HK40000003B - Methods, systems, and apparatus for dynamic pick and place selection sequence based on sample rack imaging data - Google Patents

Description

Methods, systems, and apparatus for dynamic pick and place selection sequences based on sample holder imaging data

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Serial No. 62/362,535, filed on July 14, 2016, the contents of which are incorporated herein by reference in their entirety.

Technical Field

The present disclosure generally relates to methods and apparatus suitable for picking up and placing specimen containers from and into a sample rack in a system for processing biological fluids.

Background Art

In medical testing and processing, the use of robotics can minimize exposure to or contact with biological fluid samples (otherwise referred to herein as "samples") and/or can significantly improve productivity. For example, in some automated testing and processing systems (e.g., clinical analyzers), sample containers (such as test tubes) can be transported from and to sample racks (sometimes referred to as "cassettes"), as well as from and to testing or processing locations on a testing or processing device.

This transport can be accomplished using an automated mechanism, such as a robot with a coupled gripper. The gripper can have opposing gripper fingers configured to grasp a corresponding sample container during transport. The samples can be of different sizes (e.g., height and/or diameter) or types. The gripper can be moved by the robot in two or more coordinate directions. In this manner, a sample container (containing a sample to be tested or processed) can be gripped by the gripper and then moved from one location to another.

For example, in a pick operation, the robot gripper can be moved above the theoretical center position of the sample rack's receiver and lowered to a specified height with the gripper fully open, and then closed to grip the sample container. The gripper is then raised to pull the sample container out of the receiver. In a place operation, the gripper and the sample container it has grasped can be moved together over the center of the sample rack's receiver and lowered toward the receiver to place the sample container to the desired depth, and then the gripper fingers are fully opened to release the sample container. The gripper is then raised. Thus, using these pick and place operations, sample containers can be moved into and out of multiple receivers in a sample rack. However, in order to maximize the use of the machine's footprint, the receivers in such sample racks are very closely spaced.

Therefore, methods and apparatus are sought that can improve the efficiency of pick and place operations in testing and handling systems.

Summary of the Invention

In one embodiment, an improved method for operating a gripper is provided. The method includes providing a robot including a gripper movable by the robot in a coordinate system and including gripper fingers; providing a sample rack including receptacles accessible by the gripper, at least some of the receptacles being adapted to receive sample containers; providing data acquired by imaging about the sample rack and the sample containers; and determining, based on the data, accessible target receptacles for one of a pick operation and a place operation.

In a system embodiment, a gripper positioning system is provided. The gripper positioning system includes: a robot including a gripper movable by the robot in a coordinate system and including gripper fingers; a sample rack including receptacles accessible by the gripper fingers, at least some of the receptacles containing sample containers; and a controller coupled to the robot and operatively configured to: access data obtained from one or more images regarding the sample rack and the sample containers, the data including population data and configuration data, and determine accessible target receptacles for one of a pick operation or a place operation based on the population data and the configuration data.

In an apparatus embodiment, a gripper positioning apparatus is provided. The gripper positioning apparatus includes a robot including a gripper movable by the robot in a coordinate system and including gripper fingers; and a controller coupled to the robot and operatively configured to access data regarding a sample rack and a sample container obtained from one or more images and, based on the data, determine an accessible target receptacle for one of a pick operation and a place operation.

From the following detailed description showing a plurality of example embodiments including the best mode for implementing the present disclosure, other aspects, features and advantages of the present disclosure can be easily apparent. The present disclosure can also have different embodiments, and its various details can be modified in various aspects, all of which do not depart from the scope of the present disclosure. Therefore, the present disclosure will cover all modifications, equivalents and substitutes that fall within the scope of the present disclosure as defined in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 shows a schematic top view of a sample rack including sample containers according to the prior art.

2 illustrates a schematic side view of a gripper positioning system configured to perform a dynamic gripper finger positioning method according to one or more embodiments.

3A illustrates a partial top plan view of a sample rack including a target sample container surrounded by some empty receptacles and some full receptacles, shown in a configuration with gripper fingers opened (separated) an intermediate distance, according to one or more embodiments.

3B illustrates a partial top plan view of a sample holder including a sample container in a receptacle, shown in a configuration with gripper fingers opened (separated) an intermediate distance, according to one or more embodiments.

4A-4E illustrate schematic diagrams illustrating various sample container population scenarios according to one or more embodiments.

5 illustrates a schematic top view of a sample container transport system configured to perform a dynamic gripper finger positioning method according to one or more embodiments.

FIG6 shows a flow chart of a method of operating a gripper according to an embodiment.

DETAILED DESCRIPTION

Jams, collisions, and/or vibrations of sample containers may occur from time to time in robots, such as those used to perform robotic pick and place operations in clinical analyzers or other testing or processing systems (e.g., centrifuges, refrigerated areas).

In particular, as shown in FIG1 , sample containers 102, 102L (e.g., blood collection tubes) used in automated in vitro diagnostic (IVD) equipment are typically provided in an open-top (uncapped) state and filled with biological fluid samples 105 (some are labeled), i.e., bio-hazardous liquids (e.g., blood, serum or plasma, urine, interstitial fluid, brain fluid, spinal fluid, or other body fluids). The sample containers 102, 102L are stored in a generally vertical orientation within receivers 106R (some are labeled) within a sample rack 106 (with the first two and a half rows filled with sample containers 102, 102L).

To maximize the use of the device's footprint, the receptacles 106R of the sample rack 106 are spaced very closely together. To accommodate sample containers 102 of various diameters, a spring 108 (some are labeled), such as one or more leaf-type springs, may sometimes be placed in each receptacle 106R to attempt to either center the sample container 102 or force the sample container 102 against the defined walls of the receptacle 106R (as shown), all while generally maintaining the sample container 102 in a vertical orientation.

However, due to mechanical tolerances and the placement of the sample containers 102, each sample container 102 may be tilted somewhat away from a true vertical orientation in one or more directions (e.g., X and/or Y as shown), thereby reducing the desired tube-to-tube clearance. Furthermore, because sample containers 102 of varying diameters are often processed simultaneously on a given device (e.g., row 3 shown contains some sample containers 102L having relatively larger diameters than the sample containers 102 contained in rows 1 and 2), the spacing between adjacent sample containers 102, 102L in the sample rack 106 may vary from receiver 106R to receiver 106R based on tube size and tilt orientation. Furthermore, the offset caused by the presence of the spring 108 may place the center of the sample container 102, 102L at a location other than the center of the receiver 106R. Similarly, some receivers 106R may be empty.

The close spacing of the receivers 106R, combined with the high throughput expectations of IVD devices, may result in occasional undesirable contact (e.g., jamming, collisions, and/or vibrations) between the sample containers 102, 102L and the robotic grippers and/or gripper fingers during processing. Such contact may slow down automated processing because damage caused by contact may necessitate manual operator intervention to correct. For example, in extreme cases, such contact may result in tube breakage, spillage, and/or sample loss, all of which may require downtime for repair/cleanup.

In the prior art, a simple row-by-row sequential picking and/or placement based on a simple picking algorithm is used to predetermine the order in which the sample containers 102 are picked and/or placed in the sample rack 106. This predetermined selection order does not account for possible differences in placement (e.g., offset), size (e.g., diameter or height), or even type of sample containers 102, 102L residing within the receptacles 106R of the sample rack 106. If not accounted for, these differences may result in contact or may result in obstruction of the gripper fingers, and may make it more difficult for the gripper fingers to access the sample containers 102, 102L in the predetermined order without causing possible damage to the sample (e.g., spillage) or requiring operator intervention.

In view of the foregoing, one or more embodiments of the present disclosure provide methods, systems, and apparatus for dynamically (in real time) determining the order in which accessible sample containers are picked or placed in target accessible receptacles (i.e., dynamically selecting a pick and/or placement order) based on data obtained by imaging a sample rack. The data obtained by imaging may include sample rack population data and/or sample container configuration data. Population data is data regarding the presence or absence of adjacent sample containers in the receptacles of the sample rack (and more specifically, adjacent sample containers surrounding a particular target receptacle). Configuration data is data regarding the orientation and/or dimensions of sample containers surrounding the target receptacle, as well as the orientation and/or dimensions of the target sample container itself. After the sample rack 106 has been imaged via a sample rack imaging system, such sample rack imaging systems are known in the art, the population data and/or configuration data are made available for each receptacle 106R in the sample rack 106.

According to one or more embodiments, visual data (e.g., configuration data and/or population data) can be used to dynamically adjust the order or sequence of picking and/or placing. In one embodiment, the order in which the sample containers 102, 102L are picked up by the gripper fingers can be adjusted based on the configuration and/or population data obtained through imaging. In another embodiment, the order in which the sample containers 102, 102L are placed by the gripper fingers can be adjusted based on the configuration and/or population data obtained through imaging.

Methods, apparatuses, and systems according to one or more embodiments may consider population data of sample containers 102 in a sample rack 106 and/or configuration data of sample containers 102 in a sample rack 106 to dynamically determine a desired pick and/or place order.

For example, the methods, apparatus, and systems may consider population data, such as whether surrounding receptacles 106R contain sample containers 102 or are empty. Similarly, one or more embodiments may consider configuration data regarding the dimensions (e.g., diameter and/or height) of one or more of the surrounding sample containers, the offset of adjacent sample containers toward or away from a particular target sample container, the tube type (e.g., capped tube, uncapped tube, tube top sample cup, etc.) of the target sample container, and any offset of the target sample container (in the case of a pick operation).

The ability to dynamically select the order in which the grippers pick up and/or place the sample containers 102 can significantly reduce the tendency toward contact (e.g., jamming, bumping, and/or vibration) and, therefore, reduce damage to the sample containers 102, 102L and/or reduce spillage and loss of the biological fluid sample 105. This can reduce IVD instrument downtime and the need for operator intervention.

Features of these and other aspects and embodiments of the disclosure will be described herein with reference to FIGURES 2-6.

According to one or more system embodiments, with reference to FIG2 , a gripper positioning system 200 is shown and described. The gripper positioning system 200 includes a robot 210 for grasping and transferring a target sample container 102T (e.g., a blood collection container, bottle, etc.) from a first location to a second location. The gripper positioning system 200 can be used in any testing instrument or device, such as an automated clinical analyzer, an assay instrument, or other processing equipment such as a centrifuge, in which sample containers 102, 102L containing biological fluid samples 105 are moved to or from a sample rack 106.

For example, the robot 210 can move a target sample container 102T from the sample rack 106 to a sample container carrier 532 (e.g., a puck - FIG. 5 ) that can move on a track 540. The track 540 moves the sample container 102 to an instrument or device for testing or processing. In one or more embodiments, the testing instrument or device can be used to determine the composition (e.g., analyte concentration) of the biological fluid sample 105 contained in the sample container 102 or otherwise perform processing thereon. The track 540 can include one or more branches 540A to provide an opportunity for the sample container carrier 532 to branch off from the main channel 540B.

Referring again to FIG2 , the robot 210 includes a gripper 212 coupled to a movable portion of the robot 210, such as a movable arm or portion of a gantry. For example, the robot 210 may be an R, θ, Z robot as shown in FIG2 . Alternatively, the robot may be a gantry robot 510 as shown and described herein with respect to FIG5 . In each case, the robot 210 , 510 moves the gripper 212 in a coordinate system (e.g., in X, Y, and Z). The robot 210 shown in FIG2 may include a base 210B that can be coupled to a frame 214 of a test instrument or device; an upright portion 210U configured to move vertically (in the +Z and -Z directions) along a vertical axis 211Z; a telescoping portion 210T configured to move radially (in the +R and -R directions); and a rotating portion 210R configured to move rotationally (in the +θ and -θ directions) about the vertical axis 211Z. As used herein, a "gripper" means any component coupled to a robot component (e.g., to a robot arm or a frame component) that is used in robotic operations to grasp and move an item (e.g., a sample container 102) from one location to another to perform a pick and/or place operation. For example, the robot 210 , 510 may be used to place a target sample container 102T into a target receiver 106T in the sample rack 106 , or to pick up a target sample container 102T from a target receiver 106R in the sample rack 106 .

The gripper 212 may include two gripper fingers 212A, 212B that are movable relative to each other, may be generally opposed to each other, and are adapted to grip an item, such as a sample container 102 (e.g., a blood collection tube or bottle). The gripper fingers 212A, 212B may be driven to open and close by an actuation mechanism 212L coupled to each of the gripper fingers 212A, 212B. The actuation mechanism 212L may be any suitable mechanism that moves the gripper fingers 212A, 212B in opposite directions. The actuation mechanism 212L may act linearly to move each gripper finger 212A, 212B in a linear translation, or otherwise cause the gripper fingers 212A, 212B to pivot. The relative movement of the gripper fingers 212A, 212B may be the same (but in opposite directions) or different. The gripper fingers 212A, 212B may open and close in any suitable direction in the X-Y plane (e.g., in the X direction or the Y direction or a combination thereof).

In some embodiments, a rotary actuator 212R can be provided that is constructed and operable to rotate the gripper fingers 212A, 212B to any specified rotational position/orientation. Thus, the lines of action for opening and closing the gripper fingers 212A, 212B can be rotated to coincide with areas on the sample holder 106 that meet the threshold minimum gap. Areas in the sample holder 106 that are determined to meet the threshold minimum gap can be determined by imaging. In particular, a receiver 106R that meets the threshold minimum gap can be selected as a target receiver 106T for performing a pick and/or place operation there. Selection can be based on population data and/or configuration data obtained by imaging. The +X, -X, +Y, and -Y directions as mentioned herein can be as shown. As shown, the Y direction moves paper in and out.

In more detail, the actuator 212L can be driven by an electric, pneumatic, or hydraulic servo motor, etc., coupled to the gripper fingers 212A, 212B. The gripper fingers 212A, 212B can move along any sliding mechanism so that they can be constrained to linear motion. Other suitable mechanisms for causing the gripper fingers 212A, 212B to grip can be used. Similarly, in some embodiments that provide rotational capability, the rotary actuator 212R can be configured and operable to rotate the gripper fingers 212A, 212B. The rotary actuator 212R can be an electric, pneumatic, or hydraulic servo motor, etc.

The actuator 212L and the rotary actuator 212R can be driven in response to a drive signal from the robot controller 216. One or more linear position encoders 212LE and/or rotary encoders 212RE can be included to provide position feedback about the degree of opening of the gripper fingers 212A, 212B and/or the rotational orientation of the gripper fingers 212A, 212B. In addition, although two gripper fingers 212A, 212B are shown, embodiments of the present disclosure are equally applicable to grippers 212 having more than two gripper fingers 212A or 212B. Other gripper 212 types can also be used. The robot 210, 510 can be any suitable robot type capable of moving the gripper 212 in space (e.g., three-dimensional space) to transport the sample container 102.

Referring again to FIG. 2 , in one or more embodiments, the robot 210 may include a rotary motor 218R adapted to rotate the rotating portion 210R in a rotational direction (e.g., +/-θ) to a desired angular orientation. The robot 210 may also include a vertical motor 218Z coupled to the upright portion 210U and adapted to move the gripper 212 in a vertical direction (e.g., along a vertical axis 211Z, shown in phantom). In one or more embodiments, the robot 210 may include a translation motor 218T adapted to impart translational motion to the gripper 212 coupled to the rotating portion 210R (e.g., in a +/-R direction). However, while an R, θ, Z robot is shown, other suitable robot types, robot motors, and mechanisms for imparting X, Y, R, θ, and/or Z motion, or other combinations thereof, may be provided. Suitable position feedback mechanisms, such as from linear and/or rotary encoders, may be provided for each degree of motion (X, Y, R, θ, and/or Z).

In one or more embodiments, the robot 210 can be used to achieve three-dimensional motion of the gripper 212 in a coordinate system (e.g., X, Y, and Z) so that the sample container 102, 102L can be placed in or removed from the target receiver 106T of the sample rack 106, or placed in or removed from other locations in a test instrument or processing equipment. Optionally, the robot 210 can achieve rotation of the gripper 212 about the gripper rotation axis 220 so that the gripper fingers 212A, 212B can be precisely rotationally oriented relative to the target receiver 106T of the sample rack 106.

The robotic controller 216 may include suitable microprocessors, memory, power supplies, regulating electronics, circuits, and drivers suitable for executing and controlling robotic motion and for controlling the position of the gripper 212 in an X, Y, and Z coordinate system, as well as controlling the rotational orientation and/or degree of opening distance of the gripper fingers 212A, 212B.

In FIG2 , a sample rack imaging system 221 may be provided within the gripper positioning system 200 to capture images of the sample rack 106 . The sample rack imaging system 221 may include a rack image capture device 222 and an image capture controller 224 . Specifically, the rack image capture device 222 (e.g., a digital camera) may be positioned in any suitable location. In one or more embodiments, multiple images of the sample rack 106 may be acquired from multiple perspectives. For example, the rack image capture device 222 may be positioned above a movable sample rack loading drawer 225 that may be movable relative to the frame 214 . The sample rack 106 may be supported by the movable sample rack loading drawer 225 and moved into a testing instrument or processing equipment to a location accessible by the robot 210 . During this movement, the rack image capture device 222 may capture multiple digital images of the top of the sample rack 106 . Other devices for capturing images may also be used.

Image processing software stored in the image capture controller 224 can receive and process multiple digital images. From the images, data including population data and/or configuration data can be generated. The population data and/or configuration data can be accessed by the robot controller 216. Access can be by downloading data from the image capture controller 224 or by obtaining access to a database resident on the image capture controller 224.

Alternatively, the robot controller 216 and the image capture controller 224 may be combined in a common controller and configured to process the images captured by the rack image capture device 222 and also control the movement and operation of the robot 210 and the gripper 212 . Further details of the sample holder imaging system 221 and the image capture controller 224 can be found in: U.S. Patent Publication No. US2016/0025757, filed on March 14, 2014, by Pollack et al., entitled “Tube Tray Vision System”; PCT Application Publication No. WO2015/191702, filed on June 10, 2015, and entitled “Drawer Vision System”; PCT Application No. PCT/US2016/018100, filed on February 16, 2016, and entitled “Locality-Based Detection Of Tray Slot Types And Tube Types In A Vision System”; and PCT Application No. PCT/US2016/018100, filed on February 16, 2016, and entitled “Locality-Based Detection Of Tray Slot Types And Tube Types In A Vision System”. System”; and PCT Application No. PCT/US2016/018109, filed on February 16, 2016, and entitled “Image-Based Tube Slot Circle Detection For AVision System.”

More specifically, population data refers to data regarding which receivers 106R in the sample rack 106 are empty and which receivers contain sample containers 102 therein. For example, as shown in FIG2 , the population data indicates that the target receiver 106T labeled “B” is empty, and the receivers 106R labeled “A,” “C,” “D,” and “E” all contain sample containers 102, 102L. The population data, alone or in combination with the configuration data, can be used to select the next target sample container 102T for a pick operation or the target receiver 106T for a place operation.

Configuration data is defined herein as information regarding the geometry and/or orientation of one or more sample containers 102, 102L residing in the sample holder 106. The configuration data may include a maximum sample container outer diameter, an offset distance of the top of the sample container 102, 102L relative to the center of the receptacle 106R in which it resides, a height of the sample container 102, 102L, or a tube type (e.g., capped tube, uncapped tube, including a tube-top sample cup, etc.).

For example, the configuration data may indicate that the sample container 102L has a relatively large diameter, that the sample container 102 is offset in the X and/or Y direction due to the action of a spring (e.g., spring 108), or because the sample container 102, 102L is tilted in the receiver 106R. The configuration data obtained from the imaging may also indicate sample containers 102 having relatively small or intermediate diameters, and may provide, for example, the distance between the center of the target sample container 102T and any adjacent sample containers 102, 102L. The size, offset, and gap may be obtained by first identifying geometric features in the image and then counting the pixels.

Population data, configuration data, or a combination of both are used, at least in part, to determine target receivers 106T that are believed to be accessible by the gripper fingers 212A, 212B. The target receivers 106T may be selected by pre-surveying the available receivers 106R prior to a pick operation or a place operation.

An accessible target receptacle is a receptacle (e.g., target receptacle 106T) that has been determined to meet a threshold minimum clearance. The threshold minimum clearance is predetermined and measured along an available line of action relative to the target sample container 102T. For example, referring to FIG3A , consider the following scenario: the sample container 102T in the target receptacle 106T is the "target sample container," i.e., the sample container 102 that is intended to be picked up by the gripper fingers 212A, 212B during a pick operation. However, before picking up the sample container 102T by the gripper fingers 212A, 212B, the method can determine whether the target receptacle 106T, in which the target sample container 102T is received, is accessible. By determining this, the risk of clogging, contact between adjacent sample containers, spillage, etc. is reduced, thereby improving the efficiency of the automated testing instrument or processing equipment.

To determine whether the target receiver 106T is accessible (i.e., whether it meets the threshold minimum clearance), population data and/or configuration data for the target sample container 102T and surrounding sample containers 102 and receivers 106R can be accessed and used. In this case, as shown in FIG3A , configuration data for the sample containers 102 in receivers 106R numbered 2, 4, 6, and 8 in the sample rack 106 is obtained and analyzed. Similarly, population data can be used to determine that receivers 106R numbered 1, 3, 7, and 9 are empty.

The analysis can be performed by selecting a first receiver as a potential target receiver 106T and testing whether a threshold minimum clearance is achievable along any available line of action. For example, in a fixed gripper design (i.e., no rotation capability), only clearance along the line of action 325A for that receiver 106R would be investigated.

The method for selecting a receiver to test against a threshold can be as simple as moving from receiver to receiver until a receiver that meets the threshold minimum clearance is found. If multiple lines of action (e.g., lines of action 325A-325C) are available due to the gripper 212's rotational capability, each line of action (325A-325C) used to test the receiver 106R can be individually tested for the threshold minimum clearance. Once a clearance value falls within a range above the threshold, a pick or place can be performed. If a receiver 106R does not meet the threshold minimum clearance, another receiver 106R is investigated to see if it meets the threshold minimum clearance. This continues until a target receiver 106T that meets the minimum threshold clearance is found.

The population data for the receivers 106R surrounding the target receiver 106T can indicate which of the receivers 106R surrounding the target receiver 106T contain sample containers 102, 102L. In the event that there are empty receivers 106R along the line of action 325A, such as at positions 1, 2, 3, 7, and 9, it can be automatically determined that the gaps on that side of the target sample container 102T are above a threshold. Therefore, the line of action 325A can be immediately selected. The open distance measured between the sample container contact surfaces of the gripper fingers 212A and 212B can be set to a maximum. Line of action 325A can be selected over line of action 325C because the offset direction of the sample container tops provides a high probability that gripping the sample container along line of action 325A will correct the orientation from a tilted orientation to a vertical orientation, i.e., correct the tilted target sample container 102T.

In addition, the configuration data may indicate which of the adjacent sample containers 102, 102L are sample containers 102L having a relatively large diameter. The configuration data may also indicate that the target sample container 102T is tilted (i.e., offset from the center of the target receptacle) or otherwise offset to reduce or increase the gap between the target sample container 102T and any surrounding sample containers 102, 102L.

The configuration data may also indicate the tube type of the target sample container 102T. Knowing the tube type is important in situations where the gap between two sample containers 102 is very close to the minimum threshold gap, making it difficult to determine whether the receptacle 106R is actually accessible. For some tube types, a smaller threshold gap may be allowed because the tube type is more robust, while for other tube types, such as tube-top sample cups, a larger threshold gap may be used because the tube type is more fragile. Thus, in some embodiments, the threshold gap may be selected based on the type of sample container 102 present in the target receptacle 106T or in the surrounding receptacles 106R.

From the imaging data, it can be determined whether the target receiver 106T is accessible, i.e., the target receiver 106T is properly accessible by the gripper fingers 212A, 212B (e.g., without contact therewith), or whether the target receiver 106T is blocked from access. Blocked access means that the gripper fingers 212A, 212B cannot be inserted without a high probability of contact with one or more sample containers 102, 102L surrounding the target sample container 102T. For a pick operation, after all possible lines of action have been analyzed and no line of action allows a minimum threshold clearance between a sample container 102 within the receiver 106R and one of the adjacent sample containers 102, it can be determined that the receiver 106R is blocked. If one of the lines of action provides the minimum threshold clearance between the receiver 106R and the adjacent sample container 102, it can be determined that the receiver 106R is accessible. In some cases, the minimum threshold clearance can be provided by adjusting the gripper 212 in the X and/or Y directions. In other cases, the minimum threshold gap can be provided by adjusting the opening distance between the gripper fingers 212A, 212B. In some embodiments, adjustments to the position of the gripper 212 in both the X and/or Y directions and the opening distance between the gripper fingers 212A, 212B can be performed to provide the minimum gap.

If the target receiver 106T is not accessible, a strategy can be developed based on imaging data, wherein the strategy involves selecting accessible adjacent sample containers 102, 102L and removing them first so that the target receiver 106T is accessible. For example, as shown in FIG3B , the sample container 102B shown in the receiver 106RB, which is labeled C7, is effectively blocked. When no matter how the gripper rotation orientation, gripper opening distance, or X or Y positioning are located, no available line of action includes the minimum gap, blocking is determined. The sample container 102B is considered to be blocked because the sample containers 102, 102L in the receivers 106R, which are labeled B7, B6, C6, D6, are too close to meet the minimum gap on one side of the blocked sample container 102B. Therefore, in order to be able to pick up the blocked sample container 102B, it must first be unblocked.

By removing the unblocked sample container 102 in the adjacent adjacent receptacle, designated A7, along line of action 325E, this can effectively "unblock" the target receptacle 106RB. Target receptacle 106RB can then be made accessible and can then be picked up along a line of action (e.g., such as along line of action 325F). Alternatively, the sample container 102 in receptacle 106R, designated B6, can be removed to provide unblocking of the blocked sample container 102B. In each case, there may be numerous options for unblocking the blocked receptacle 106RB.

In one embodiment, the method can test in a round-robin fashion whether each removal can unblock the target receiver 106RB. Once an object that will unblock is found, it can be removed and the previously blocked, now unblocked sample container 102B can be picked up. In other embodiments, where multiple unblocking options are available, the removal of the sample container 102, 102L that will reveal the line of action with the largest gap can be selected.

For each blocked receiver 106RB, embodiments of the method can search sequentially in a clockwise or counterclockwise direction from any starting position and investigate whether any of the adjacent sample containers 102, 102L can be removed, and if so, whether their removal would effectively release the line of action, thereby enabling the blocked sample container 102B to be unblocked. In some embodiments, all blocked receivers 106RB in the sample rack 106 can be identified based on imaging data, and each blocked receiver 106RB can be given a precedence relative to unblocked receivers 106R, so that adjacent sample containers 102, 102L can be selected to unblock the blocked state. Any number of schemes can be implemented to unblock blocked receivers.

In some embodiments, the picking operation may occur in an ordered sequence, such as row by row, column by column, or in any other ordered pattern, and when a blocked receiver 106RB is detected, a picking move may be made to attempt to unblock the blocked receiver 106RB. If no move is available at this time, the ordered sequence will simply continue until a move is available.

In some embodiments, after the first pick or place is performed, the system and method can be used to analyze the rest of the sample rack 106 and generate a comprehensive pick and place strategy that takes into account population data and/or configuration data. The pick or place order can be quickly determined and determined while picking up the first accessible sample container 102. The system can determine all accessible sample containers 102 and all "blocked" sample containers 102. In some embodiments, all accessible sample containers 102 can be picked up first, and then it can be determined which of the sample containers 102 that were once considered "blocked" have become "unblocked." These "unblocked" sample containers 102 are now accessible and can be picked up. This can be repeated until all sample containers 102 have been "unblocked," are considered accessible, and are picked up.

In some embodiments, sorting the receivers 106R can also be used to determine the order in which the sample containers 102 are picked. Referring now to Figures 4A-4E, various possible configurations of a target sample container, indicated by T, and its adjacent sample containers 102 to the left and right along the line of action are shown. The line of action is shown as horizontal, but vertical and diagonal lines of action can also be used in this sorting method. In the sorting process, some of these configurations can be given relatively high numerical scores (i.e., indicating that the target sample container T involved in this configuration should be picked first or given priority), while some configurations can be given relatively low numerical scores (i.e., indicating that the target sample container T involved in this configuration should be picked later or last). For example, Figure 4A shows the best possible configuration in which the receivers 106R on either side of the target sample container T are empty (indicated by an X). This configuration can be given a numerical score of 10, or another relatively high numerical score. This target sample container T can be selected first for the picking operation.

4B , however, may be given a relatively low numerical score, such as a numerical score of 9. The target sample container T has only one adjacent sample container, and the adjacent sample container 102 is offset distally (indicated by "OA"), so the gap between the target sample container T and its adjacent sample container may still meet the minimum threshold gap, and the target sample container T may still be reasonably accessible.

In Figure 4C, a configuration is shown that includes a target sample container T having an empty receptacle (X) on its left side and a receptacle 106R on its right side that houses a sample container 102 that is offset (indicated by "OT") toward the target sample container T. This may be given a relatively low score, such as 8.

In FIG4D , a configuration is shown that includes a target sample container T having two full receptacles 106R on both the right and left sides thereof, and both of these receptacles 106R contain a centered sample container 102 having a relatively large diameter (indicated by “LD”). Compared to the configurations in FIG4A-4C , the configuration in FIG4D may be given a relatively lower score, such as a score of 7, due to the lower clearance provided by the larger diameter sample container LD.

In situations similar to those in FIG. 4B and FIG. 4C , offsetting the gripper fingers 212A, 212B in X and/or Y can create a minimum threshold gap for the target sample container T to be considered accessible. In the configuration shown in FIG. 4E , the gripper fingers 212A, 212B may not be offset because the target sample container T is surrounded by two sample containers LOT, which are tilted and offset toward the target sample container T. Therefore, there may not be a minimum threshold gap between the target sample container T and its adjacent sample container LOT, and the target sample container T may be considered "blocked." This configuration may be assigned a relatively low score, such as a score of 1 or any other relatively low score, which may indicate a "blocked" state. Therefore, the target sample container T may be picked up after the other sample containers LOT have been picked up, thereby freeing up the area surrounding them.

Using sorting, a dynamic order in which sample containers 102 are picked can be determined based on the "most accessible" receptacle 106R, i.e., the receptacle 106R that is assigned a higher sort value and is picked first. Similarly, the dynamic order in which sample containers 102 are picked can be determined without sorting and simply by determining which of the receptacles 106R meet a minimum threshold clearance between the sample container 102 contained in the receptacle 106R and an adjacent sample container 102, i.e., which of the receptacles 106R are accessible and which are blocked. The dynamic order can be determined by surveying all available receptacles, available receptacles in a region, or surveying each receptacle individually and determining whether they meet a minimum clearance criterion set for the gripper fingers 212A, 212B and sample rack 106 being used. In some embodiments, the minimum clearance threshold can be set based on an experimental run to ensure that no contact occurs during a high percentage of pick and place operations.

The systems and methods described above can be used to dynamically select accessible target receptacles for sequential placement operations. To determine whether a receptacle 106R is accessible, population data, configuration data, or a combination of both can be used in a manner similar to the placement operation. Population data refers to data regarding which of the receptacles 106R are empty and can be used to determine the target receptacle 106R into which the sample container 102 is desired to be placed. Configuration data refers to information regarding specific adjacent sample containers 102, including maximum sample container diameter, sample container offset distance, or tube type (e.g., capped tube, uncapped tube, tube-top sample cup, etc.). Configuration information from previous pick operations can also be stored in the image capture controller 224 and can be accessed by the robot controller 216 during subsequent placement operations. This allows the placement strategy to be configured in a manner that maximizes clearance between adjacent sample containers 102. For example, the placement strategy can be configured to avoid placing two sample containers 102 with relatively large diameters adjacent to each other in a receptacle 106R. Likewise, sample containers 102 including tube-top sample containers can be placed away from large sample containers 102L. Similarly, dynamic placement can be performed in every other row or column to initially increase placement gaps.

Consider the sample rack 106 in FIG3B , which has multiple rows of receptacles 106R (rows 6 through 9 are shown), some of which contain sample containers 102, 102L. For example, the predetermined order may include starting with the first receptacle 106R (A6) in row 6. Population data indicates that receptacles 106R labeled A6 and E6 are empty, while receptacles 106R labeled B6, C6, D6, and E6 contain sample containers 102, 102L. Therefore, based on the population data and configuration data, it can be determined that receptacles 106R labeled A6 and E6 are both accessible. Accessibility can be determined by ensuring that a minimum clearance is met on both sides along a specific line of action that can be implemented by the gripper 212. Therefore, the placement order can be determined based on whether a receptacle 106R is accessible. In some embodiments, if a receiver 106R is inaccessible, then based on the imaging data, the placement operation may skip that receiver 106R and be placed in the next accessible receiver 106R. The next pick move may attempt to unblock the receiver 106R that was found to be inaccessible.

FIG5 illustrates a sample container transport system 500 in which a dynamic selection method can be implemented. The sample container transport system 500 includes a sample rack 106 positioned within the reach of a gripper 212 (shown in dashed lines). The gripper 212 can be mounted to a transverse slide 510C of a rack robot 510, which can move back and forth on a crossbar 510B to access any column of the sample rack 106. Similarly, the crossbar 510B can move forward and backward along left and right slide rails 510L and 510R to allow access to any row of the sample rack 106. The gripper can move vertically (in and out of paper) to raise and lower the sample container 102. Thus, the gripper 212 can be moved in an X, Y, and Z coordinate system. A dynamic pick operation can be performed according to the methods described above to pick sample containers 102 from the sample rack 106 based on imaging data obtained from the rack image capture device 222 and the image capture controller 224 and transport the sample containers 102 to a sample container carrier 532 (e.g., a puck) residing on and moving about the track 540. Similarly, sample containers 102 can be placed back into the sample rack 106 using a dynamic placement operation upon return from testing and/or processing. The pick and place sequence can be selected as described above and can be based on population data, configuration data, or both population data and configuration data. The track 540 can transport the sample containers 102 to various devices or instruments to perform testing or otherwise process the samples contained in the sample containers 102. The track 540 can include one or more branches 540A from a main channel 540B to all loading and unloading channels. In some embodiments, dynamic placement can include a strategy for returning specific sample container carriers 532 in a specified order, thereby providing a placement strategy that increases placement spacing in the sample rack.

According to another embodiment of the present disclosure, a method 600 of operating a gripper (e.g., gripper 212) is provided. In 602, the method 600 includes providing a robot (e.g., robot 210, 510) including a gripper (e.g., gripper 212), the gripper being movable by the robot in a coordinate system (e.g., in X, Y, and Z) and including gripper fingers (e.g., gripper fingers 212A, 212B), and in 604, the method 600 includes providing a sample rack (e.g., sample rack 106) including receptacles (e.g., 106R, 106T) accessible by the gripper, at least some of the receptacles being adapted to receive sample containers (e.g., 102, 102L, 102T).

Furthermore, at 606, method 600 includes providing data obtained by imaging regarding a sample holder (e.g., sample holder 106) and sample containers (e.g., sample containers 102, 102L), and finally, at 608, method 600 includes determining an accessible target receiver (e.g., 106T) for either a pick operation or a place operation based on the data. The data obtained by imaging may be population data and/or configuration data. Determining the accessible target receiver (e.g., 106T) may include, in the case of a pick operation, testing the clearance between the target sample container 102T and surrounding sample containers 102, 102L to ensure that a minimum threshold clearance is provided. In the case of a place operation, accessibility involves determining the clearance around the target receiver (e.g., 106T) and comparing the clearance to a target threshold value based on the type of sample container 102 being placed and, possibly, the type of sample containers surrounding the target receiver 106T.

Although specific devices, systems, and methods have been shown by way of example embodiments herein, it should be understood that other and different embodiments are possible. This disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the appended claims.

Claims (18)

1. A method for operating a gripper, the method comprising: A robot is provided that includes the gripper, the gripper being movable by the robot in a coordinate system and including gripper fingers; A sample holder is provided, the sample holder including receivers accessible by the gripper, at least some of the receivers being adapted to accommodate sample containers; Provides data about the sample holder and the sample container obtained through imaging; Based on the data, a reachable target receiver is determined for either a pick-up operation or a place-down operation. The data includes construction data, which includes one or more of the following: maximum sample container diameter, sample container offset distance, or tube type. 2. The method of claim 1, wherein, for the placement operation, the reachable target receiver is empty. 3. The method according to claim 2, wherein the method comprises: placing a target sample container in the accessible target receiver. 4. The method of claim 1, wherein, for the picking operation, the accessible target receiver contains a target sample container. 5. The method of claim 4, wherein the reachable target receiver is a receiver that satisfies a minimum threshold gap along the line of action relative to the target sample container. 6. The method of claim 5, wherein the method comprises a clamp having rotational capability and more than one line of action. 7. The method of claim 6, wherein the method includes determining whether one or more action lines satisfy the threshold minimum gap. 8. The method according to claim 1, further comprising: Determine whether one or more of the receivers are blocked. 9. The method of claim 1, wherein the data includes group data, the group data being data about which of the receivers include sample containers. 10. The method of claim 9, wherein the reachable target receiver is determined at least in part based on group data. 11. The method of claim 1, wherein the reachable target receiver is determined at least in part based on construction data. 12. The method of claim 1, wherein the reachable target receiver is determined based on population data and construction data. 13. The method of claim 1, wherein the method comprises: further dynamically selecting additional accessible target receivers based on the data for subsequent pickup or placement operations. 14. The method of claim 1, wherein the reachable target receiver is determined by sorting at least some of the receivers based on both constructed data and group data. 15. The method of claim 1, wherein the accessible target receiver is selected to include a first empty receiver and a second empty receiver on opposite sides of the accessible target receiver. 16. The method of claim 1, further comprising a blocked receiver, wherein surrounding sample containers are removed to unblock the blocked receiver. 17. A gripper positioning system, the gripper positioning system comprising: A robot including the gripper, the gripper being movable by the robot in a coordinate system and including gripper fingers; Sample holder, the sample holder including receivers accessible by the gripper fingers, at least some of the receivers containing sample containers; and A controller, which is coupled to the robot and is operablely configured to: Access data about the sample holder and the sample container obtained from one or more images, the data including population data and construction data, and Based on the group data and the constructed data, a reachable target receiver is determined for either the pick-up operation or the place-down operation. The construction data includes one or more of the following groups: maximum sample container diameter, sample container offset distance, or tube type. 18. A gripper positioning device, the gripper positioning device comprising: A robot including the gripper, the gripper being movable by the robot in a coordinate system and including gripper fingers; and A controller, which is coupled to the robot and is operablely configured to: Access data obtained from one or more images regarding the sample holder and the sample containers contained within it, and Based on the data, a reachable target receiver is determined for either the pick-up or the place-down operation; The data includes: Sample data, which refers to the data on which receiver includes the sample container, and The construction data includes one or more of the following: maximum sample container diameter, sample container offset distance, or tube type.