 within the
housing of assay instrument 108. In some embodiments, housing panel
168 of assay instrument 108 defines an opening 170, and spur
conveyor subassembly 116 extends from buffer conveyor subassembly
114 and through opening 170 into the interior of assay instrument
108. In some embodiments, opening 170 is sized such that a carrier
101 and processing receptacle 103 coupled thereto can pass through
opening 170.
[0218] Spur conveyor subassembly 116 can be coupled to buffer
conveyor subassembly 114. In some embodiments, as best shown in
FIGS. 2-4 and 6, spur conveyor subassembly 116 is coupled to buffer
conveyor subassembly 114 at a position that is aligned with
diverter 150. In some embodiments as best seen in FIGS. 4 and 6,
spur conveyor subassembly 116 is substantially perpendicular to
buffer conveyor subassembly 114. In other embodiments (not shown),
spur conveyor subassembly 116 is at a non-perpendicular angle
relative buffer conveyor subassembly 114. In some embodiments, spur
conveyor subassembly 116 bisects buffer conveyor subassembly
114.
[0219] In some embodiments as best seen in FIG. 5, spur conveyor
subassembly 116 includes a movable gripper 188 that is movably
coupled, for example, translatably coupled, to a base 186. For
example, base 186 can define a groove (not shown), and gripper 188
can define a flange (not shown) translatably received within the
groove of base 186, which allows gripper 188 to move relative to
base 186 in the direction of the groove. Gripper 188 can move along
a direction 190. Gripper 188 is configured to selectively grasp a
carrier 101 at position 153 and transport the carrier 101 (along
with the coupled processing receptacle 103) to the processing
position 154 within a housing of assay instrument 108.
[0220] Referencing FIGS. 5 and 22-26, gripper 188 of spur conveyor
subassembly 116 can include at least two movable prongs 189
configured to secure the carrier 101 to gripper 188, for example,
by applying an effective amount of pressure to a carrier 101. As
shown in FIGS. 5 and 22-26, gripper 188 has two movable prongs 189.
In some embodiments, movable prongs 189 are pivotally coupled to a
base 197 of gripper 188. For example, each movable prong 189 can be
coupled to base 197 using a pivot pin 199 extending (e.g.,
substantially vertically) from base 197 about which each prong 189
pivots. Base 197 can be configured to engage a bottom surface of
carrier 101. For example, when diverter 150 transports a carrier
101 from position 147 on buffer conveyor subassembly 114 to
position 153 on spur conveyor subassembly 116, diverter 150 places
the carrier 101 on top of base 197 of gripper 188. After the
carrier 101 is transferred to base 197 of gripper 188, movable
prongs 189 grasp carrier 101 by pivoting about pivot pin 199 toward
each other and applying an effective amount of pressure to carrier
101 to secure the carrier 101 to gripper 188.
[0221] Gripper 188 can also include a wall 205 extending (e.g.,
substantially vertically) from base 197 of gripper 188. Wall 205 is
configured to stop movement of a carrier 101 in a direction toward
processing position 154 when diverter 150 transports a carrier 101
from position 147 on buffer conveyor subassembly 114 to position
153 on spur conveyor subassembly 116. In some embodiments, wall 205
is spaced apart from pivot pin 199 in a direction toward buffer
subassembly 114.
[0222] In some embodiments, each prong 189 includes a first prong
portion 191 that extends substantially perpendicularly (for
example, vertically) away from base 186. First prong portion 191
can have a shape that closely corresponds to the perimeter of
carrier 101. For example, if carrier 101 is a circular puck, first
prong portion 191 can have a corresponding arcuate shape that
closely corresponds the circularly periphery of carrier 101. In
some embodiments, each prong 189 of gripper 188 also includes a
second prong portion 193 that extends substantially perpendicularly
(for example, horizontally) from first portion 191 towards a center
of gripper 188. When gripper 188 is grasping a carrier 101, second
prong portion 193 overlaps (in a vertical direction) at least a
portion of carrier 101 as best shown in FIG. 5.
[0223] In some embodiments (as best seen in FIG. 26), first prong
portion 191 of prong 189 defines a protrusion 206 on a surface
facing a carrier 101 on base 197 of gripper 188. Protrusion 206 is
configured to be received in a groove 302 defined by carrier 101,
which is explained further below in reference to FIGS. 17 and 18,
when gripper 188 is in a closed configuration. When gripper 188 is
in the closed configuration, protrusion 206 overlaps (in a vertical
direction) at least a portion of the surface defining groove 302 of
carrier 101. If a force is applied to carrier 101 in a direction
away from base 186 of spur conveyor subassembly 116, protrusion 206
substantially prevents movement of carrier 101 in a direction of
the applied forces, which secures carrier 101 to gripper 188 and
spur conveyor subassembly 116. For example (referencing FIG. 8),
protrusion 206 can hold carrier 101 down as a distal end of
pipettor 158 of assay instrument 108 is removed from a processing
receptacle 103 coupled to the carrier 101 at processing position
154. Removing the distal end of pipettor 158 from processing
receptacle 103 can generate a force in the direction of movement of
pipettor 158, and protrusion 206 of prongs 189 can hold the carrier
101 down. For example, in some embodiments, receptacle 103 includes
a cap 159. Cap 159 defines a hollow cavity that is sealed on top
with a metallic foil 161. The hollow cavity of cap 159 can be
filled with a porous filter 165, and the bottom of the hollow
cavity is sealed with another metallic foil 169. As the distal end
of pipettor 158 is removed from processing receptacle 103, the
distal end passes through the bottom foil 169, the filter 165, and
the top metallic foil 161, generating a force in the direction of
movement of pipettor 158. Protrusions 206 of prongs 189 hold
carrier 101 in place by resisting this generated force.
[0224] In some embodiments (not shown), first prong portion 191 and
second prong portion 193 are sized such that second portion 193
contacts the overlapped surface (for example, a top surface) of
carrier 101 coupled to gripper 188 when gripper 188 is in the
closed configuration. This way, if a force is applied to carrier
101 in a direction away from base 186 of spur conveyor subassembly
116, second prong portion 193 substantially prevents movement of
carrier 101 in a direction of the applied forces, which secures
carrier 101 to gripper 188 and spur conveyor subassembly 116. For
example (referencing FIG. 8), second prong portion 193 can hold
carrier 101 down as a distal end of pipettor 158 of assay
instrument 108 is removed from a processing receptacle 103 coupled
to a carrier 101 at processing position 154. Removing the distal
end of pipettor 158 from processing receptacle 103 can apply a
force in the direction of movement of pipettor 158, and second
prong portions 193 of prongs 189 can hold the carrier 101 down.
[0225] In some embodiments, second prong portions 193 of gripper
prongs 189 are sized such than when prongs 189 are at a fully
closed and grasping carrier 101 (i.e., at the closed configuration
of gripper 188), there is a gap between the second prong portions
193 of prongs 189. This gap is sized to allow processing receptacle
103 to extend from carrier 101 in a direction away from base 186.
The second prong portions 193 are sized such that the distal ends
of each second prong portion 193 contact a processing receptacle
103 passing through the gap defined there between, thereby applying
a force to receptacle 103 as best seen in FIGS. 25 and 26. This
contact generates an axial retaining force (e.g., via friction) on
receptacle 103 that secures receptacle 103 to carrier 101 when a
force is applied to receptacle 103 in a direction away from carrier
101 and base 186 of spur conveyor subassembly 116 (for example, a
force applied to receptacle 103 when the distal end of pipettor 158
is removed from receptacle 103). In some embodiments, each second
prong portion 193 includes an elastomeric (for example, rubber)
portion 195 that contacts receptacle 103. Elastomeric portion 195
can be configured to compress (which in turn enlarges the gap
between second prong portions 193 through which a receptacle 103
passes) when contacting the receptacle 103. This compression allows
gripper 188 to accommodate receptacles 103 having varying
diameters, for example, diameters varying from about 8 mm to about
20 mm, including diameters of 12 mm and 16 mm. Elastomeric portion
195 can also increase the coefficient of friction at the interface
between second prong portion 193 and receptacle 103, which
increases the axial retaining force gripper 188 generates while
grasping receptacle 103 with prongs 189. In some embodiments, the
contact of second prong portions 193 against receptacle 103 can
also help align receptacle 103 in a desired orientation (for
example, in the vertical orientation) within spur conveyor
subassembly 116.
[0226] Gripper 188 is configured to move between (1) an open
configuration at which a carrier 101 is capable of moving relative
to gripper 188 and (2) a closed configuration at which carrier 101
is secured to gripper 188. For example, FIG. 24 illustrates gripper
188 at the open configuration. At the open configuration, prongs
189 of gripper 188 are separated from each other such that prongs
189 do not contact carrier 101 or receptacle 103. Accordingly,
protrusion 206 of each prong 189 is not received within groove 302
of carrier 101, and elastomeric portion 195 of each prong 189 does
not contact receptacle 103. This open configuration of gripper 188
allows diverter 150 to easily (1) transfer a carrier 101 from
position 147 on buffer conveyor subassembly 114 to position 153 on
spur conveyor subassembly 116 such that carrier 101 is placed on
top of base 197 of gripper 188, and/or (2) transfer another carrier
101 from position 153 on spur conveyor subassembly 116 to position
163 on buffer conveyor subassembly 114. In some embodiments, prongs
189 are biased to the closed configuration, for example, by using
an extension spring 211. In other embodiments, prongs 189 are
unbiased or biased to the open configuration using, for example, a
compression spring.
[0227] FIGS. 25 and 26 illustrate gripper 188 at the closed
configuration according to an embodiment. After carrier 101 is
transferred onto base 197 of gripper 188 by diverter 150, gripper
188 moves to the closed configuration by pivoting prongs 189 about
pivot pin 199 towards each other until prongs 189 contact the
carrier 101 and apply an effective amount of pressure to the
carrier 101 to secure the carrier 101 to gripper 188. At the closed
configuration, protrusion 206 of each prong 189 is received within
groove 302 of carrier 101, and elastomeric portion 195 of each
prong 189 contacts receptacle 103. At the closed configuration, if
a force is applied to carrier 101 in a direction away from base 186
of spur conveyor subassembly 116, protrusion 206 substantially
prevents movement of carrier 101 in a direction of the applied
forces, thereby securing carrier 101 to gripper 188 and spur
conveyor subassembly 116. And at this closed configuration, the
generated axial retaining force (e.g., via friction) on receptacle
103 by elastomeric portions 195 can secure receptacle 103 to
carrier 101 when a force is applied to receptacle 103 in a
direction away from carrier 101 and base 186 of spur conveyor
subassembly 116.
[0228] In some embodiments, spur conveyor subassembly 116 is
configured to move prongs 189 of gripper 188 to the open
configuration when gripper 188 is at position 153. At position 153,
gripper 188 receives a carrier 101 transferred by diverter 150 from
buffer subassembly 114 and/or delivers a carrier 101 to be
transferred by diverter 150 to buffer subassembly 114. And spur
conveyor subassembly 116 is configured to move prongs 189 of
gripper 188 to the closed configuration after carrier 101 is placed
onto base 197 of gripper 188. In some embodiments, prongs 189 move
to the closed configuration while gripper 188 is at position 153,
and in other embodiments, prongs 189 move to the closed
configuration after gripper 188 moves from position 153 and towards
processing position 154. Spur conveyor subassembly 116 is also
configured to maintain prongs 189 of gripper 188 at the closed
configuration when gripper 188 is at the processing position 154,
thereby ensuring carrier 101 and processing receptacle 103 are held
down as a distal end of pipettor 158 of assay instrument 108 is
removed from processing receptacle 103.
[0229] In some embodiments, movement of prongs 189 between the open
and closed configurations is actuated by a cam interface. For
example, base 186 of spur conveyor subassembly 116 can define a
pair of elongated and symmetric grooves 207 that extend from
processing position 154 to position 153. Proximate processing
position 154 grooves 207 are substantially parallel, and proximate
position 153 grooves 207 extend outward away from each other in a
substantially V- or U-shape fashion. Each prong 189 includes a pin
209 (best shown in FIGS. 23 and 26) configured to be received
within a respective groove 207. As gripper 188 moves along spur
conveyor subassembly 116, pins 209 of prongs 189 interface with the
surfaces defining grooves 207, which moves prongs 189 between the
open and closed configurations. For example, as gripper 188 moves
towards position 153, pins 209 move outwards as they each travel in
a respective outwardly extending portion of a respective groove
207, which in turn moves prongs 189 to the open configuration via a
cam interface between pins 209 and the surface that defines grooves
207. And as gripper 188 moves back towards processing position 154,
pins 209 move inward as they travel back towards the parallel
portion of grooves 207, which in turn moves prongs 189 to the
closed configuration via a cam interface between pins 209 and the
surface that defines grooves 207.
[0230] In other embodiments, movement of prongs 189 between the
open and closed configurations is selectively controlled by
electro-mechanical configurations. For example, gripper 188 can
include another drive assembly (e.g., a motor with belts, links, or
gears) operatively coupled to prongs 189. The drive assembly can
move prongs 189 between the open and closed configurations.
[0231] Spur conveyor subassembly 116 can also include a drive
assembly 192 mounted to base 186. Drive assembly 192 is configured
to selectively move gripper 188 along direction 190. In some
embodiments, drive assembly 192 includes a motor operatively
coupled to gripper 188 via one or more gears, pulleys, links, or
belts. In some embodiments, drive assembly 192 is positioned on a
side of processing position 154 away from position 153 of spur
conveyor subassembly 116. For example, referencing FIG. 22, drive
assembly 192 can be operatively coupled to a drive belt 320 that is
operatively coupled to gripper 188, for example, to base 197 of
gripper 188. Drive belt 320 can be rotationally mounted to spur
conveyor subassembly 116 by a pair of rotating axles 322 and 324.
Drive assembly 192 is operatively coupled to axle 322 by one or
more of gears, pulleys, and belts (not shown in FIG. 22) to power
axle 322 and, thereby, move belt 320. The position of gripper 188
is fixed relative to drive belt 320. Referencing FIG. 22, as drive
belt 320 rotates in a counter-clockwise direction, gripper 188
moves towards diverter 150, and as drive belt 320 rotates in a
clockwise direction, gripper 188 moves towards processing position
154.
[0232] In other embodiments, instead of or in addition to gripper
188, spur conveyor subassembly 116 includes a single movable track
that transports carrier 101 between position 153 and processing
position 154. Drive assembly 192 is configured to selectively move
the track and, in turn, transport a carrier 101 in both directions
190. In such embodiments, a carrier 101 can sit on top of the
movable track as the track moves with the carrier 101.
[0233] For example, in some embodiments, a movable track moves
carrier 101 from position 153 to processing position 154, and at
processing position 154, a stationary gripper 188 grasps carrier
101 securing carrier 101 at processing position 154. After gripper
188 grasps carrier 101, automated pipettor 158 can aspirate a
portion of a sample in a receptacle coupled to the carrier 101
being grasped by gripper 188. After a sample is aspirated, gripper
188 can release the carrier 101, and the movable track can
transport the carrier back to position 153.
[0234] In some embodiments, spur conveyor subassembly 116 includes
both gripper 188 and diverter 150. In other embodiments, spur
conveyor subassembly 116 omits one of either gripper 188 or
diverter 150. For example, spur conveyor subassembly 116 can
include gripper 188, but not diverter 150, or spur conveyor
subassembly 116 can include diverter 150, but not gripper 188.
[0235] Spur conveyor subassembly 116 can also include a cover 182
in some embodiments. Cover 182 overlaps at least a portion of the
path defined by spur conveyor subassembly 116 to help prevent
cross-contamination from substances dropping from pipettor 158 as
it moves within the housing of assay instrument 108 or from other
processes occurring within the housing of assay instrument 108. In
some embodiments, cover 182 overlaps substantially the entire
portion 183 (shown in FIG. 4) of the path between position 153 and
processing position 154 that is within the housing of assay
instrument 108. For example, one end of cover 182 is adjacent an
inner surface of housing panel 168 of assay instrument 108, which
defines opening 170, and the other end of cover 182 is adjacent and
overlaps processing position 154. Accordingly, when position 153 is
outside the housing of assay instrument 108 and processing position
154 is within the housing of assay instrument 108, a portion 184 of
the path defined by spur conveyor subassembly 116 is outside the
housing and uncovered, but the portion 183 of the path defined by
spur conveyor subassembly 116 that is inside the housing and is
covered and substantially enclosed by cover 182, thereby reducing
the risk of cross-contamination. Cover 182 is sized and shaped to
allow processing receptacle 103 coupled to a carrier 101 to pass
from position 153 to processing position 154. In some embodiments
as shown in FIG. 5, cover 182 has a substantially inverted U-shape,
or any other suitable shape.
[0236] In some embodiments, a portion of cover 182 overlapping
processing position 154 defines an opening 194. Opening 194 can be
circular in some embodiments as shown in FIGS. 5, 6, and 8. Opening
194 is configured to allow a distal end of pipettor 158, for
example, which includes a disposable tip or probe, to pass and then
be inserted into processing receptacle 103 coupled to carrier 101,
which is positioned at processing position 154 and secured at that
position 154 by gripper 188. In some embodiments, cover 182 also
includes an alignment plate 196. As shown in FIG. 5, alignment
plate 196 is a separate component from the remainder of cover 182.
But in other embodiments, alignment plate 196 can be formed
integrally with the remainder of cover 182. Alignment plate 196
defines a tapered surface that surrounds opening 194 defined by
cover 182. The tapered surfaces can automatically align the distal
end of pipettor 158 as the distal end of pipettor 158 is moved
toward processing receptacle 103 if pipettor 158 is slightly
misaligned relative to receptacle 103.
[0237] Cover 182 can be coupled to base 186. In some embodiments,
cover 182 is removably coupled to base 186. In such removable
embodiments, cover 182 can be removed for cleaning. In other
embodiments, cover 182 is permanently coupled to base 186. In some
embodiments, cover 182 is composed of a material compatible with
being decontaminated in a bleach solution.
[0238] In other embodiments (not shown), instead of cover 182 being
part of spur conveyor subassembly 116, cover 182 is part of assay
instrument 108.
[0239] Spur conveyor subassembly 116 can also include a receptacle
alignment block 198 in some embodiments. Alignment block 198 is
configured to automatically align a processing receptacle 103
coupled to a carrier 101 at the processing position 154 at an
orientation aligned with the direction of travel of pipettor 158
(for example, receptacle alignment block 198 can orient receptacle
103 in a vertical orientation). Alignment block 198 defines a
recess configured to receive a portion of receptacle 103 coupled to
a carrier 101 at the processing receptacle 103. As the portion of
receptacle 103 is received within this recess defined by alignment
block 198, processing receptacle 103 coupled to the carrier 101 is
automatically aligned with the direction of travel of pipettor 158
and with opening 194 defined by cover 182. In some embodiments,
alignment block 198 is positioned on a side of processing position
154 away from position 153.
[0240] As shown in FIG. 8, pipettor 158 of assay instrument 108 is
configured to move along direction 210. As pipettor 158 moves in
direction 210 toward base 186, a distal tip of pipettor 158 is
inserted through opening 194 defined by cover 182 until it is
inserted within processing receptacle 103, which is coupled to a
carrier 101 positioned at processing position 154.
[0241] In some embodiments, spur conveyor subassembly 116 includes
a sensor 156 configured to detect information (e.g., an identifier)
of the carrier 101, the processing receptacle 103 coupled to the
carrier 101, or both, when the carrier 101 is positioned at
processing position 154 of assay instrument 108. For example, in
some embodiments, sensor 156 is positioned near a terminal end of
the path defined by spur conveyor subassembly 116 along which a
carrier 101 is transported. In some embodiments, sensor 156 is
covered by cover 182. In some embodiments, sensor 156 is adjacent
base 186 of spur conveyor subassembly 116 and is below gripper 188.
In some embodiments, assay instrument 108 is configured to start
aspirating at least a portion of a sample from the processing
receptacle 103 coupled to a carrier 101 at the processing position
154 of assay instrument 108 based on the detected identifier of the
carrier 101, the processing receptacle 103 coupled to the
respective carrier 101, or both, by sensor 156. In some embodiments
in which at least one of the carrier 101 and the respective
processing receptacle 103 includes an RFID tag that transmits an
identifier or other information, sensor 156 is an RFID antenna
configured to detect the identifier or other information
transmitted by the RFID tag on the at least one of carrier 101 and
processing receptacle 103. In other embodiments in which at least
one of the carrier 101 and the respective processing receptacle 103
includes a machine readable label, for example, a barcode, that
includes the identifier or other information, sensor 156 is an
image sensor, for example, a barcode reader, configured to detect
the label on the at least one of carrier 101 and processing
receptacle 103. In some embodiments, sensor 156 is also configured
to detect the presence of a carrier 101 at position 154.
[0242] Intermediate conveyor assembly 133 includes a controller
200. In some embodiments, controller 200 is positioned on spur
conveyor subassembly 116. For example, controller 200 can be
mounted to cover 182. In some embodiments, controller 200 includes
one or more processors, one or more of drivers for the drive
assemblies, and one or more communication interfaces as described
further below. In some embodiments, controller 200 is operatively
coupled to one or more of drive assembly 172 of buffer conveyor
subassembly 114, drive assembly 202 of diverter 150, and drive
assembly 192 of gripper 188 to control the operations of these
components.
[0243] FIGS. 11-13 schematically illustrate various exemplary
system architectures of controller 200 relative to host conveyor
assembly 102 and assay instrument 108.
[0244] As shown in FIG. 11, controller 200 is operatively and
directly coupled to buffer conveyor subassembly 114 via one or more
communication links 212 and spur conveyor subassembly 116 via one
or more communication links 214 in some embodiments. In such
embodiments, controller 200 can directly control the track of
buffer conveyor subassembly 114 and the gripper 188 of spur
conveyor subassembly 116 via respective communication links 212 and
214. For example, controller 200 can send a control signal via
communication link 212 to drive assembly 172 of buffer conveyor
subassembly 114, and controller 200 can send a control signal via
communication link 214 to drive assembly 192 of spur conveyor
subassembly 116. Controller 200 can also directly monitor the
sensors of buffer conveyor subassembly 114 and the sensors of spur
conveyor subassembly 116. For example, controller 200 can receive a
signal via communication link 212 from sensor 148 on buffer
conveyor subassembly 114 that is indicative of whether a carrier
101 is present at position 147, and controller 200 can receive a
signal via communication link 214 from sensor 156 on spur conveyor
subassembly 116 indicative of information, for example, an
identifier, detected from carrier 101, receptacle 103, or both,
when the carrier 101 is at processing position 154. Controller 200
can also directly control diverter 150 on spur conveyor subassembly
116 using a control signal transmitted via communication link 214.
In some embodiments, controller 200 controls diverter 150 by
adjusting the control signal transmitted to diverter 150 based on
the signal received from sensor 148. In some embodiments,
controller 200 is in communication with the controllers of assay
instruments 108 via one or more communication links 218, for
example, CAN, RS485, RS422, Ethernet, USB, or wireless
communication interfaces. Controller 200 is also in communication
with the controller of host conveyor assembly 102 via one or more
communication links 216, for example, CAN, RS485, RS422, Ethernet,
USB, or wireless communication interfaces.
[0245] As shown in FIG. 12, controller 200 is operatively and
directly coupled to only spur conveyor subassembly 116 via one or
more communication links 214 according to another embodiment.
Controller 200 can directly control the track of spur conveyor
subassembly 116 via communication link 214. For example, controller
200 can send a control signal via communication link 214 to drive
assembly 192 of spur conveyor subassembly 116. Controller 200 can
also directly monitor the sensors of spur conveyor subassembly 116.
For example, controller 200 can receive a signal via communication
link 214 from sensor 156 on spur conveyor subassembly 116
indicative of information, for example, an identifier, detected
from carrier 101, receptacle 103, or both, when the carrier 101 is
at processing position 154. Controller 200 can also directly
control diverter 150 on spur conveyor subassembly 116 using a
control signal transmitted via communication link 214. In some
embodiments, the controller of host conveyor assembly 102 can
directly control buffer conveyor subassembly 114 via one or more
communication links 220. For example, the controller of host
conveyor assembly 102 can directly control the track of buffer
conveyor subassembly 114 via communication link 220. For example,
the controller of host conveyor assembly 102 can send a control
signal via communication link 220 to drive assembly 172 of buffer
conveyor subassembly 114. The controller of host conveyor assembly
102 can also directly monitor the sensors of buffer conveyor
subassembly 114. For example, the controller of host conveyor
assembly 102 can receive a signal via communication link 220 from
sensor 148 on buffer conveyor subassembly 114 that is indicative of
whether a carrier 101 is present at position 147. In some
embodiments, the controller of host conveyor assembly 102 controls
diverter 150 by adjusting the control signal transmitted to
diverter 150 based on the signal received from sensor 148.
Controller 200 is in communication with the controllers of assay
instruments 108 via one or more communication links 218, for
example, CAN, RS485, RS422, Ethernet, USB, or wireless
communication interfaces. Controller 200 is also in communication
with the controller of host conveyor assembly 102 via one or more
communication links 216, for example, CAN, RS485, RS422, Ethernet,
USB, or wireless communication interfaces.
[0246] As shown in FIG. 13, the controller of host conveyor
assembly 102 is operatively and directly coupled to buffer conveyor
subassembly 114 via one or more communication links 222 and to spur
conveyor subassembly 116 via one or more communication links 220
according to another embodiment. In such embodiments, the
controller of host conveyor assembly 102 can directly control the
track of buffer conveyor subassembly 114 and gripper 188 of spur
conveyor subassembly 116 via respective communication links 220 and
222. For example, the controller of host conveyor assembly 102 can
send a control signal via communication link 220 to drive assembly
172 of buffer conveyor subassembly 114, and the controller of host
conveyor assembly 102 can send a control signal via communication
link 222 to drive assembly 192 of spur conveyor subassembly 116.
The controller of host conveyor assembly 102 can also directly
monitor the sensors of buffer conveyor subassembly 114 and spur
conveyor subassembly 116. For example, the controller of host
conveyor assembly 102 can receive a signal via communication link
220 from sensor 148 on buffer conveyor subassembly 114 that is
indicative of whether a carrier 101 is present at position 147, and
the controller of host conveyor assembly 102 can receive a signal
via communication link 222 from sensor 156 on spur conveyor
subassembly 116 indicative of information, for example, an
identifier, from carrier 101, receptacle 103, or both, when the
carrier 101 is at processing position 154. The controller of host
conveyor assembly 102 can also directly control diverter 150 on
buffer conveyor subassembly 114 using a control signal transmitted
via communication link 220. In some embodiments, the controller of
host conveyor assembly 102 controls diverter 150 by adjusting the
control signal transmitted to diverter 150 based on the signal
received from sensor 148. In such embodiments, controller 200 is in
communication with the controllers of assay instruments 108 via one
or more communication links 218, for example, CAN, RS485, RS422,
Ethernet, USB, or wireless communication interfaces, and controller
200 is also in communication with the controller of host conveyor
assembly 102 via one or more communication links 216, for example,
CAN, RS485, RS422, Ethernet, USB, or wireless communication
interfaces.
[0247] FIG. 14 schematically illustrates a configuration of system
100 that also includes a lab information system 223. As shown in
FIG. 14, system 100 includes a lab information system 223,
processing instrument 104, and a plurality of assay instruments
108a-108c. The controller of processing instrument 104 is in
communication with lab information system 223 via one or more
communication links 228. And the controller of processing
instrument 104 is in communication with the controller of host
conveyor assembly 102 via one or more communication links 230. As
explained above, the controller of host conveyor assembly 102 can
be in communication with controllers 200a-c of respective
intermediate conveyor assemblies 133a-133b via respective one or
more communication links 216a-c. Controllers 200a-c are in
communication with respective communication interfaces 232a-c, for
example, COP modules, of controllers 226a-c of respective assay
instruments 108a-c via respective one or more communication links
234a-c. Controllers 226a-226c of assay instruments 108a-c are in
communication directly or indirectly with lab information system
223. For example, as shown in FIG. 14, controllers 226a-c of assay
instruments 108a-c are directly in communication with an
intermediate communication module 236 via respective communication
links 238a-c. In some embodiments, intermediate communication
module 236 acts as a firewall between lab information system 223
and assay instruments 108. Intermediate communication module 236 is
in communication with lab information system 223 via one or more
communication links 240. In some embodiments, intermediate
communication module 236 is omitted such that controllers 226a-226c
communicate directly with lab information system 223 via
communication links 238a-c. In some embodiments, communication
links 228, 230, 216a-216c, 218a-218c, 234a-234c, 238a-238c, and 240
can be any one of CAN, RS485, RS422, Ethernet, USB, wireless
communication interfaces, or a combination thereof.
[0248] FIG. 15 schematically illustrates a controller 200
operatively and directly coupled to buffer conveyor subassembly 114
and spur conveyor subassembly 116 according to an embodiment. As
shown in FIG. 15, controller 200 includes a processor 242, for
example, a microcontroller such as a PIC microcontroller.
Controller 200 includes one or more communication interfaces, for
example, a CAN interface 244A, an Ethernet interface 244B, an
isolated CAN interface 244C, an isolated RS485 and/or RS422
interface 244D, a USB interface 244E for programming or debugging,
or any combination thereof. Controller 200 can also include one or
more power supplies 246, for example, a 3.3 VDC or 12.0 VDC power
supply.
[0249] Controller 200 can also include one or more drivers 248 for
controlling one or more drive assemblies of spur conveyor
subassembly 116. For example, controller 200 can include one
stepper motor driver 248 for controlling drive assembly 192 that
moves gripper 188 of spur conveyor subassembly 116, and another
stepper motor driver for controlling drive assembly 202 that moves
diverter 150.
[0250] Controller 200 can further include one or more RFID
interfaces 250 for communicating with interfaces of RFID sensors on
buffer conveyor subassembly 114 and spur conveyor subassembly 116.
For example, controller 200 can include one RFID interface 250 for
communicating with an RFID interface 264 of RFID sensor 156 on spur
conveyor subassembly 116, and include another RFID interface 250
for communicating with an RFID interface 264 of an optional RFID
sensor 262 on buffer conveyor subassembly 114.
[0251] Additionally, controller 200 can include one or more sensor
interfaces 252 for communicating with interfaces 262 of sensors on
buffer conveyor subassembly 114 and spur conveyor subassembly 116.
For example, controller 200 can include one sensor interface 252
for communicating with interface 260 of sensor 166 on buffer
conveyor subassembly 114, one interface 252 for communicating with
an interface 278 of an optional sensor 276 configured to determine
whether a carrier is present at position 154, one interface 252 for
communicating with an interface 282 of an optional sensor 280
configured to determine the orientation of diverter 150, and one
interface 252 for communicating with an interface 284 of sensor
148.
[0252] Controller 200 also includes one or more power outputs 254.
For example, controller 200 can include four power outputs 254. One
power output 254 supplies power to a logic power input 256 of
conveyor subassembly 114. One power output 254 supplies power to
drive assembly 172 that moves the track defining input and output
portions 146 and 162 of buffer conveyor subassembly 114. One power
output 254 that supplies power to a power input 268 of optional
stop unit 266 of buffer conveyor subassembly 114. And one power
output 254 that supplies power to power input 274 of gripper
188.
[0253] Any one of the above described components can be omitted
from controller 200 or modified based upon the design of buffer
conveyor subassembly 114 and spur conveyor subassembly 116.
[0254] As shown in FIG. 15, buffer conveyor subassembly 114 can
include a CAN interface 258 in some embodiments.
[0255] In some embodiments, the controller of host conveyor
assembly 102, the controller for processing instrument 104, and the
controller for assay instrument 108 can be structured similar to
the above described controller 200.
[0256] Lab information system 223 manages patient and laboratory
information. In some embodiments, lab information system 223
includes a server or host computer having a database, and
application software for receiving, storing, and processing patient
and laboratory information. In some embodiments, lab information
system 223 generates a schedule for processing samples within
sample containing receptacles 105 introduced within lab automation
system 100 using processing instrument 104 and one or more of assay
instruments 108. For example, lab information system 223 can
generate a schedule for processing samples within sample containing
receptacles 105 introduced within lab automation system 100 that
optimize the use of reagents by processing instrument 104 and assay
instruments 108, optimize the use (increase the throughput or
ensure periods of instrument availability to run random access
assays) of processing instrument 104 and assay instruments 108. Lab
information system 223 can also generate a schedule for samples
within sample containing receptacles 105 introduced within lab
automation system 100 that route the samples to the appropriate
assay instrument 108 depending on the type of assay to be performed
or the type of analyte to be discriminated. According to the
generated schedule, lab automation system 100 routes carriers 101
to the appropriate one of assay instruments 108a, 108b, and
108c.
[0257] In some embodiments (for example, any of the embodiments of
FIGS. 11-13), controller 200 of intermediate conveyor subassembly
133 communicates various information to the controller of the
respective assay instrument 108 using communication link 218. For
example, controller 200 can communicate one or more of the
following types of information to and from the controller of assay
instrument 108: (1) the status of assay instrument 108 (e.g.,
whether assay instrument 108 is (a) idle, (b) ready for processing
a sample from processing receptacle 103 coupled to a carrier 101 at
processing position 154, (c) processing, or (d) in failure state),
(2) the status of intermediate conveyor assembly 133 (e.g., whether
intermediate conveyor assembly 133 is (a) idle, (b) whether input
portion 146 of buffer conveyor subassembly 114 has carriers 101 for
transferring to spur conveyor subassembly 116, (c) whether buffer
conveyor subassembly 114 is transferring carriers 101 to spur
conveyor subassembly 116, or (d) whether intermediate conveyor
assembly 133 is in failure state); (3) the status of processing
position 154 in assay instrument 108 (e.g., whether processing
position 154 is (a) empty, (b) occupied by a carrier 101 having an
unprocessed (not yet aspirated) processing receptacle 103, or (c)
occupied by a carrier 101 having a processed (already aspirated)
processing receptacle 103); (4) the number of carriers 101 in input
portion 146 of buffer conveyor subassembly 114; (5) the number of
carriers 101 in output portion 162 of buffer conveyor subassembly
114; (6) the number of carriers 101 output portion 162 of buffer
conveyor subassembly 114 can receive from spur conveyor subassembly
116 before being full; (7) information read by sensor 156 from
carrier 101, receptacle 103, or both, at processing position 154,
for example, an identifier read from an RFID tag on carrier 101;
(8) information read by sensors 144 or 148 from carrier 101,
receptacle 103, or both, at positions 141 or 147, for example, an
identifier read from an RFID tag on carrier 101; (9) a request or
confirmation of a new carrier 101 being positioned at processing
position 154; and (10) a request or confirmation of whether a
receptacle 103 coupled to a carrier 101 is not be processed at
processing position 154.
[0258] In some embodiments (for example, any of the embodiments of
FIGS. 11-13), controller 200 of intermediate conveyor subassembly
133 communicates various information to the controller of host
conveyor assembly 102 using communication link 216. Communication
link 216 can be CAN, RS485, RS422, USB, or Ethernet communication
interfaces. For example, the following information can be
communicated between controller 200 and the controller of host
conveyor assembly 102: (1) the status of host conveyor assembly 102
(e.g., whether host conveyor assembly 102 is (a) idle or (b) in a
failure state); (2) the status of intermediate conveyor assembly
133 (e.g., (a) whether intermediate conveyor assembly 133 is idle,
(b) whether input portion 146 of buffer conveyor subassembly 114 is
full, (c) whether a carrier 101 is on output portion 162 of buffer
conveyor subassembly 114, or (d) whether intermediate conveyor
assembly 133 is in a failure state); (3) the number of carriers 101
on input portion 146 of buffer conveyor subassembly 114; (4) the
number of carriers 101 that input portion 146 of buffer conveyor
subassembly 114 can receive from host conveyor assembly 102 before
being full; (5) the number of carriers 101 on output portion 162 of
buffer conveyor subassembly 114; (6) information read by sensors
146 or 148 from carrier 101, receptacle 103, or both, at positions
141 or 147, for example, an identifier read from an RFID tag on
carrier 101; (7) information read by sensor 156 from carrier 101,
receptacle 103, or both, at processing position 154, for example,
an identifier read from an RFID tag on carrier 101; (8) a request
or confirmation of a carrier 101 being transported to buffer
conveyor subassembly 114 from host conveyor assembly 102; and (9) a
request or confirmation of a carrier 101 being transferred from
buffer conveyor subassembly 114 to host conveyor assembly 102.
[0259] E. Exemplary Embodiments of Assay Instruments 108
[0260] In some embodiments, one or more of assay instruments 108
are each configured to perform one or more assays on samples
contained within cavities defined by assay receptacles 160. For
example, the one or more assay instruments 108 can be configured to
perform one or more assays that determine the presence of an
analyte (for example, a biological analyte such as a pathogenic
organism (e.g., bacterium, fungus, or protozoan) or virus) in a
sample. In some embodiments, these assays can include performing
nucleic acid amplification reactions on the samples. Exemplary
nucleic acid amplification reactions include polymerase chain
reactions, transcription-based amplification reactions, strand
displacement amplification reactions, and ligase chain reactions.
In other embodiments, assays can include, for example, nucleic acid
detection immunoassays, immunoassays, and chemical assays.
[0261] In some embodiments, one assay instrument 108, for example,
assay instrument 108a, performs one assay, and another assay
instrument 108, for example, assay instrument 108b or 108c performs
a different assay.
[0262] For example, assay instrument 108a can perform a first assay
on samples in assay receptacles 160 that determines the presence of
a first type of analyte (e.g., antibodies, antigens, nucleic acids,
toxins, or other chemicals), while another assay instrument 108b or
108c is configured to perform a different assay that determines the
presence of a second type of analyte different than the first type
of analyte. For example, one assay instrument 108 can perform an
assay configured to detect the presence of a certain nucleic acid,
while another assay instrument 108 performs a different assay to
detect the presence of a certain antibody.
[0263] In some embodiments, the targeted analyte indicates that a
particular bacterium, fungus, protozoan, or virus is present in the
sample. In some embodiments, one assay instrument 108 is configured
to perform an assay that detects the presence of a first
analyte--the presence of which indicates that a particular
bacterium, fungus, protozoan, or virus is present in the
sample--while another assay instrument 108 is configured to perform
a different assay that detects the presence of a different
analyte--the presence of which indicates that a different
bacterium, fungus, protozoan, or virus is present in the sample.
For example, one assay instrument 108 can perform an assay
configured to detect the presence of an analyte, the presence of
which indicates that a specific virus, for example, a hepatitis C
virus (HCV), is present in the sample. And another assay instrument
108 performs a different assay to detect the presence of a
different analyte--the presence of which indicates that a different
virus, for example, a human immunodeficiency virus (HIV), is
present in the sample.
[0264] In yet another example, one assay instrument 108 is
configured to perform one assay that includes performing a first
type of nucleic acid amplification reaction on a sample contained
within assay receptacle 160, while another assay instrument 108 is
configured to perform a different assay that includes performing a
different type of nucleic acid amplification reaction. For example,
one assay instrument 108 can perform an assay that includes
subjecting samples to conditions (e.g., adding reagent(s) and
exposing samples to certain temperature(s) including thermocycling
or isothermal conditions) that promote a certain type of nucleic
acid amplification reactions, for example, a polymerase chain
reaction, while another assay instrument 108 can perform a
different assay that includes subjecting samples to conditions
(e.g., adding reagent(s) and exposing samples to certain
temperature(s) including thermocycling or isothermal conditions)
that promote a different type of nucleic acid amplification
reaction, for example, a transcription-based amplification
reaction. Or for example, one assay instrument 108 performs one
assay that includes performing real-time amplification reactions
that can be used to determine the presence and amount of a target
nucleic acid in a sample in assay receptacle 160, while another
assay instrument 108 performs a different assay that includes
performing "end-point" amplification assays. Real-time
amplification assays can be used to determine the presence and
amount of a target nucleic acid in a sample which, by way of
example, is derived from a pathogenic organism (e.g., bacterium,
fungus, or protozoan) or virus. Real-time amplification assays are
often referred to as quantitative assays. By determining the
quantity of a target nucleic acid in a sample, a practitioner can
approximate the amount or load of the organism or virus in the
sample. Real-time amplification assays can also be used to screen
blood or blood products intended for transfusion for blood borne
pathogens, such as hepatitis C virus (HCV) and human
immunodeficiency virus (HIV). Real-time assays can also be used to
monitor the efficacy of a therapeutic regimen in a patient infected
with a pathogenic organism or virus, or that is afflicted with a
disease characterized by aberrant or mutant gene expression.
Real-time amplification assays can also be used for diagnostic
purposes, as well as in gene expression determinations. Exemplary
assay instruments 108 for performing real-time amplification assays
are disclosed by Macioszek et al. in U.S. Pat. No. 7,897,337.
[0265] In end-point amplification assays, the presence of
amplification products containing the target sequence or its
complement is determined at the conclusion of an amplification
procedure. End-point amplification assays are sometimes referred to
as qualitative assays because such assays do not indicate the
amount of a target analyte present, but provide a qualitative
indication regarding the presence of the target analyte. Exemplary
assay instruments 108 for end-point detection are disclosed by
Ammann et al. in U.S. Pat. No. 6,335,166.
[0266] In some embodiments, one or more of assay instruments 108
are configured to perform assays that capture, amplify, and detect
nucleic acids from target organisms in samples.
[0267] In some embodiments, assay instruments 108 are configured to
perform a target capture process that isolates nucleic acid of the
target analyte (e.g., virus, bacterium, fungus, protozoan,
mammalian cells, etc.) and purifies nucleic acid for amplification.
U.S. application Ser. No. 12/465,323, filed May 13, 2009, to Becker
et al. describes various exemplary target capture processes. Assay
instruments 108 can be configured to lyse the target analyte, which
can be in a variety of biological matrices (including urine and
blood), with target capture reagents ("TCR"), whereby the nucleic
acid is released.
[0268] In some embodiments, assay instruments 108 are configured to
perform assays on a sample in a single assays receptacle 160 using
common reagents as a one-step process. In some embodiments, assay
instruments 108 can detect low-abundance nucleic acid, and use
specific controls to obtain quantitative results.
[0269] In some embodiments, assay instrument 108 can include a
thermal cycler (not shown) for exposing the sample in assay
receptacle 160 to temperatures that are cycled between two or more
different temperatures.
[0270] In some embodiments, assay instruments 108 are each
configured to perform a plurality of different assays, for example,
different molecular assays, including nucleic acid based
amplification assays, nucleic acid detection immunoassays,
immunoassays, and/or chemical assays, on a plurality of samples. In
some embodiments, assay instruments 108 are each configured perform
different target nucleic acid amplification reactions. For example,
one assay instrument 108 is configured to perform a first target
nucleic acid amplification reaction on a first subset of a
plurality of samples, and perform a second, different target
nucleic acid amplification reaction on a second subset of the
plurality of samples.
[0271] In some embodiments, each assay instrument 108 includes a
first module configured to perform at least one of the steps of a
first target nucleic acid amplification reaction, and a second
module configured to perform at least one of the steps of a second
target nucleic acid amplification.
[0272] In some embodiments, each assay instrument 108 includes
various devices configured to receive one or more assay receptacles
160, within each of which is performed one or more steps of a
multi-step assay, for example, a nucleic acid test (NAT) designed
to detect a virus or organism (e.g., bacterium, fungus, or
protozoan). Each assay instrument 108 can be configured to perform
one or more of the following processes: adding substances such as
sample fluid, reagents (e.g., target capture reagents used in the
target capture process to isolate the target nucleic acid (e.g.,
magnetically responsive particles with immobilized polynucleotides,
polynucleotide capture probes, and reagents sufficient to lyse
cells containing the targeted nucleic acids), amplification
reagents used in nucleic acid amplification reactions to amplify
the target nucleic acid or portion thereof (e.g., oligonucleotides
for use in producing one or more detectable amplicons for the
target nucleic acid), buffers, oils, labels (i.e., a moiety or
compound that is detected or leads to a detectable signal such as
luminescent or fluorescent compounds), probes (e.g., nucleic acid
oligomers that fully or partially hybridize to a target sequence in
a nucleic acid, or in an amplicon containing the target sequence or
its complement, under conditions that promote hybridization (e.g.,
under stringent hybridization conditions) to allow detection of the
target sequence or amplicon), or any other reagent) and/or removing
substances from an assay receptacle 160; agitating an assay
receptacle 160 to mix the contents thereof; maintaining and/or
altering the temperature of the contents of an assay receptacle
160; heating or chilling the contents of an assay receptacle 160;
altering the concentration of one or more components of the
contents of an assay receptacle 160; separating or isolating
constituent components of the contents of an assay receptacle 160;
detecting an electromagnetic signal emission (e.g., light) from the
contents of an assay receptacle 160; halting an on-going reaction
in an assay receptacle 160; deactivating a nucleic acid in an assay
receptacle 160 from further amplification, or any combination
thereof.
[0273] In some embodiments, each assay instrument 108 can include
an assay receptacle 160 input device that includes structure for
receiving and holding one or more empty an assay receptacle 160
before assay receptacles 160 are used for performing one or more
process steps of an assay, for example, a nucleic acid test. The
receptacle input device may comprise a compartment, for example, a
drawer or cabinet.
[0274] In some embodiments, each assay instrument 108 includes one
or more bulk reagent container compartments configured to store one
or more bulk containers that hold bulk reagents or hold waste
material.
[0275] In some embodiments, each assay instrument 108 includes a
first bulk reagent container compartment configured to store at
least one bulk container that holds a nucleic acid amplification
reagent, and a separate second bulk reagent container compartment
configured to store at least one bulk container that holds a sample
preparation reagent, for example, a target capture reagent. In some
embodiments, each assay instrument 108 includes a bulk reagent
container compartment that stores both a bulk container that holds
a nucleic acid amplification reagent and a bulk container that
holds a sample preparation reagent, for example, a target capture
reagent.
[0276] Each assay instrument 108 can also include a manual sample
input bay configured to manually receive and hold processing
receptacles 103 containing samples.
[0277] Each assay instrument 108 can include at least one automated
pipettor 158 configured to transfer fluids, for example, sample
fluids, reagents, bulk fluids, waste fluids, etc., to and from
assay receptacles 160, other receptacles, and processing
receptacles 103 coupled to carriers 101 at processing position 154
within assay instrument 108. Pipettor 158 can be configured for
controlled, automated movement and access to the assay receptacles
160, bulk receptacles holding reagents, processing receptacles in
the sample input bay, and processing receptacles 103 coupled to
carriers 101 at processing position 154.
[0278] In some embodiments in which each assay instrument 108 is
configured to perform a nucleic acid test, reaction reagents
contained within assay instrument 108 may comprise target capture
reagents, lysis reagents (e.g., detergents such as lithium lauryl
sulfate and sodium dodecyl sulfate), nucleic acid amplification
reagents (e.g., the primers, polymerases, nucleoside triphosphates,
and salts needed for an amplification), and/or labels.
[0279] In some embodiments, each assay instrument 108 includes
temperature ramping stations configured to hold one or more assay
receptacles 160 in an environment that is maintained at higher or
lower than ambient temperatures so as to raise or lower the
temperature of the contents of the receptacles. In some
embodiments, no reaction is performed on a sample at the
temperature ramping station. In some embodiments, the temperature
ramping station is used to raise or lower the temperature to the
approximate temperature of another station in assay instrument 108
where a subsequent process step will be performed.
[0280] In some embodiments, each assay instrument 108 also includes
one or more heater modules configured to receive a plurality of
assay receptacles 160 and maintain the receptacles in an elevated
temperature environment.
[0281] Also, in some embodiment in each assay instrument 108 is
configured to perform a nucleic acid test, each assay instrument
108 can include sample-processing components, such as magnetic
separation wash stations configured to isolate and/or separate a
target nucleic acid immobilized on target capture reagent from the
remaining contents of assay receptacle 160.
[0282] In some embodiments, each assay instrument 108 can further
include chilling modules configured to receive one or more assay
receptacles 160 and hold the receptacles in a lower than ambient
temperature environment so as to reduce the temperature of the
contents of the receptacles.
[0283] And in some embodiments, each assay instrument 108 can
include a detector configured to receive an assay receptacles 160
and detect signals (e.g., optical signals) emitted by the contents
of the assay receptacles 160. In one implementation, the detector
includes a luminometer for detecting luminescent signals emitted by
the contents of an assay receptacles 160 and/or a fluorometer for
detecting fluorescent emissions. Each assay instrument 108 can also
include one or more signal detecting devices, such as fluorometers,
coupled to one or more of the incubators that are configured and
controlled to detect, for example, at specified, periodic
intervals, signals emitted by the contents of the assay receptacles
160 contained in the incubator while a process, such as nucleic
acid amplification, is occurring within the reaction
receptacles.
[0284] Each assay instrument 108 can include a receptacle transfer
device configured to transport assay receptacles 160 to one or more
of the incubators, load stations, temperature ramping stations,
wash stations, and chilling modules contained within the housing of
assay instrument 108.
[0285] In some embodiments, each assay instrument 108 is configured
to perform an assay that includes the nucleic acid amplification
reaction and, in some embodiments, includes measuring fluorescence
in real-time (i.e., as the amplification reaction is occurring).
Each assay instrument 108 can include a thermal cycler/signal
detector, a centrifuge, magnetic elution stations, and reagent pack
loading stations. In some embodiments, automated pipettor 158 is
configured to have access to the magnetic elution stations and the
reagent pack loading stations.
[0286] In some embodiments, the bulk reagents within the bulk
reagent containers within assay instrument 108 can include a sample
preparation reagent (e.g., target capture reagent (TCR), a wash
solution, an elution reagent, or any other sample preparation
reagent), a reconstitution reagent, or any other required bulk
reagent. In some embodiments, the bulk reagent containers hold a
quantity of the bulk reagent sufficient to perform between about 50
to 2,000 assays. In some embodiments, the bulk reagents are for
performing isothermal nucleic acid amplification reactions.
[0287] In some embodiments, each assay instrument 108 can be
configured to perform two or more assays that include nucleic acid
amplification reactions that require different reagents, including
one or more unit-dose reagents--reagents that are unitized into an
amount or concentration sufficient to perform one or more steps of
a single assay for a single sample. On such assay instrument 108 is
described in U.S. application Ser. No. 14/213,900, filed Mar. 14,
2014, to Buse et al.
[0288] Results of the assays performed by each of assay instruments
108 may be displayed on an instrument user interface of assay
instrument 108 communicated to laboratory information system
223.
[0289] F. Exemplary Embodiments of Carrier 101
[0290] As used in this application, a "carrier" refers to any
device that is configured to operatively couple to at least one
receptacle (for example, a sample containing receptacle, a
processing receptacle, or any other receptacle) for transporting
the at least once receptacle within system 100. Carriers 101 are
configured to maintain the orientation of the respective
receptacles coupled thereto as the carriers are transported
throughout the system. For example, in some embodiments, carriers
101 are pucks having a cylindrical portion defining a recess
configured to receive a portion the receptacle. In some puck
embodiments, carrier 101 includes a clamping device configured to
apply a retaining force to the receptacle placed within the recess
of carrier 101 such that the receptacle is retained within the
carrier 101.
[0291] FIGS. 17 and 18 illustrate an embodiment of carrier 101. As
shown in FIG. 17, carrier 101 includes a cylindrical main body 286
having a top end portion 288 and a bottom end portion 290. In other
embodiments, main body 286 can have non-cylindrical shapes.
[0292] In some embodiments, main body 286 is sized to fit on each
of intermediate conveyor assembly 106, host conveyor assembly 102,
and intermediate conveyor assemblies 133A-133C. When carrier 101 is
placed on intermediate conveyor assembly 106, host conveyor
assembly 102, or intermediate conveyor assemblies 133A-133C, bottom
end portion 290 is adjacent, for example, a movable track of
respective intermediate conveyor assembly 106, host conveyor
assembly 102, and intermediate conveyor assemblies 133A-133C.
[0293] In some embodiments, top end portion 288 defines a recess
292, which can be circular in some embodiments. Recess 292 is
configured to receive at least one movable retaining member 294.
For example, as shown in FIG. 17, circular recess 292 is configured
to receive three movable retaining members 294. The retaining
members 294 each have annular sector shape (when viewed in plan)
and collectively form an annulus defining an interior recess
portion 296, which can be circular in some embodiments, configured
to receive a portion, for example, a bottom portion of a processing
receptacle 103 to couple the processing receptacle 103 to the
carrier 101. In some embodiments, each retaining member 294
includes a tapered surface 308 that aligns receptacle 103 with the
center of recess portion 296 when receptacle 103 is being inserted
in recess portion 296. In other embodiments, carrier 101 can
include less than three or more than three movable retaining
members 294. And in other embodiments, retaining members 294 can
have other non-annular sector shapes when viewed in plan. In yet
other embodiments, retaining members 294 can define an interior
recess portion 296 that has a non-circular shape. In some
embodiments, the depth of recess portion 296 and the placement of a
machine readable label, for example, a barcode, on receptacle 103
are such that when the bottom portion of a receptacle 103 is
inserted within recess portion 296, the machine readable label on
receptacle 103 is not obstructed by any portion carrier 101 and
such that a sensor, for example, a barcode reader, can read the
label on receptacle 103.
[0294] In some embodiments, carrier 101 includes one or more
retaining fasteners (for example, as shown in FIGS. 17 and 18, a
screw and corresponding washer) configured to secure retaining
members 294 within recess 292 of carrier 101. In some embodiments,
retaining fasteners are stainless steel or a non-ferrous material
so as to not interfere with any RFID tag on carrier 101 or
receptacle 103. Correspondingly, in some embodiments, all
components of carrier 101 are composed of a non-ferrous material so
as to not interfere with any RFID tag on carrier 101 or receptacle
103.
[0295] Retaining members 294 are biased toward a center of recess
portion 296 such that each retaining member 294 applies a force to
a bottom portion of processing receptacle 103 inserted in recess
portion 296, generating an axial retaining force (e.g., via
friction) that secures receptacle 103 to carrier 101. In some
embodiments, the magnitude of the applied force to the bottom
portion of processing receptacle 103 is sufficient to generate an
axial retaining force that secures receptacle 103 to carrier 101 as
carrier 101 is transported by any one of intermediate conveyor
assembly 106, host conveyor assembly 102, and intermediate conveyor
assemblies 133A-133C. In some embodiments, the magnitude of the
applied force to the bottom portion of processing receptacle 103 is
not so great as to squeeze receptacle 103 upward and out of recess
portion 296. In some embodiments, the sum of the axial retaining
forces generated by retaining members 294 and the axial retaining
forces generated by gripper 188 via second portions 193 of prongs
189 (as described above) is equal to or greater than any axial
force applied to receptacle 103 in the opposite direction of the
generated retaining forces (for example, a force applied to
receptacle 103 as the distal end of pipettor 158 is removed from
receptacle 103). In some embodiments, this sum of axial retaining
forces applied to receptacle 103 is equal to or greater than about
four pounds. In some embodiments, this sum of axial retaining
forces applied to receptacle 103 is equal to or greater than about
6 pounds.
[0296] In some embodiments, carrier 101 includes a biasing device
that biases retaining members 294 toward the center of recess
portion 296 to apply the forces to the bottom portion of processing
receptacle 103 inserted in recess portion 296. For example, in some
embodiments, each retaining member 294 can define one or more
periphery grooves 304 configured to receive respective one or more
garter springs 306 that bias each retaining member 294 toward the
center of recess portion 296 to apply forces to the bottom portion
of processing receptacle 103 inserted in recess portion 296.
[0297] In some embodiments, movable retaining members 294 have a
radial stroke such that inner recess portion 296 can have a varying
size that accommodates receptacles 103 of varying diameters. For
example, in some embodiments, inner recess portion 296 can
accommodate receptacles 103 having diameters varying from about 8
mm to about 20 mm, including receptacles 103 having a diameter of
12 mm or 16 mm.
[0298] In some embodiments, main body 286 defines one or more
periphery, circumferential grooves. For example, as shown in FIGS.
17 and 18, main body 286 defines a lower groove 300. Lower groove
300 can be configured to mate with corresponding protrusions on any
one of intermediate conveyor assembly 106, host conveyor assembly
102, and intermediate conveyor assemblies 133A-133C to prevent
carrier 101 and the receptacle 103 coupled thereto from tipping
over as carrier 101 is transported along the respective conveyor
assembly. For example, one or more guide rails of intermediate
conveyor assembly 106, host conveyor assembly 102, and/or
intermediate conveyor assemblies 133A-133C can define a protrusion
that is received within lower groove 300 of carrier 101 as carrier
101 is transported along the respective conveyor assembly. When the
protrusion on the guide rail is received within lower groove 300 of
carrier 101 the carrier is substantially prevented from tipping
over relative to the track(s) of the respective intermediate
conveyor assembly 106, host conveyor assembly 102, and/or
intermediate conveyor assemblies 133A-133C, thereby also preventing
receptacle 103 coupled thereto from tipping over.
[0299] Main body 286 can also define a second, upper groove 302.
Upper groove 302 can be configured to mate with corresponding
protrusions on gripper 188 to hold carrier 101 down as a distal end
of an aspirator 158 is removed from receptacle 103 when carrier 101
is at the processing position 154 of assay instrument 108. For
example, first portion 191 of each prong 189 of gripper 188 can
form a protrusion that mates with groove 302 of carrier 101 to hold
carrier 101 down to base 186 within spur conveyor 116 of
intermediate conveyor assembly 133.
[0300] As shown in FIGS. 18, 29, 30, and 37, upper and lower
grooves 301 and 302 can have various shapes, sizes, and
orientations.
[0301] In some embodiments, bottom end portion 290 defines a recess
310 configured to receive one or more components. For example,
recess 310 can be shaped to closely receive one or more RFID tags
or any other types of transponders. In some embodiments, recess 310
includes a first portion 312 shaped to receive first type of
component and a second portion 314 shaped to receive a different
type of component. For example, as shown in FIG. 17, first portion
312 can have a cylindrical shape configured to closely receive an
RFID tag that operates at one frequency, and second portion 314 can
have a rectangular shape configured to closely receive a different
type of RFID tag that operates at a different frequency. As shown
in FIG. 17, second portion 314 of recess 310 can extend from a
surface defining first portion 312 of recess 310 toward top end
portion 288 of main body 286. In some embodiments, the center of
first portion 312 of recess 310 and the center of second portion
314 of recess 310 are coaxial with each other and, in some
embodiments, are coaxial with the center of recess portion 296 that
receives receptacle 103.
[0302] This application also discloses new, original, and
ornamental designs for a carrier 101, reference being had to, for
example, the designs of FIGS. 27-37, forming a part thereof. In
FIGS. 27-37, the broken lines show portions of the sample carrier
that form no part of the disclosed designs.
2. Exemplary Embodiments of Use and Sample Processing Methods
[0303] Embodiments of processing samples using one or more of
processing instrument 104, intermediate conveyor assembly 106, host
conveyor assembly 102, intermediate conveyor assemblies 133, and
assay instruments 108 will now be described. In some embodiments,
processing instrument 104 reads information (e.g., an identifier)
from carrier 101, processing receptacle 103, or both, using, for
example, sensor 138, and the controller of processing instrument
104 transmits the read information, for example, an identifier, of
carrier 101, processing receptacle 103, or both, to lab information
system 223 via communication link(s) 228. Lab information system
223 can then associate the sample dispensed into receptacle 103
with the identifier on carrier 101, receptacle 103, or both, read
by a sensor. Afterwards, intermediate conveyor assembly 106 can
transport the carrier 101 and processing receptacle 103 coupled
thereto from processing instrument 104 to host conveyor assembly
102. These steps can then be repeated for one or more additional
processing receptacles 103 and carriers 101.
[0304] As shown in FIG. 1, host conveyor assembly 102 transports
the carriers 101 and receptacles 103 coupled thereto (which were
received from intermediate conveyor assembly 106) along first
portion 118 toward assay instrument 108a. As carriers 101 pass
sensor 144, sensor 144 reads information from carrier 101,
receptacle 103, or both, and transmits a signal to a controller of
host conveyor assembly 102 that includes the read information. The
controller of host conveyor assembly 102 can then determine whether
the read information, for example, an identifier, is associated
with a first sample on which assay instrument 108a is scheduled to
perform an assay on the sample in the receptacle 103. This
determination can be based on information stored in the laboratory
information system 223. If the read information from carrier 101 or
receptacle 103 passing sensor 144 is associated with a sample on
which assay instrument 108a is scheduled to perform an assay, the
controller of host conveyor assembly 102 then sends a control
signal to diverter 142a to divert the respective carrier 101 from
host conveyor assembly 102 to input portion 146 of buffer conveyor
subassembly 114 of intermediate conveyor assembly 133a. If the read
information from carrier 101 or receptacle 103 passing sensor 144a
is not associated with a sample on which assay instrument 108a is
scheduled to perform an assay, the controller of host conveyor
assembly 102 adjusts the control signal transmitted to diverter
142a, which then divert the respective carrier 101 to a downstream
portion 145a of host conveyor assembly 102 that bypasses
intermediate conveyor assembly 133a and assay instrument 108a. Host
conveyor assembly 102 then continues to transport the carrier 101
toward the next assay instrument 108b.
[0305] As the next carrier 101 passes sensor 144a, sensor 144a
reads information from that carrier 101, receptacle 103 coupled to
that carrier 101, or both, and transmits a signal to the controller
of host conveyor assembly 102 that includes the read information.
The controller of host conveyor assembly 102 can then determine
whether the read information, for example, an identifier, is
associated with a sample on which assay instrument 108a is
scheduled to perform an assay based on information stored in the
laboratory information system 223. If the read information is
associated with a sample on which assay instrument 108a is
scheduled to perform an assay, the controller of host conveyor
assembly 102 then sends a control signal to diverter 142a to divert
the next carrier 101 from host conveyor assembly 102 to input
portion 146a of buffer conveyor subassembly 114a of intermediate
conveyor assembly 133a. If the read information from the subsequent
carrier 101 is not associated with a sample on which assay
instrument 108a is scheduled to perform an assay, the controller of
host conveyor assembly 102 adjusts the control signal transmitted
to diverter 142a to divert the subsequent carrier 101 to a
downstream portion 145a of host conveyor assembly 102 that bypasses
intermediate conveyor assembly 133a and assay instrument 108. Host
conveyor assembly 102 then continues to transport the subsequent
carrier 101 toward the next assay instrument 108b.
[0306] Host conveyor assembly 102 can divert a plurality of
carriers 101 to input portion 146a of buffer conveyor subassembly
114a until input portion 146a of buffer conveyor subassembly 114 is
full. At that point, the controller of host conveyor assembly 102
will continue to divert carriers 101 to downstream portion 145a of
host conveyor assembly 102 regardless of whether the sample
contained within receptacle 103 coupled to carrier 101 is scheduled
for an assay to be performed by assay instrument 108a until space
is available on input portion 146a of buffer conveyor subassembly
114a to accept additional carriers 101.
[0307] Once a carrier 101 is diverted from host conveyor assembly
102 to input portion 146a of buffer conveyor subassembly 114a, the
controller of host conveyor assembly 102 provides a notification to
controller 200a of intermediate conveyor assembly 133a that a
carrier 101 was diverted. And in some embodiments, the controller
of host conveyor assembly 102 transmits information about the
diverted carrier 101, for example, an identifier of the carrier
101, receptacle 103, or both, to controller 200a.
[0308] Once a predetermined minimum number of carriers 101 have
been queued on input portion 146a, controller 200a can notify the
controller of assay instrument 108a that the predetermined minimum
number of carriers 101 and, thus, samples in processing receptacles
103 are available for processing by assay instrument 108a. In some
embodiments, the predetermined minimum number of carriers 101 is at
least five carriers 101. In other embodiments, the predetermined
minimum number of carriers 101 is less than five. In some
embodiments, the predetermined minimum number of carriers 101
equals the number of cavities defined by a signal assay receptacle
160. For example, if a single assay receptacle 160 defines five
cavities for receiving five samples, the predetermined minimum
number of carriers equals five.
[0309] Input portion 146a transports diverted carriers 101 towards
position 147 on buffer conveyor subassembly 114a and queues a
plurality of carriers 101 until assay instrument 108a is ready to
start processing samples contained in receptacles 103 coupled to
carriers 101. In some embodiments, as a carrier 101 on buffer
conveyor subassembly 114a passes sensor 148a, sensor 148a reads
information from the passing carrier 101, receptacle 103, or both,
and transmits a signal to controller 200a of intermediate conveyor
assembly 133a that includes the read information. Controller 200a
of intermediate conveyor assembly 133a can then determine whether
the read information, for example, an identifier, is associated
with or matches the information transmitted from the controller of
host conveyor assembly 102 to intermediate conveyor assembly 133a
about the respective diverted carrier 101. If the read information
matches or is associated with the transmitted information,
controller 200a of intermediate conveyor assembly 133a sends a
control signal to diverter 150a to divert the respective carrier
101 from input portion 146a of buffer conveyor subassembly 114a to
spur conveyor subassembly 116a. If the read information does not
match or is not associated with the transmitted information,
controller 200a of intermediate conveyor assembly 133a adjusts the
control signal to diverter 150a to divert the carrier 101 from
input portion 146a of buffer conveyor subassembly 114a directly to
output portion 162a of buffer conveyor subassembly 114a, bypassing
spur conveyor subassembly 116a.
[0310] After being transferred to spur conveyor subassembly 116a of
intermediate conveyor assembly 133a, spur conveyor subassembly 116a
transports the carrier 101 to processing position 154a within assay
instrument 108a. For example, gripper 188 clamps the carrier 101 at
position 153a, and moves towards processing position 154a until the
carrier 101 is at position 154a. Sensor 156a can then read
information from the carrier 101, receptacle 103 coupled thereto,
or both, when carrier 101 is at processing position 154a. Sensor
156a can also transmit a signal to controller 200a of intermediate
conveyor assembly 133 that includes the read information.
Controller 200a of intermediate conveyor assembly 133a can then
determine whether the read information, for example, an identifier,
is associated with a sample on which assay instrument 108a is
scheduled to perform an assay. This determination can be based on
information stored in the laboratory information system 223. In
some embodiments, another sensor of spur conveyor subassembly
detects whether carrier is indeed at position 154a. If the read
information is associated with a sample on which assay instrument
108a is scheduled to perform an assay, controller 200a then sends a
notification to the communication interface of the controller of
assay instrument 108 that processing of the sample within the
processing receptacle 103 coupled to carrier 101 located at
processing position 154 can begin. As explained above, pipettor
158a of assay instrument 108a can aspirate at least a portion of a
sample from receptacle 103 coupled to carrier 101 at processing
position 154a, and pipettor 158a can subsequently dispense the
aspirated sample portion into a cavity defined by assay receptacle
160a. After assay instrument 108a completes the processing of
samples within processing receptacle 103 coupled to carrier 101 at
processing position 154a, the communication interface of the
controller of assay instrument 108 sends a notification to
controller 200a of intermediate conveyor assembly 133a that
processing is complete, and spur conveyor spur conveyor subassembly
116a then transports the carrier 101 away from processing position
154a and back to position 153 on spur conveyor subassembly 116a.
Diverter 150a can then transport the carrier 101 to output portion
162a of buffer conveyor subassembly 114a. In some embodiments, the
total time it takes to (1) transport carrier 101 from position 153a
to processing position 154a using spur conveyor subassembly 116a,
(2) process the sample contained with the sample receptacle 103
coupled to the carrier 101 at position 154a (i.e., aspirate at
least a portion of a sample from receptacle 103 using automated
pipettor 158a of assay instrument 108a), and (3) transport the
carrier 101 from processing position 154 to position 153 using spur
conveyor subassembly 116 takes less than or equal to about 1
minute.
[0311] If the information read by sensor 156 is not associated with
a sample on which assay instrument 108a is scheduled to perform an
assay, controller 200a notifies the communication interface of the
controller of assay instrument 108 that processing should not
begin, and spur conveyor subassembly 116a transports the carrier
101 back to position 153a. Diverter 150a then transports the
carrier to output portion 162a of buffer conveyor subassembly 114a.
The steps of transporting a carrier 101 from position 153a to
processing position 154a using spur conveyor subassembly 116,
processing the sample contained with the sample receptacle 103
coupled to the carrier 101 at position 154a, and transporting the
carrier 101 from processing position 154a to position 153a using
spur conveyor subassembly 116a is repeated as long as long as
minimum number of carriers 101 are on the input portion 146a of
buffer conveyor subassembly 114a, the output portion 162a of buffer
conveyor subassembly 114a is not full, and consumables, waste
space, and reagents are available within assay instrument 108a.
[0312] Output portion 162a of buffer conveyor subassembly 114a
transports the carrier 101 received from spur conveyor subassembly
116a to position 167a. When sensor 166a detects the presence of a
carrier 101 at position 167a, diverter 164a is actuated and
transports the carrier 101 back to host conveyor assembly 102.
[0313] Host conveyor assembly 102 continues to transport the
carriers 101 that were either bypassed by assay instrument 108a
toward the next assay instrument 108b or received from output
portion 162a of buffer conveyor subassembly 114a of intermediate
conveyor assembly 133a toward the next assay instrument 108b. As
carriers 101 approach assay instrument 108b and pass sensor 144b,
sensor 144b reads information from the carriers 101, receptacles
103, or both, and sensor 144b transmits a signal to the controller
of host conveyor assembly 102 that includes the read information.
The controller of host conveyor assembly 102 then determines
whether the read information, for example, an identifier, is
associated with samples on which assay instrument 108b is scheduled
to perform an assay based on information stored in the laboratory
information system 101. If this read information is associated with
samples on which assay instrument 108b is scheduled to perform an
assay, the controller of host conveyor assembly 102 then sends a
control signal to diverter 142b to divert the respective carriers
101 from host conveyor assembly 102 to input portion 146b of buffer
conveyor subassembly 114b of intermediate conveyor assembly 133b.
If the read information is not associated with samples on which
assay instrument 108b is scheduled to perform an assay, the
controller of host conveyor assembly 102 can adjust the control
signal transmitted to diverter 142b to divert the respective
carriers 101 to a downstream portion 145b of host conveyor assembly
102 that bypasses intermediate conveyor assembly 133b and assay
instrument 108b. Host conveyor then continues to transport the
bypassed carriers 101 toward the next assay instrument 108c.
[0314] The step of diverting carriers from host conveyor assembly
102 to input portion 146b of buffer conveyor subassembly 114b of
intermediate conveyor assembly 133b can continue for subsequent
carriers 101 passing sensor 144b until input portion 146b of buffer
conveyor subassembly 114b is full. At that point, the controller of
host conveyor assembly 102 will continue to divert carriers 101 to
portion 145b of host conveyor assembly 102 regardless of whether
the sample contained within receptacle 103 coupled to the carrier
101 is scheduled for an assay to be performed by assay instrument
108b until space is available on input portion 146b of buffer
conveyor subassembly 114b to accept additional carriers 101. In
some embodiments, loading input portion 146b of buffer conveyor
subassembly 114b continues until at least a predetermined minimum
number of carriers, for example, five carriers 101, have been
queued on input portion 146b. Once a minimum number of carriers 101
have been queued, controller 200b can notify the controller of
assay instrument 108 that the predetermined minimum number of
carriers 101 (and thus samples in processing receptacles 103)
available for processing by assay instrument 108. Once diverted to
input portion 146b of buffer conveyor subassembly 114b, the
controller of host conveyor assembly 102 provides a notification to
controller 200b of intermediate conveyor assembly 133b that a
carrier 101 was diverted to input portion 146b and, in some
embodiments, transmits information about the diverted carrier 101,
for example, an identifier of the carrier 101, receptacle 103, or
both, to controller 200b. Buffer conveyor subassembly 114b
transports the carrier 101 toward position 147b on and queues the
carrier. In some embodiments, as a carrier 101 on buffer conveyor
subassembly 114b passes sensor 148b, sensor 148b reads information
from a respective carrier 101, receptacle 103, or both, and
transmits a signal to controller 200b of intermediate conveyor
assembly 133b that includes the read information. Controller 200b
can then determine whether the read information, for example, an
identifier, is associated with the information transmitted from the
controller of host conveyor assembly 102 to intermediate conveyor
assembly 133 about the diverted carrier 101. If the read
information matched the transmitted information, controller 200b of
intermediate conveyor assembly 133b sends a control signal to
diverter 150b to divert the respective carrier 101 from input
portion 146b of buffer conveyor subassembly 114b to spur conveyor
subassembly 116b. If the read information does not match the
transmitted information, controller 200b of intermediate conveyor
assembly 133b adjusts the control signal to diverter 150b to divert
the carrier 101 from input portion 146b of buffer conveyor
subassembly 114b directly to output portion 162b of buffer conveyor
subassembly 114b, bypassing spur conveyor subassembly 116b.
[0315] If a carrier 101 is diverted to spur conveyor subassembly
116b of intermediate conveyor assembly 133b, spur conveyor
subassembly 116b transports the carrier 101 to processing position
154b within assay instrument 108b. For example, gripper 188 clamps
the carrier 101 at position 153b and moves towards position 154b
until the carrier 101 is at position 154b. Sensor 156b can then
read information from the carrier 101, receptacle 103, or both,
when carrier 101 is at processing position 154b and transmits a
signal to controller 200b of intermediate conveyor assembly 133b
that includes the read information. Controller 200b can then
determine whether the information read by sensor 144b, for example,
an identifier, is associated with a sample on which assay
instrument 108b is scheduled to perform an assay. This
determination can be based on information stored in the laboratory
information system 223. In some embodiments, another sensor of spur
conveyor subassembly 116b detects whether carrier is indeed at
position 154b. If the read information is associated with a sample
on which assay instrument 108b is scheduled to perform an assay,
controller 200b then sends a notification to the communication
interface of the controller of assay instrument 108b that
processing of the sample within the receptacle 103 coupled to
carrier 101 located at processing position 154b can begin. After
assay instrument 108b completes the processing of the sample within
processing receptacle 103 coupled to carrier 101 at processing
position 154b, the communication interface of the controller of
assay instrument 108 sends a notification to controller 200b of
intermediate conveyor assembly 133b that processing is complete,
and spur conveyor subassembly 116b transports the carrier 101 back
to position 153b. Diverter 150b then transports the carrier 101 to
output portion 162b of buffer conveyor subassembly 114b.
[0316] If the information read by sensor 156b is not associated
with a sample on which assay instrument 108b is scheduled to
perform an assay, controller 200b notifies the communication
interface of the controller of assay instrument 108b that
processing should not begin, and spur conveyor subassembly 116b
transports the carrier 101 back to position 153b, and diverter 150b
transfers the carrier 101 to output portion 162b of buffer conveyor
subassembly 114b. The step of transporting a carrier 101 from
position 153b to processing position 154b using spur conveyor
subassembly 116b, processing the sample contained within the sample
receptacle 103 coupled to the carriers 101 at position 154b, and
transporting the carrier 101 from processing position 154b to
position 153b using spur conveyor subassembly 116b is repeated as
long as (1) a predetermined minimum number of carriers 101 are on
the input portion 146b of buffer conveyor subassembly 114b, (2) the
output portion 162b of buffer conveyor subassembly 114b is not
full, and (3) consumables, waste space, and reagents are available
within assay instrument 108b.
[0317] Output portion 162b of buffer conveyor subassembly 114b
transports the carriers 101 received from spur conveyor subassembly
116b to position 167b. When sensor 166b detects the presence of a
carrier 101 at position 167b, diverter 164b is actuated and
transports the carrier 101 back to host conveyor assembly 102.
[0318] Host conveyor assembly 102 transports the carriers 101
either bypassed by assay instrument 108b or received from output
portion 162b of buffer conveyor subassembly 114b toward the next
assay instrument 108c. As carriers 101 approach diverter 122,
sensor 126 detects the presence of a carrier 101 within a recess
defined by diverter 122, and the controller of host conveyor
assembly 102 in communication with sensor 126 actuates diverter 122
to transfer the carrier 101 to second portion 120 of host conveyor
assembly 102. Second portion 120 of host conveyor assembly
continues to transport carriers 101 toward assay instrument 108c
and such that carriers 101 pass sensor 144c. Sensor 144c reads
information (e.g., an identifier) from the carriers 101,
receptacles 103, or both, and transmits a signal to the controller
of host conveyor assembly 102 that includes the read information.
The controller of host conveyor assembly 102 then determines
whether the read information, for example, an identifier, is
associated with samples on which assay instrument 108c is scheduled
to perform an assay. This determination can be based on information
stored in the laboratory information system 223. If this read
information is associated with a sample on which assay instrument
108c is scheduled to perform an assay, the controller of host
conveyor assembly 102 then sends a control signal to diverter 142c
to divert the respective carrier 101 from host conveyor assembly
102 to input portion 146c of buffer conveyor subassembly 114c of
intermediate conveyor assembly 133c. If the read information is not
associated with a sample on which assay instrument 108c is
scheduled to perform an assay, the controller of host conveyor
assembly 102 adjusts the control signal transmitted to diverter
142c, which diverts the respective carrier 101 to a portion 145c of
host conveyor assembly 102 that bypasses intermediate conveyor
assembly 133c and assay instrument 108c. Host conveyor then
continues to transport the bypassed carriers 101 toward diverter
124 and the next assay instrument 108a.
[0319] Host conveyor assembly 102 can continue to divert carriers
101 from host conveyor assembly 102 to input portion 146c of buffer
conveyor subassembly 114c of intermediate conveyor assembly 133c
until input portion 146c of buffer conveyor subassembly 114c is
full. At that point, the controller of host conveyor assembly 102
will continue to divert carriers 101 to downstream portion 145c of
host conveyor assembly 102 regardless of whether the sample
contained within receptacle 103 coupled to the carrier 101 is
scheduled for an assay to be performed by assay instrument 108c,
until space is available on input portion 146c of buffer conveyor
subassembly 114c to accept additional carriers 101.
[0320] Once a carrier 101 is diverted from host conveyor assembly
102 to input portion 146a of buffer conveyor subassembly 114a, the
controller of host conveyor assembly 102 provides a notification to
controller 200a of intermediate conveyor assembly 133a that a
carrier 101 was diverted. And in some embodiments, the controller
of host conveyor assembly 102 transmits information about the
diverted carrier 101, for example, an identifier of the carrier
101, receptacle 103, or both, to controller 200a.
[0321] Once a predetermined minimum number of carriers 101 have
been queued on input portion 146c, controller 200c can notify the
controller of assay instrument 108c that the predetermined minimum
number of carriers 101 and, thus, samples in processing receptacles
103 are available for processing by assay instrument 108c. In some
embodiments, the predetermined minimum number of carriers 101 is at
least five carriers 101. In other embodiments, the predetermined
minimum number of carriers 101 is less than five. In some
embodiments, the predetermined minimum number of carriers 101
equals the number of cavities defined by a signal assay receptacle
160c. For example, if a single assay receptacle 160c defines five
cavities for receiving five samples, the predetermined minimum
number of carriers equals five.
[0322] Input portion 146c transports diverted carriers 101 towards
position 147c on buffer conveyor subassembly 114c and queues a
plurality of carriers 101 until assay instrument 108c is ready to
start processing samples contained in receptacles 103 coupled to
carriers 101. In some embodiments, as a carrier 101 on buffer
conveyor subassembly 114c passes sensor 148c, sensor 148c reads
information from the passing carrier 101, receptacle 103, or both,
and transmits a signal to controller 200c of intermediate conveyor
assembly 133c that includes the read information. Controller 200c
of intermediate conveyor assembly 133c can then determine whether
the read information, for example, an identifier, is associated
with or matches the information transmitted from the controller of
host conveyor assembly 102 to intermediate conveyor assembly 133c
about the respective diverted carrier 101. If the read information
matches or is associated with the transmitted information,
controller 200c of intermediate conveyor assembly 133c sends a
control signal to diverter 150c, which diverts the respective
carrier 101 from input portion 146c of buffer conveyor subassembly
114c to spur conveyor subassembly 116c. If the read information
does not match or is not associated with the transmitted
information, controller 200c of intermediate conveyor assembly 133c
adjusts the control signal to diverter 150c, which divert the
carrier 101 from input portion 146c of buffer conveyor subassembly
114c directly to output portion 162c of buffer conveyor subassembly
114c, bypassing spur conveyor subassembly 116c.
[0323] After being transferred to spur conveyor subassembly 116c of
intermediate conveyor assembly 133b, spur conveyor subassembly 116c
transports the carrier 101 to processing position 154c within assay
instrument 108c. For example, gripper 188 clamps the carrier 101 at
position 153c, and moves towards processing position 154c until the
carrier 101 is at position 154c. Sensor 156c can then read
information from the carrier 101, receptacle 103 coupled thereto,
or both, when carrier 101 is at processing position 154c. Sensor
156c can also transmit a signal to controller 200c of intermediate
conveyor assembly 133 that includes the read information.
Controller 200c of intermediate conveyor assembly 133c can then
determine whether the read information, for example, an identifier,
is associated with a sample on which assay instrument 108c is
scheduled to perform an assay. This determination can be based on
information stored in the laboratory information system 223. In
some embodiments, another sensor of spur conveyor subassembly
detects whether carrier 101 is indeed at position 154c. If the read
information is associated with a sample on which assay instrument
108c is scheduled to perform an assay, controller 200c then sends a
notification to the communication interface of the controller of
assay instrument 108 that processing of the sample within the
processing receptacle 103 coupled to carrier 101 located at
processing position 154 can begin. As explained above, pipettor
158c of assay instrument 108c can aspirate at least a portion of a
sample from receptacle 103 coupled to carrier 101 at processing
position 154c, and pipettor 158c can subsequently dispense the
portion of the aspirated sample into a cavity defined by assay
receptacle 160c. After assay instrument 108c completes the
processing of samples within processing receptacle 103 coupled to
carrier 101 at processing position 154c, the communication
interface of the controller of assay instrument 108 sends a
notification to controller 200c of intermediate conveyor assembly
133c that processing is complete, and spur conveyor spur conveyor
subassembly 116c then transports the carrier 101 away from
processing position 154c and back to position 153 on spur conveyor
subassembly 116c. Diverter 150c can then transport the carrier 101
to output portion 162c of buffer conveyor subassembly 114c. In some
embodiments, the total time it takes to (1) transport carrier 101
from position 153c to processing position 154c using spur conveyor
subassembly 116c, (2) process the sample contained with the sample
receptacle 103 coupled to the carrier 101 at position 154c (i.e.,
aspirate at least a portion of a sample from receptacle 103 using
automated pipettor 158c of assay instrument 108a), and (3)
transport the carrier 101 from processing position 154 to position
153 using spur conveyor subassembly 116 takes less than or equal to
about 1 minute.
[0324] If the information read by sensor 156 is not associated with
a sample on which assay instrument 108c is scheduled to perform an
assay, controller 200c notifies the communication interface of the
controller of assay instrument 108 that processing should not
begin, and spur conveyor subassembly 116c transports the carrier
101 back to position 153c. Diverter 150c then transports the
carrier to output portion 162c of buffer conveyor subassembly 114c.
The steps of transporting a carrier 101 from position 153c to
processing position 154c using spur conveyor subassembly 116,
processing the sample contained with the sample receptacle 103
coupled to the carrier 101 at position 154c, and transporting the
carrier 101 from processing position 154c to position 153c using
spur conveyor subassembly 116c is repeated as long as long as
minimum number of carriers 101 are on the input portion 146c of
buffer conveyor subassembly 114c, the output portion 162c of buffer
conveyor subassembly 114c is not full, and consumables, waste
space, and reagents are available within assay instrument 108c.
[0325] Output portion 162c of buffer conveyor subassembly 114c
transports the carrier 101 received from spur conveyor subassembly
116c to position 167c. When sensor 166c detects the presence of a
carrier 101 at position 167c, diverter 164c is actuated and
transports the carrier 101 back to host conveyor assembly 102.
[0326] Host conveyor assembly 102 continues to transport the
carriers 101 either bypassed by assay instrument 108c or received
from output portion 162c of buffer conveyor subassembly 114a toward
the next assay instrument 108a. As carriers 101 approach diverter
124, sensor 128 detects the presence of a carrier 101 within a
recess defined by diverter 124, and the controller of host conveyor
assembly 102 in communication with sensor 128 actuates diverter
124, which transfers the carrier to first portion 118 of host
conveyor assembly 102. First portion 118 of host conveyor assembly
102 continues to transport carriers 101 toward assay instrument
108a.
[0327] FIG. 16 illustrates an exemplary embodiment of processing
carriers 101 and sample receptacles 103 using host conveyor
assembly 102 and any one pairing of intermediate conveyor
assemblies 133a, 133b, and 133c, and assay instruments 108a, 108b,
and 108c. At step 302, intermediate conveyor assembly 133 awaits a
carrier 101 and processing receptacle 103 coupled to the carrier
101 from host conveyor assembly 102. For example, intermediate
conveyor assembly 133 waits for diverter 142 to transport a carrier
101 from host conveyor assembly 102 to input portion 146 of buffer
conveyor subassembly 114.
[0328] At step 304, information read from carrier 101, receptacle
103, or both, on host conveyor assembly 102 is compared with
information stored in laboratory information system 223 to
determine whether a sample contained within the processing
receptacle 103 is scheduled for an assay to be performed by the
respective assay instrument 108. If it is verified that an assay is
to be performed by the respective assay instrument 108 on the
sample contained within processing receptacle 103, diverter 142
transports the respective carrier 101 and receptacle 103 to input
portion 146 of buffer subassembly 114. At step 306, system 100
determines whether there is a predetermined minimum number of
carriers 101 and receptacles 103 on input portion 146 of buffer
conveyor subassembly 114 to begin processing with assay instrument
108. If a predetermined minimum number of carriers 101 and
receptacles 103 are not present on input portion 146 of buffer
conveyor subassembly 114, steps 302 and steps 304 are repeated.
Once a predetermined minimum number of carriers 101 and receptacles
103 are present on input portion 146 of buffer conveyor subassembly
114, system 100 continues to step 308.
[0329] At step 308, information about the samples contained in
receptacles 103 coupled to carriers on input portion 146 of buffer
conveyor subassembly 114 is transmitted to assay instrument 108.
This information can be information read from carriers 101 or
receptacles 103 from any of the sensors within system 100, or the
information can include specific identification of what assays to
perform on which samples in receptacles 103 on input portion 146 of
buffer conveyor assembly 114.
[0330] Next, at step 310, carriers 101 are transported one at a
time to processing position 154 of assay instrument 108. For
example, input portion 146 transports a carrier to position 147,
diverter 150 transports carrier 101 to position 153, and gripper
188 of spur conveyor subassembly 116 transports carrier 101 to
processing position 154.
[0331] At step 312, intermediate conveyor assembly verifies that
the sample contained in receptacle 103 coupled to the carrier 101
at processing position 154 of assay instrument 108 is scheduled for
an assay to be performed by the respective assay instrument 108.
For example, information read by sensor 156a from carrier 101,
receptacle 103, or both, when carrier 101 is at processing position
154 of assay instrument 108 is compared with information stored in
laboratory information system 223 or with information received from
host conveyor assembly 102 about the respective carrier 101 and
receptacle 103. If the sample in receptacle 103 coupled to the
carrier 101 at processing position 154 of assay instrument 108 is
scheduled for an assay to be performed by the respective assay
instrument 108, system 100 continues to step 314.
[0332] At step 314, assay instrument 108 processes the sample
contained within receptacle 103 coupled to carrier 101 at
processing position 154. For example, assay instrument 108 can
aspirate a portion of the sample contained within receptacle 103
using automated pipettor 158 of assay instrument 108, and can
dispense the aspirated portion of the sample into a cavity defined
by an assay receptacle 160. In some embodiments, assay instrument
108 aspirates a plurality of portions of the sample contained
within receptacle 103 using automated pipettor 158 of assay
instrument 108, and dispenses the plurality of aspirated portions
of the sample into either a plurality of cavities defined by a
single assay receptacle 160 (for example, an MTU) or a plurality of
cavities defined by a plurality of assay receptacles 160. Assay
instrument 108 can then perform one or more assays on the sample
portions dispensed into assay receptacle(s) 160.
[0333] At step 316, after interaction between assay instrument 108
and receptacle 103 coupled to the carrier 101 at processing
position 154 of assay instrument 108, carrier 101 and the
respective receptacle 103 are transported back to host conveyor
assembly 102. For example, gripper 188 of spur conveyor subassembly
116 transports the carrier 101 from processing position 154 to
position 153, diverter 150 transports the carrier 101 from position
153 to position 163 on output portion 162 of buffer conveyor
subassembly 114, and output portion 162 transports the carrier 101
to a position adjacent diverter 164 at which diverter 164
transports the carrier 101 back to host conveyor assembly 102.
[0334] At step 318, system 100 determines whether there are
additional carriers 101 and respective receptacles 103 for
processing on input portion 146 of buffer conveyor subassembly 114.
If so, steps 310-316 are repeated. If not, intermediate conveyor
assembly 133 returns to step 306 and waits for a predetermined
number of receptacles to be queued on input portion 146 of buffer
conveyor subassembly 116.
3. Hardware and Software
[0335] Aspects of this disclosure are implemented via control and
computing hardware components, user-created software, data input
components, and data output components. Hardware components include
computing and control modules (e.g., system controller(s)), such as
microprocessors and computers, configured to effect computational
and/or control steps by receiving one or more input values,
executing one or more algorithms stored on non-transitory
machine-readable media (e.g., software) that provide instruction
for manipulating or otherwise acting on the input values, and
output one or more output values. Such outputs may be displayed or
otherwise indicated to an operator for providing information to the
operator, for example information as to the status of the
instrument or a process being performed thereby, or such outputs
may comprise inputs to other processes and/or control algorithms.
Data input components comprise elements by which data is input for
use by the control and computing hardware components. Such data
inputs may comprise position sensors, motor encoders, as well as
manual input elements, such as graphic user interfaces, keyboards,
touch screens, microphones, switches, manually-operated scanners,
voice-activated input, etc. Data output components may comprise
hard drives or other storage media, graphic user interfaces,
monitors, printers, indicator lights, or audible signal elements
(e.g., buzzer, horn, bell, etc.).
[0336] Software comprises instructions stored on non-transitory
computer-readable media which, when executed by the control and
computing hardware, cause the control and computing hardware to
perform one or more automated or semi-automated processes.
[0337] While the present disclosure has been described and shown in
considerable detail with reference to certain illustrative
embodiments, including various combinations and sub-combinations of
features, those skilled in the art will readily appreciate other
embodiments and variations and modifications thereof as encompassed
within the scope of the present disclosure. Moreover, the
descriptions of such embodiments, combinations, and
sub-combinations is not intended to convey that the disclosure
requires features or combinations of features other than those
expressly recited in the claims. Accordingly, the present
disclosure is deemed to include all modifications and variations
encompassed within the spirit and scope of the following appended
claims.
[0338] It is to be appreciated that the Detailed Description
section, and not the Summary and Abstract sections, is intended to
be used to interpret the claims. The Summary and Abstract sections
may set forth one or more but not all exemplary embodiments of the
present invention as contemplated by the inventor(s), and thus, are
not intended to limit the present invention and the appended claims
in any way.
[0339] Embodiments have been described above with the aid of
functional building blocks illustrating the implementation of
specified functions and relationships thereof. The boundaries of
these functional building blocks have been arbitrarily defined
herein for the convenience of the description. Alternate boundaries
can be defined so long as the specified functions and relationships
thereof are appropriately performed.
[0340] The foregoing description of the specific embodiments will
so fully reveal the general nature of the invention that others
can, by applying knowledge within the skill of the art, readily
modify and/or adapt for various applications such specific
embodiments, without undue experimentation, and without departing
from the general concept of the present invention. Therefore, such
adaptations and modifications are intended to be within the meaning
and range of equivalents of the disclosed embodiments, based on the
teaching and guidance presented herein. It is to be understood that
the phraseology or terminology herein is for the purpose of
description and not of limitation, such that the terminology or
phraseology of the present specification is to be interpreted by
the skilled artisan in light of the teachings and guidance.
[0341] The breadth and scope of the present invention should not be
limited by any of the above-described exemplary embodiments, but
should be defined only in accordance with the following claims and
their equivalents.
[0342] While the invention has been described in connection with
the above described embodiments, it is to be understood that the
invention is not to be limited to the disclosed embodiments, but,
on the contrary, is intended to cover various modifications and
equivalent arrangements included within the spirit and scope of the
appended claims.
[0343] All documents referred to herein are hereby incorporated by
reference herein. No document, however, is admitted to be prior art
to the claimed subject matter.
[0344] Furthermore, those of the appended claims which do not
include language in the "means for performing a specified function"
format permitted under 35 U.S.C. .sctn.112, 6, are not intended to
be interpreted under 35 U.S.C. .sctn.112, 6, as being limited to
the structure, material, or acts described in the present
specification and their equivalents.
* * * * *