WO2000038046A1 - Dispositif automatise permettant de charger une centrifugeuse - Google Patents

Dispositif automatise permettant de charger une centrifugeuse Download PDF

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Publication number
WO2000038046A1
WO2000038046A1 PCT/US1998/027283 US9827283W WO0038046A1 WO 2000038046 A1 WO2000038046 A1 WO 2000038046A1 US 9827283 W US9827283 W US 9827283W WO 0038046 A1 WO0038046 A1 WO 0038046A1
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WO
WIPO (PCT)
Prior art keywords
centrifuge
tube
adaptors
adaptor
tubes
Prior art date
Application number
PCT/US1998/027283
Other languages
English (en)
Inventor
Ronald M. Hubert
Rodney D. Miller
Original Assignee
Quest Diagnostics Investments Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Quest Diagnostics Investments Incorporated filed Critical Quest Diagnostics Investments Incorporated
Priority to PCT/US1998/027283 priority Critical patent/WO2000038046A1/fr
Priority to CA002356270A priority patent/CA2356270A1/fr
Priority to EP98966042A priority patent/EP1145104A4/fr
Priority to AU22030/99A priority patent/AU2203099A/en
Priority to JP2000590038A priority patent/JP4382990B2/ja
Publication of WO2000038046A1 publication Critical patent/WO2000038046A1/fr

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
    • G01N35/0099—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor comprising robots or similar manipulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B04—CENTRIFUGAL APPARATUS OR MACHINES FOR CARRYING-OUT PHYSICAL OR CHEMICAL PROCESSES
    • B04B—CENTRIFUGES
    • B04B11/00—Feeding, charging, or discharging bowls
    • B04B11/04—Periodical feeding or discharging; Control arrangements therefor
    • B04B2011/046—Loading, unloading, manipulating sample containers
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
    • G01N2035/00465—Separating and mixing arrangements
    • G01N2035/00495—Centrifuges
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
    • G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
    • G01N35/04—Details of the conveyor system
    • G01N2035/0401—Sample carriers, cuvettes or reaction vessels
    • G01N2035/0406—Individual bottles or tubes

Definitions

  • This invention relates to an automated device for loading a centrifuge using robotics and an intermediate staging area for loading and unloading of tube carriers. More specifically this invention relates to a robotic device, also called a station, which is capable of transferring test tubes from a device which brings sample to be centrifuged to the vicinity of the centrifuge, arranges them in a balanced fashion in centrifuge sample carriers on an intermediate staging area, loads and unloads the centrifuge, and transfers the processed samples to their originating point, or to a third point or device.
  • a robotic device also called a station
  • Centrifuging is a necessary step in the processing of blood samples in a clinical laboratory setting. Most current clinical tests require that serum or plasma be separated from red blood cells, and other blood debris, before an assay can be run on the sample. Most often this is accomplished by centrifugation, although dialysis- or filtration-type technologies are used in some operations, particularly where only a small quantity of sample is available. But for the most part, centrifugation is an essential preparatory step in the processing and testing of blood samples in a clinical laboratory setting.
  • centrifuge takes 7 to 10 minutes for cycling through a load of tubes, i.e., loading up the centrifuge baskets, spinning down the blood samples, and unloading the processed tubes. Most if not all sample prep steps involving centrifugation is now done prior to loading tubes onto the automated routing system. In that context, where centrifugation is required, the centrifuge is loaded and unloaded manually off-line, then centrifuged sample tubes are loaded onto the routing system. A manual operation requires staffing, requires additional human handling of tubes, and requires decision making as to which tubes to place in which carrier to achieve a balanced load in the centrifuge.
  • a manual operation can be rate limiting and is more expensive than would be an efficient automated robotics system.
  • Some attempts have been made to automate the centrifugation step.
  • One system is currently being marketed by Coulter® Corporation, Miami, Florida, USA. It uses a 4-stage system to prepare samples. Tubes are loaded into racks in an inlet module; the racks are moved via conveyor to a bar-code reader; then the racks move to a centrifuge module which uses a robotic arm to pick tubes needing centrifugation from the racks, loads them directly into the centrifuge baskets in the centrifuge, and returns them directly to the racks on the conveyor; after which the racks are routed to other processing devices prior to being routed to assay stations.
  • the robotic load/unload operation must remain inactive during the centrifuge's spin cycle; it can not be loading and unloading tubes during the spin cycle since it moves tubes between transport rack and centrifuce tube adaptor in the centrifuge. What is needed is a more efficient system which minimizes the time lost to the overall operation caused by the necessary wait for the centrifuge's spin cycle to be completed. If some operation could be slotted into this down-time, some operation which has to be done in any event, the overall efficiency of the operation could be greatly enhanced. This invention provides such a solution.
  • this invention relates to a process for automating the processing of samples through at least one fault-tolerant centrifuge using a device which has a processing station interposed between a tube collection or transport device and a fault-tolerant centrifuge, the station comprising: a) a staging area for tube adaptors compatible with the centrifuge; b) a dual function tool having: i) a tube gripper which can recognize and adapt to tubes of different heights and diameters on the tube collection or transport device and which routes tubes between the tube collection or transport device and the centrifuge adaptors on the staging area; and ii) an adaptor gripper capable of transporting adaptors to and from said centrifuge, the process comprising: a) under automated control: (1) identifying the height and diameter of a tube on the tube collection or transport device; (2) selecting a tube which have a pre-set height and diameter;
  • this invention relates to a robotic device for automating the processing of samples through a fault-tolerant centrifuge, the device comprising: a) a tube collection or transport device interfaced with, b) a processing station interposed between the tube collection or transport device and at least one fault-tolerant centrifuge and interfaced with c) a fault-tolerant centrifuge, the station having i) a staging area for tube adaptors compatible with the centrifuge; and ii) a dual function tool having a) a tube gripper which
  • Fig. 1 Elevated frontal view of the device showing tube conveyor, robotic arm, staging area, and centrifuge.
  • Fig. 2a Frontal view of the robotic arm with tube gripper in the up position and adaptor gripper in the down position, and the arm's transport mechanisms.
  • Fig. 2b Frontal view of the robotic arm with adaptor gripper in the up position and tube gripper in the down position, and the arm's transport mechanisms.
  • Fig. 3 a Frontal view of the tube gripper mechanism in closed position.
  • Fig. 3b Frontal view of the tube gripper in the open position.
  • Fig. 4 Side view of the mandrel and its control mechanism.
  • FIG. 5 Exploded view of the mandrel control mechanism.
  • Fig. 6 Exploded view of the middle section of the tube gripper mechanism showing the hall-effect device used to control the gripper fingers.
  • Fig. 7 Exploded view of the finger control mechanism.
  • FIG. 8 Frontal view of adaptor gripper without an adaptor.
  • FIG. 9 Frontal view of the adaptor gripper with adaptor.
  • Fig. 10 Exploded view of the Z-axis compliance control device.
  • Fig. 13 Detailed view of the adaptor gripper hand with outrigger pins.
  • FIG. 14 Top view of a universal adaptor. Detailed description of the Invention
  • this invention provides a device which can increase the throughput of sample tubes which must be ganged for further processing by picking tubes a collection device, organizing them in a preferred fashion in a carrier, moving the carrier to the work-station or device, returning the carriers to the staging area, and unloading tubes to the original operation or to a third site or operation.
  • a specific and preferred operation of this type is the use of this device to pick clinical sample tubes from a conveyor line, place them in centrifuge adaptors so that paired adaptors are balanced, transferring the adaptors from the staging area into and removing them from the centrifuge, and returning the tubes to the conveyor line. Filling and unloading adaptors during the spin cycle of the centrifuge provides a substantial time saving operation.
  • the basic operation of the station is to load tubes from the automated transport system into the tube adaptors in a balanced fashion, and then load adaptors into the centrifuge. After centrifugation, the adaptors are removed from the centrifuge and the individual tubes are returned to the line. Unless otherwise stated, a PC (586/90 machine) was used to control the operation of this device. Code for controlling the robotics was provided by Hyundai Robotics. The top level operating system used Windows NT 4.0.
  • the preferred sample tube automated transport system is the device described in US patent 5,623,415. All specific operations set out below are made with reference to the device described in that patent. But this is merely an exemplary device.
  • This invention can be used with any automated device, or can be used as a stand-alone operation mode, i.e., in a mode where the tubes are presented to it by a static or semi-static device which is used for processing sample tubes requiring centrifugation.
  • the payload on the Y axis was set at 7 Kg. Tube cycle time was set at 5 seconds.
  • An example of a fault-tolerant centrifuge is the AccelSpinTM Centrifuge and AS-3000 Rotor sold by the Spinco Business Center of Beckman Instruments, Inc., Palo Alto, CA, USA. This device has a 10 gram fault tolerance between paired adaptors. Overview of Station Operational Requirements
  • the specific embodiment of this invention is an automated centrifuge station having the following components: a) A tube router ('interface gate'), that allows the station to retrieve individual specimen tubes from a laboratory-wide tube transport system. After centrifugation, the gate allows the tubes to be returned to the transport system for additional processing, b) Tube 'adaptors', each capable of holding 16 tubes (four rows of four tubes). c) A centrifuge, capable of holding four tube adaptors, ninety degrees apart, d) A robotic arm, capable of i) moving tubes between the interface gate and the tube adaptors ii) moving tube adaptors into and out of the centrifuge Robotic tube and adaptor device
  • the dual function tool has a tube gripper and an adapter gripper on separate vertical axises. When one gripper is made operational it is lowered and the other gripper is raised to an inactive position; when one is up, the other is always down. Gripping/releasing controls are built into each gripper and each set of controls acts independently.
  • the preferred tube gripper is a two-finger device with a mandrel positioned between and above the cavity scribed by the two fingers. This mandrel is used to sense tube height.
  • the tube gripper is moved to a position where the fingers are on either side of the tube and the mandrel is above the tube and projecting into the cavity scribed by the fingers.
  • the tool then lowers gripper, the mandrel touches the top of the tube and is moved vertically.
  • Sensors on the mandrel interface with sensors on its housing to detect a tube that is either to tall, is within a defined acceptable range, or is to short. If the tube height is within the pre-set acceptable height range, the fingers are activated and close on the tube, and by that operation detect tube diameter.
  • An acceptable tube is then lifted from its holder, the tool is directed to move to a position over an adapter, based on the parameters of the tube then in the gripper, and placed in a one or the other of the paired adaptorsr in a fashion which results in a balanced load being effected between paired adaptors. If the tube is not acceptable, it is not gripped, and the tool is retracted and sent in search of another tube.
  • the adaptor gripper in the dual function tool is engineered to grip the adaptor in a manner which provides for lifting and moving adaptors back and forth between the staging area and the rotor spindel in the centrifuge.
  • This can be accomplished by a number of means.
  • the universal adaptor was given a set of wings with rectangular holes extending vertically above the top plain of the tube holder into which are matched rectangular projections on the arms of the adaptor gripper.
  • the gripper arms are moved to a position central to the wings, the holes and projections are aligned, and the arms are moved out causing the arms' projections to insert into the holes of the wings.
  • the adaptor is gripped and mainpulated.
  • this adaptor manipulating means is a means for righting adaptors which end up canted at the end of the spin cycle.
  • This righting means can take many shapes and forms, and will necessarily depend on the shape of the device used to secure adaptors to the robotic hand and the shape of the adaptors.
  • the preferred righting means disclosed herein involves two mechanisms, either of which may be used, either together or independently. In one iteration the locking device has a set of equal length fingers extending from the bottom of each side of the gripper hand.
  • Normal gripper operations is to have the arms in the "open", position, i.e., positioned more centrally to the axis of the gripper, so the locking mechanism can be inserted inside the wings of the adaptor, expand and lock up with the wings.
  • this normal or default position when the robot moves to secure an adaptor after it has been through the spin cycle, if there is a canted adaptor, one set of these fingers, or "outrigger” posts, will contact the top of one side of a canted adaptor before the other, and as it continues to descend, right the adaptor.
  • a second method was developed to right canted adaptors.
  • the adaptor gripper rather than remaining in the "open” mode which is the default mode, goes to "closed” mode, the arm descends, causing the bottom of the gripper's outrigger posts on one side of the hand to contact the top of an adaptor, then to continue descending while pushing on the adaptor, until the adpator is horizontal or essentially horizontal. At that point, the gripper is programmed to lift slightly (if necessary), go to the default "open” mode, reinsert itself fully into the adaptor, and move to the "closed” mode, thus locking up with its wings and gripping the adaptor.
  • Tube size handling requirement In a preferred embodiment, the tube handling device must be capable of manipulating tubes of heights from 75mm to 100mm. The tube diameter may also vary from 13mm to 16mm. With appropriate adaptation, this device can be made to handle a tube of any height and diameter that can be processed by a given size centrifuge.
  • a universal adaptor was designed that can hold tubes varying in height from 75 mm to 100 mm.
  • the essence of this universal adaptor is the fact that all tubes seat at the same level, leaving the top of the tubes to be at different heights. This was done because the preferred mode of operation was to grip each processable tube at the same height from the bottom of the tube, without regard to its height. This is but one example of how the tube size handling process can be programmed.
  • a centrifuge usually holds four adaptors, located 90 degrees apart. Due to the high centrifugal forces, a pair of adaptors, loaded 180 degrees apart in the centrifuge, must weigh nearly the same or the centrifuge mechanics can be damaged. The maximum allowed imbalance for an adaptor pair is up to 100 grams, given the current state of the art of centrifuges. A 10 gram tolerant device is currently under development by Beckman Instruments.
  • a pair of adaptors are built at the same time. That is, the first arriving tube is placed in adaptor 1, the second tube is placed in adaptor 2, the third tube is placed in which ever adaptor is lighter, the fourth tube is again placed in whichever adaptor is lighter.
  • the weight of a tube is estimated from its height and diameter, numbers detected via gripper sensors and fed back to the system control software. This estimate is made based on the average gross weight for at tube of that diameter, a number which was programmed into the software and correlated with tube height and diameter. In this way, even if a partial load must be centrifuged, the opposing adaptor will weigh the same within the fault limit of the centrifuge.
  • adaptor 1 and adaptor 2 When adaptor 1 and adaptor 2 are filled, the process is repeated with adaptor 3 and adaptor 4. This is the preferred algorithm.
  • An alternative is to use a third adaptor, or a tube holding device, to serve as an intermediate repository so tubes can be shuttled amongst the three adaptors (or two adaptors and the holder) until the operating paired adaptors are in balance. In this operation tubes can be taken from the heavier adaptor and moved to the lighter adaptor, or moved to the intermediate holder. Balance also can be achieved by taking an appropriate sized tube from the intermediate holder and placing it in the appropriate one of the paired adaptors to achieve balance. While it is a preferred operation to place the next tube in the lighter adaptor, that operation is not an essential feature of this invention.
  • a target throughput is as follows:
  • the system is under the control of the factory control package provided by Hyundai Robotics, called the factory host.
  • the station must be able to accept control commands (such as start-up and shutdown), report status (such as a failed bar code reader), and report the bar code ID of the tubes as they leave the station.
  • control commands such as start-up and shutdown
  • report status such as a failed bar code reader
  • the station must safely respond to a variety of operating conditions, including Broken tubes
  • the station Since the station must be able to gracefully and quickly recover from interruptions in processing (such as power failures, tube jams, e-stop activation, etc.), the station must track the location of all adaptors and tubes as they travel through the station. The tracking information must be frequently written to non- volatile storage (such as a hard disk) to ensure speedy and reliable recovery. Auto-calibration
  • the robotic part of the station must know where to place the tubes and the adaptors. This means a variety of locations must be 'taught' to the station. If the station requires maintenance and a piece of the station must be removed, it is highly desirable that the station be able to continue operation without having to have its locations 're-taught'. To accomplish this, an auto-calibration package must be implemented. This package includes sensors to detect the slight change in position of the robotic locations as well as software to calculate the new locations, based on sensor feedback. Manual control of station
  • any other output bit such as a bit controlling a safety device
  • the station must be able to display its sensors.
  • the station consists of 12 adaptor slots on the table (3 rows of 4 slots). 4 of the slots (1 row) have adaptors with tubes waiting to be processed. 4 of the slots (1 row) have adaptors that have been unloaded (adaptors are empty). 4 of the slots (1 row) are empty ('no adaptor' slots), ready to receive the processed adaptors from the centrifuge. 4 adaptors with processed tubes are located in the centrifuge. Generally it is preferred to work with three rows on the staging platform, one row being empty, one row having adaptors which are being filled from the the conveyor line, and the other row being a row of apators which contain tubes which have been centrifuged and are being processed back into the automated sample routing device.
  • the four adaptors are fully loaded with 64 tubes (16 tubes per adaptor) waiting to be centrifuged.
  • the slots on the table that hold these adaptors are called the "in process adaptor" slots.
  • the centrifuge there are four tube adaptors, designated "processed A, B, C, and D".
  • the adaptors are full, containing 64 tubes (16 tubes per adaptor) waiting to be returned to the transport line.
  • the normal, steady-state cycle is as follows: Adapter Loading Cycle, universal adaptor: The centrifuge door is automatically opened.
  • the robot lowers the adaptor tool so that the adaptor fingers are available for use. (The adaptor tool is lowered.)
  • the robot moves to the centrifuge and removes one of the "processed" adaptors, creating a "no adaptor” slot in the centrifuge.
  • the "processed" adaptor is placed in a "no adaptor" slot on the machine table.
  • the robot moves an "in process” adaptor to the "no adaptor” slot in the centrifuge, creating a "no adaptor” slot on the. (4 empty adaptor slots will be created in a different row on the table during each cycle. This row of 4 slots will be used to receive processed adaptors from the centrifuge from the next cycle.)
  • the centrifuge is rotated 180° so that the next "processed" adaptor is exposed in the door opening.
  • Steps 1-5 are repeated until the centrifuge contains the 4 adaptors waiting to be processed, and the table has 4 adaptors full of tubes waiting to be returned to the line.
  • the centrifuge is commanded to begin spinning. It will spin for 8 minutes, and will automatically stop.
  • the robot lowers the tube tool so that the tube fingers are available for use. (The adaptor tool is raised as the tube tool is lowered.)
  • a tube (in a puck) arrives at an interface gate from the transport system.
  • the robot notes whether the tube is long or short, then picks up the tube and places it into an available position in "empty adaptor A". By removing a tube, an empty puck is created at he interface gate.
  • the station controller keeps track of the estimated weight of 'adaptor A' and its mate, 'adaptor B'.
  • the gripper sensors can also close on a tube to determine if the tube is 13 mm or 16 mm, which further refines the weight estimate.
  • the robot moves to one of the “processed” adaptors ("processed adaptor A”) and removes a processed tube.
  • the tube is placed in the empty puck at the interface gate, the bar code is read and reported to factory host, and the tube is released back into the transport system.
  • the time to pick up a new tube and replace a processed tube should be about 8 seconds (that is, 7 1/2 tubes per minute "in” and 7 1/2 tubes per minute “out”).
  • Another tube arrives at the interface gate on the transport system.
  • the robot picks up the tube.
  • the robot places the tube into the lighter of the two adaptor pairs.
  • the robot retrieves another "processed” tube from "processed adaptor A' or "processed adaptor B".
  • the tube is placed in the empty puck at the interface gate,
  • Steps 10-15 are repeated until the 4 adaptors that used to be "empty adaptor A”, “empty adaptor B”, etc. are now full of “in process” tubes, both long and short.
  • the adaptors are renamed “in process adaptor A” and “in process adaptor B”, etc.
  • the 64 "processed” tubes (from “processed adaptor A”, “processed adaptor B”, etc.) have been returned to the line.
  • These adaptors are now renamed "empty adaptor A”, “empty adaptor B”, “empty adaptor C” and "empty adaptor D”.
  • Step 16 is now repeated using "empty adaptor A”, “empty adaptor B”, etc. "processed adaptor C”, “processed adaptor D”, etc. When the empty adaptors are full, they are renamed “in process adaptor C”, “in process adaptor D”, etc.
  • the robot moves to one of the "processed" adaptors and removes a processed tube.
  • the tube is placed in the empty puck at the interface gate and released back into the transport system.
  • Step 1 is repeated until all processed tubes have been returned to the transport system.
  • the station will not unload the next batch of centrifuged adaptors until all processed tubes from the previous batch have been returned to the line.
  • a user-defined routine is executed. This allows a 'hook' into custom initialization, such as cycling power to a robot if required to reset the robot.
  • the open/close state of the gripper must be established by gripper sensors.
  • a tube If a tube is in the gripper, it must be manually removed by the operator after some screen prompts. The gripper must be opened in preparation for grabbing the first adaptor or tube.
  • the robot must be homed to establish its initial position.
  • the centrifuge must be homed to establish its initial position.
  • the system must establish the state of all the adaptor slots, both on the table and in the centrifuge. In the centrifuge, it does this by moving to each of the adaptor positions and moving the gripper fingers into a position that will trigger the jam detector if an adaptor is present.
  • Adaptors present on the table are checked by optic sensors. Once the location of all adaptors are known, the operator is shown an image of the machine's derived configuration. The operator can enter correction from an interactive display if there are errors in auto-configuration.
  • the system must 'sign-on' to the factory control package factory host by issuing a SIGNON status message and waiting for a 'startup' command from factory host. It is noted that the initialization includes homing the robot. To ensure safe operation, the order of homing the robot axes must be under user control. For example, it is often required to move the 'z' axis up first (i.e., home 'z' first) before the X or Y axes are moved.
  • a user-defined routine is executed. This allows a 'hook' into custom restart, such as cycling power to a robot if required to reset the robot.
  • the open/close state of the gripper must be established by gripper sensors. If a tube is in the gripper, it must be manually removed by the operator after some screen prompts.
  • the gripper must be opened in preparation for grabbing the first adaptor or tube.
  • the robot must be homed to establish its initial position.
  • the centrifuge must be homed to establish its initial position.
  • the system must establish the state of all the adaptor slots, both on the table and in the centrifuge. It does this by reloading the stored image of the adaptor slots from a disk- based file saved repeatedly during runtime to allow graceful restart.
  • the operator is shown an image of the machine's derived configuration.
  • the operator can enter correction from an interactive display if there are errors in configuration.
  • the system must establish the state of all the tube positions within the adaptors, both on the frame and in the centrifuge. It does this by reloading the stored image of the tube locations from a disk-based file saved repeatedly during runtime to allow graceful restart.
  • the operator initiates the shutdown sequence by hitting the 'shutdown' button on the operator panel.
  • a user-defined routine is executed. This allows a 'hook' into custom shutdown, such as cycling power to a robot if required to reset the robot.
  • the system completes the centrifugation of all tubes in the centrifuge, and all tubes 'in process' in adaptors. However, no new work is accepted. If any new work arrives, the tubes are immediately released through the interface gate without processing. The system calls for empty pucks to return all remaining tubes to the line.
  • the system After all tubes have been returned to the line, the system writes an image of the state of the adaptor slots to disk, to speed up the next days' cold-start.
  • the robot is moved into a 'park' position and deactivated.
  • the centrifuge is locked in a 'park' position and deactivated.
  • factory host is sent an "INACTIVE" message, telling then factory software that the centrifuge system has become inactive.
  • each adaptor slot both on the table and in the centrifuge, must be known.
  • the slot categories are:
  • Slot has an empty or partially full adaptor, waiting to be filled with new work. Slot has no adaptor, and can accommodate an adaptor.
  • b)Each cavity in the adaptor is marked with the following information: Cavity has a long, 13 mm diameter tube Cavity has a long, 16 mm diameter tube
  • Cavity has a short, 13 mm diameter tube Cavity has a short, 16 mm diameter tube Cavity has no tube.
  • the tube-type must be recorded in order to ensure that the system stays within the weight-imbalance requirements.
  • the adaptor is marked 'present' in the station's database, and the robot will not need to verify the adaptor's presence until the next interruption of the door interlocks or the next power-down. Auto-calibration of robotic points
  • the system must be able to automatically learn the location of various sites within the work cell if they are moved slightly out of alignment. While point teaching may be required during initial installation of the machine, the typical operator has no ability to re-teach robotic points.
  • a sensor-based system must be devised to allow the robot to learn the following points if they move slightly from their factory installed locations: The centrifuge adaptor loading point. The interface gate pick-up point. The interface gate drop-off point. The points for each of the adaptor slots on the frame. The expected sensor to use will be the jam detector. By jamming, moving slightly, and checking again to see if the jam went away, the robot can 'feel' its way into the adaptor slots. Also, the location of the cavities within the adaptors must be automatically known. This will presumably be mathematically known from the origin of the adaptors in their respective slots. If the points have been grossly moved, such that auto-calibration fails, the system software will provide a way to manually move the robot, probably with the robot teach pendant.
  • the operator interface physically consists of a color CRT screen, a custom control panel with some buttons and lights, and a stack light. Most of the detailed error messages and more complicated interactions (such as robotic homing instructions) will be displayed via the CRT.
  • the purpose of the control panel is to provide a simple, "non-intimidating" interface for simple operator interactions, such as "start” and "pause”.
  • the stack light provides a quick visual indicator of proper or improper operation that is easily visible from a distance. 6.1) Operator interface -- Control panel
  • the control panel consists of the following buttons, each of which has a computer- controlled light attached: door interlock bypass on/off key-switch moving power-on button (Lit as soon as power is applied) moving power-off button main power on/off key-switch e-stop button (Lit when the button is depressed, that is, lit when activated).
  • door interlock bypass on/off key-switch moving power-on button (Lit as soon as power is applied) moving power-off button main power on/off key-switch e-stop button (Lit when the button is depressed, that is, lit when activated).
  • the operator turns the 'main power' key switch to the 'on' position.
  • the computer and logic receive power, and the computer boots up. When the computer has control, it will do some equipment checks, and instructs the operator to hit the 'moving power' button, to supply power to the centrifuge, the interface gate, and the robot.
  • the computer then begins flashing the 'initialize' button on the CRT (using the mouse).
  • the system will perform the initialization sequence detailed in section 3.3.
  • the initialize light is turned off, and the "start” button begins to flash on the CRT.
  • Hitting the "start button” causes the machine to begin normal operation, as described in section 3.0.
  • the “start” button light stops flashing and the light becomes steady.
  • the operator can hit the "pause” button on the CRT to stop the automatic program sequence.
  • the “start” light turns off, and the "pause” light begins to flash.
  • a display appears on the CRT allowing the control program to be terminated.
  • a "manual mode” can be entered which allows manual control of the machine from the CRT. This could be used, for example, to release a broken tube from the gripper, or move the robot to a position to allow operator access. If the machine has been placed into manual mode, it must be “initialized” again from the control panel. However, if the automatic mode has never been interrupted, the "pause” can be canceled by hitting the "start” button. This causes the 'pause” light to turn off and the "start” light to be lit. When the shift is over, the "shutdown” button on the CRT can be hit. This tells the machine that it should finish the work in progress, and then enter the orderly shutdown described in section 3.5.
  • shutdown will flash until shutdown is complete, at which time the “shutdown” light will be steadily lit, and the “start” light will be turned off.
  • shutdown is complete, moving power and the main computer power can be safely turned off, or the "initialize” button can be hit to begin a re-start.
  • the "partial load” button on the CRT can be hit. instead of waiting for a full adaptor, the system will load the adaptor as soon as possible. If the system has separate 'long' and 'short' adaptors, there will be two separate "partial load” buttons, one for each tube type. To stop the robot and centrifuge in an emergency, the 'e-stop' button is pressed. The power to the robot and centrifuge will be turned off, but the computer will remain live so recovery instructions can be given to the operator.
  • Operator interface - CRT display Operator interface - CRT display - Main runtime screen
  • the CRT shows a pictorial representation of the adaptor slots, with the status of the slot displayed in a color code, such as:
  • the screen image has the following letter identification inside the colored areas: "I” - in process "P” - processed "E” - empty
  • the runtime screen has a message area used to inform the operator of relevant information. For example, after the machine has been powered-up, the message area will say "Hit INITIALIZE button on CRT to initialize the machine". This will help an operator through the start-up and shutdown sequence expected by the machine.
  • the runtime screen also has an error message area. This area is reserved for error recovery information. A list of errors are given in section 9.
  • a 'startup' message has been received from the factory host.
  • the station ID as indicated to the factory host.
  • the revision level of the software being run The logic state of the interface gate: waiting for product waiting to release accumulator tube on robot acknowledge product released from accumulator waiting to release read 1 tube on robot command
  • the logic state of the robot waiting for product processing new tube returning old tube to the line loading or unloading adaptors into or out of the centrifuge. If the operator hits the 'configure' button' on the runtime screen, the operator can access the configuration screen.
  • a 'manual mode' button appears on the runtime screen. Hitting the 'manual mode' button causes the system to enter a mode where its components can be individually controlled by the operator. See section 6.2.3.
  • Operator interface - CRT display - Configuration screen There are a variety of parameters that affect the operation of the machine that can be adjusted by the operator. These parameters are displayed on the configuration screen. To access this screen, the 'configure' button on the runtime screen is hit. Optionally, the operator can be prompted to enter a password before the configuration screen is activated. The following parameters can be accessed and changed:
  • Centrifuge spin time and G force Name of all taught points, and their world coordinates.
  • the 'height offset' is the distance above a taught point the robot must move in order to clear the point with a tube in the gripper.
  • factory host character string interaction should be displayed on screen to the operator in a factory host message window.
  • Operator interface - CRT display - Manual control screen
  • the manual control screen allows the operator to access to the system in a manual mode. This mode is entered by hitting the "manual mode" button on the runtime screen, which is only available when the system is in a 'pause' state (i.e., the operator has hit 'pause' on the CRT).
  • the following things can be controlled in manual mode by hitting buttons on the manual mode screen: the robot the centrifuge door the centrifuge rotor position the gripper pneumatic lines (open/close) all output bits, including those that control the interface gate
  • the following things can be monitored in manual mode from the manual mode screen: the robot position on all axes in physical units the state of all I/O bits the gripper sensor bits: jam detect, full open, full close, close to 13 mm, close to 16 mm
  • the station cannot continue without operator intervention.
  • the GREEN light is turned off if the RED light is on.
  • YELLOW The station needs attention, such as clearing a jam at the interface gate, but the station can continue for awhile unattended.
  • Interface to factory host The station communicates to factory host via an RS232 serial line from the station controller. Communication is bi-directional. A list of supported commands are: Start command Pause Continue
  • the station will have safety doors to prevent the operator from reaching into the station.
  • the doors will have interlock switches, so the station can prevent operator access without disabling the automatic cycle.. Every time the system resumes operation following the opening of the interlocked doors, the following operation will occur to promote proper tube tracking:
  • the robot will make a sideways motion, expecting to run into the walls of the adaptor and generate a deliberate 'jam detect'. If the system fails to detect a collision with the wall of the adaptor, it is assumed that the adaptor has been moved, and the current adaptor slot has no adaptor. This will generate an error message, prompting the operator to re-initialize the station.
  • An emergency stop button (3 locations) is placed on the main frame of the machine. The button will be not be lit under normal operation. When depressed, the light will go on and all power and stored energy (compressed air) will be deactivated within 2 seconds. The robot and the centrifuge will stop moving. The computer will remain powered.
  • the station will maintain an up-to-date, non-volatile record of the status of the machine on the hard drive.
  • the non-volatile status file will be retrieved and used to facilitate a graceful re-start, with minimal operator action.
  • the jam sensor If the tube can't fit in an adaptor cavity, the jam will be detected by the jam sensor. In this case:
  • the robot moves 'full up' in z, to the 'z' limit.
  • the red stack light is turned on.
  • the operator is told to hit 'START' to restart the machine.
  • the tube is manually removed from the robot gripper by the operator and placed back on the transport system in an empty puck. The machine resumes normal operation.
  • the jam sensor If an adaptor can't fit in an adaptor slot, the jam will be detected by the jam sensor. In this case: The robot moves 'full up' in z, to the 'z' limit.
  • the red stack light is turned on.
  • the operator is told to hit 'START' to restart the machine.
  • the operator is told to clear the jam via screen messages.
  • the adaptor is manually removed from the robot gripper by the operator and placed back on the frame in an empty slot, as shown on the error recovery screen. The machine resumes normal operation.
  • the jam will be detected by the jam sensor.
  • the robot moves 'full up' in z, to the 'z' limit.
  • the red stack light is turned on.
  • the tube is manually removed from the robot gripper by the operator and placed back in an empty puck in the interface gate.
  • the station On a 'NOREAD' on a tube bar code while returning a tube to the line, the station will: Send factory host a 'NOREAD' message, if desired by lab personnel. Release the tube back into the transport system.
  • the sensors will indicate a tube is present at the pickup point, but when the robot goes to acquire the tube, its gripper sensors fail to detect a tube.
  • the robot opens its gripper.
  • the robot moves 'full up' in z, to the 'z' limit.
  • the red stack light is turned on.
  • the tooling for tube handling consists of a single set of robotic fingers mounted on the center line of the Z axis of the robot, and located in front of the adaptor tool.
  • the tube tool is held in position vertically by a pneumatic cylinder.
  • the fingers are pneumatically driven.
  • the gripper body is mounted on a rotary ball joint called a 'Unicoupler TM', model 4418, Robotic Accessories, Tipp City, Ohio, USA, that can comply in all directions. This gives the tool the ability to safely react to jam conditions.
  • the tool has a sensor to detect displacement away from center, so the station knows of jams.
  • Springs on the tool return the tool to a centered position; stiffer springs may be needed if the weight of the tool is more than the factory-provided springs can accomodate. Springs on the fingers keep the fingers closed in the event of a loss of air pressure. This ensures a tube will not be dropped if the air pressure is lost.
  • the tooling for adaptor handling consists of a single set of robotic fingers mounted on the center line of the Z axis of the robot, but behind the tube tool.
  • the adaptor tool is also held in position vertically by a pneumatic cylinder.
  • a tool is in a "working" position when it is lowered by its pneumatic cylinder.
  • the tube tool is lowered the adaptor toll is raised, and vice versa.
  • the adaptor fingers are pneumatically driven.
  • the gripper body is mounted on a rotary ball joint called a 'Unicoupler TM', that can comply in all directions. This gives the tool the ability to safely react to jam conditions.
  • the tool has a sensor to detect displacement away from center, so the station knows of jams.
  • Springs on the tool return the tool to a centered position. Springs on the fingers keep the fingers open, pressed against the adaptor handles, in the event of a loss of air pressure. This ensures an adaptor will not be dropped if the air pressure is lost.
  • the tooling will be equipped with the following sensors:
  • Tube grip fully closed Tube fingers closed on 16 mm
  • Robotic tooling Tooling 'defaults'
  • the tube gripper When power fails, the tube gripper enters a spring-loaded 'CLOSED' position. This ensures that a tube will not be dropped.
  • the adaptor gripper When power fails, the adaptor gripper enters a spring-loaded 'OPENED' position. This is because the adaptor fingers are brought inside the adaptor, and then opened to engage the handles of the adaptor. By having the adaptor fingers fail in an open position, the station ensures that an adaptor will not be dropped.
  • the tool pneumatic cylinders When power fails, the tool pneumatic cylinders will loose air pressure and allow the tools to lower, but since the line air pressure will be 0 psig, no downward force can be applied to anything that might be located under the tooling.
  • the escapement mechanism is used to capture an individual tube from the transport system and determine its bar code when returning the tube to the line.
  • the escapement consists of an upstream stop, an accumulator stop, and a downstream/read stop.
  • the 'stops' are pneumatic cylinders that stop the pucks which contain the tubes. When the pucks are stopped by the cylinder rod, the conveyor belt continues to move, slipping under the puck. When the puck is stopped, the robot can pick a tube out of the pick up point, or drop a tube into the 'read position' drop-off point.
  • the 'downstream/read' stop is slightly more complex. At that stop, a rubber wheel touches the puck, rotating it in front of a bar code reader so the bar code can be determined and reported to factory host before the tube is released back on to the line.
  • the empty puck is released from the 'accumulator' stop and held in the 'read' stop. After dropping off the 'pick up tube' into an empty adaptor cavity, the robot will pick a 'processed tube' and place it in the empty puck at the read stop. A 'downstream bar code reader' is then used to read the bar code of the processed tube, in order to inform factory host. While the read stop is used to hold the previous empty puck, the 'accumulator' stop is free to acquire the next 'in-process' tube in preparation for the next pick/place cycle. 12.0) Input / Output signals
  • a tube is at accumulator (tube may be of any type, including too small or too tall) Start button pressed
  • Robot Y homing limit read-back Robot Z homing limit read-back 19-32. Future expansion bits. Digital bit Output: Upstream stop
  • Tube rotator motor power Stack light ⁇ RED
  • the two bits comprising the tool rotator control. Two bits are required to ensure tool does not move in the event of power fail.
  • Tube bar code reader at downstream
  • Robot points will be taught manually, using the controller 'teach' package.
  • the robot can be moved by using screen-based software, or can be moved via the robotic teach pendant.
  • a 'height offset' is the distance above a taught point the robot must move in order to clear the point with a tube in the gripper. Offsets are specified using the configuration package. Handling of unsolicited events
  • Centrifuge messages There are a variety of unsolicited status events reported by the robot and the centrifuge controller that must be handled by the centrifuge controller software. Centrifuge messages:
  • Running speed, run time, and rotor position sent every second.
  • Door, door latch, and door motor status sent every two seconds.
  • Robot messages Illegal command Point data destroyed Program destroyed
  • A) machine control a) Low level hardware control (bits and serial ports): i) serial I/O
  • robot bit I/O such as jam detector ii) centrifuge
  • centrifuge command set and communications driver iii) interface gate iv) bar code reader v) supervisory communication (factory host) operator interface
  • system services a) configuration b) robot teach c) calibration d) diagnostic e) help

Abstract

L'invention concerne un dispositif automatisé permettant de charger une centrifugeuse dans lequel des tubes sont amenés à la centrifugeuse via un système d'acheminement automatisé. Ce dispositif comporte une zone de transbordement destinée aux adaptateurs de tubes, un outil à double fonction muni d'un dispositif de préhension de tubes qui amène les tubes d'un dispositif de transport aux adaptateurs de la centrifugeuse ainsi qu'un dispositif de préhension des adaptateurs qui amène les adaptateurs de tubes vers la centrifugeuse et en provenance de la centrifugeuse.
PCT/US1998/027283 1998-12-22 1998-12-22 Dispositif automatise permettant de charger une centrifugeuse WO2000038046A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
PCT/US1998/027283 WO2000038046A1 (fr) 1998-12-22 1998-12-22 Dispositif automatise permettant de charger une centrifugeuse
CA002356270A CA2356270A1 (fr) 1998-12-22 1998-12-22 Dispositif automatise permettant de charger une centrifugeuse
EP98966042A EP1145104A4 (fr) 1998-12-22 1998-12-22 Dispositif automatise permettant de charger une centrifugeuse
AU22030/99A AU2203099A (en) 1998-12-22 1998-12-22 Automated centrifuge loading device
JP2000590038A JP4382990B2 (ja) 1998-12-22 1998-12-22 遠心機への自動化されたローディング装置

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1998/027283 WO2000038046A1 (fr) 1998-12-22 1998-12-22 Dispositif automatise permettant de charger une centrifugeuse

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WO2000038046A1 true WO2000038046A1 (fr) 2000-06-29

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JP (1) JP4382990B2 (fr)
AU (1) AU2203099A (fr)
CA (1) CA2356270A1 (fr)
WO (1) WO2000038046A1 (fr)

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WO2007039524A2 (fr) * 2005-09-26 2007-04-12 Qiagen Gmbh Appareil pour traiter un materiau biologique
EP2087934A1 (fr) 2008-02-07 2009-08-12 Qiagen GmbH Procédé et dispositif destinés au traitement automatisé d'un échantillon
FR2932272A1 (fr) * 2008-06-09 2009-12-11 Stago Diagnostica Dispositif de prehension d'une cuvette de reaction
ITRM20090417A1 (it) * 2009-08-03 2011-02-04 Fond Istituto Italiano Di Tecnologia Sistema robotico di laboratorio.
DE102011054766A1 (de) * 2011-10-24 2013-04-25 Andreas Hettich Gmbh & Co. Kg Verfahren zum automatischen Beladen einer Zentrifuge mit Probenbehältern
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US8840848B2 (en) 2010-07-23 2014-09-23 Beckman Coulter, Inc. System and method including analytical units
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EP2295983A1 (fr) 2005-09-26 2011-03-16 Qiagen GmbH Dispositif pour le traitement des matériau biologique
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US20130190161A1 (en) * 2012-01-25 2013-07-25 BioNex Solutions, Inc. Vibration Response and Tuning of a Center of Mass/Gravity of a Centrifuge
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US11241788B2 (en) 2016-07-14 2022-02-08 Siemens Healthcare Diagnostics Inc. Methods and apparatus for dynamic position adjustments of a robot gripper based on sample rack imaging data
DE102019130524A1 (de) * 2019-11-12 2021-05-12 Andreas Hettich Gmbh & Co. Kg Zentrifuge zur automatischen Beladung
CN111536732A (zh) * 2020-07-10 2020-08-14 基点生物科技(成都)有限公司 一种生物样本深低温挑管工作站
CN111536732B (zh) * 2020-07-10 2020-09-29 基点生物科技(成都)有限公司 一种生物样本深低温挑管工作站

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CA2356270A1 (fr) 2000-06-29
JP4382990B2 (ja) 2009-12-16
AU2203099A (en) 2000-07-12
EP1145104A1 (fr) 2001-10-17
EP1145104A4 (fr) 2007-12-05

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