Robotic system for sorting sample tubes

• US 10,031,149 B2
• Filed: 12/22/2016
• Issued: 07/24/2018
• Est. Priority Date: 12/31/2015
• Status: Active Grant

• Current Assignee: Myriad Women's Health Incorporated (Myriad Genetics, Inc.)
• Original Assignee: Counsyl Incorporated (Myriad Genetics, Inc.)
• Inventors: Lapham, Kyle, Nash, Ethan, Turner, Peter, Haas, Kevin, Wong, Christopher
• Primary Examiner(s): Randazzo, Thomas
• Application Number:
  US15/388,193
• Publication Number:
  US 20170190056A1
• Time in Patent Office: 579 Days
• CPC Class Codes: B25J 15/0658 Pneumatic type, e.g. air blast or overpressure
• CPC Class Codes: B25J 19/023 including video camera means
• CPC Class Codes: B25J 9/042 comprising an articulated arm
• CPC Class Codes: G01N 2035/00851 process control parameters
• CPC Class Codes: G01N 2035/0493 Locating samples; identifying different tube sizes
• CPC Class Codes: G01N 35/00732 Identification of carriers, materials or components in automatic analysers
• CPC Class Codes: G01N 35/0099 comprising robots or similar manipulators robots per se B25J

Abstract

A robotic system is provided for accurately and quickly sorting sample tubes within or between sample tube racks.

Claims

1. A device for sorting sample tubes, comprising:

a robotic assembly, comprising;

a base that comprises a vertical lift shaft;

a horizontal robotic arm comprising a proximal end and a distal end, wherein the proximal end of the robotic arm is configured to be lifted vertically by the lift shaft and is configured for pivotal movement around the base; and

end of arm tooling at the distal end of the robotic arm that is configured to pick up and hold a sample tube when a vacuum is applied and to expel and deposit the sample tube into a designated slot in a tube rack when air is expelled through the tooling;

a vacuum source that is fluidly connected to the end of arm tooling and configured to pull a vacuum through the tooling;

an air source that is fluidly connected to the end of arm tooling and configured to expel air through the tooling;

a horizontal stage underneath the robotic arm and configured to hold a plurality of tube racks in a position from which the end of arm tooling may pick up and deposit sample tubes;

a vision system that is configured to record coded information on sample tubes and on the sides of tube racks in the device and to convey the coded information to a control system; and

a control system that tracks coded information provided by the vision system, and that controls the robotic assembly to pick up a coded sample tube from a first location in a first tube rack and to deposit the sample tube in a second location in a second tube rack, wherein the first tube rack and the second tube rack are the same or different,

wherein the end of arm tooling comprises;

an open column comprising a top and a bottom, extending through at least a portion of the interior of the tooling and through which a suction force is applied via the vacuum source and air is expelled via the air source;

a first fitting that is connected to the top of the column and that is fluidly connected to the vacuum source and to the air source;

an adaptor at the bottom of the column that is of a dimension suitable to connect with and retain the top of a sample tube by suction when a vacuum is applied;

an open chamber comprising a top and a bottom, located within an upper portion of the tooling, wherein the chamber surrounds the first fitting; and

a second fitting that is fluidly connected to the air source and through which air passes into the top of the chamber when air pressure is applied,

wherein the bottom of the chamber comprises a plurality of openings through which air passes when air pressure is applied, said openings extending through a lower portion of the tooling and configured to expel air through the bottom of the tooling when the device is in operation.

2. A device according to claim 1, wherein the robotic arm is a Selective Compliance Assembly Robot Arm (SCARA), comprising:

a first horizontal arm segment comprising;

a first proximal end that is configured to be lifted by the lift shaft and is configured for pivotal movement around the base, and a first distal end;

a second horizontal arm segment comprising;

a second proximal end that is rotatably coupled to the first distal end, and a second distal end;

a third horizontal arm segment comprising;

a third proximal end that is rotatably coupled to the second distal end, and a third distal end; and

the end of arm tooling connected to the third distal end.

3. A device according to claim 1, wherein the vacuum source and air source run simultaneously, wherein a vacuum is pulled through the end of arm tooling through the open column when a sample tube is picked up, wherein the vacuum is shut off when the sample tube is above a desired location in a tube rack, and wherein air is expelled briefly through the column after the vacuum is shut off, depositing the sample tube into the desired location in the tube rack.

4. A device according to claim 1, wherein the coded information comprises one-dimensional, two-dimensional, or three-dimensional bar codes on sample tubes and/or on tube racks.

5. A device according to claim 1, comprising at least one sample tube rack that comprises sample tubes, and wherein each sample tube in the rack comprises unique coded information on the bottom of the tube, wherein the tube rack comprises openings such that the coded information on the sample tubes is viewable through the bottom of the tube rack, wherein the vision system is configured beneath the bottom of the tube rack, and wherein the vision system records the locations of coded information when the tube rack is positioned above the vision system.

6. A device according to claim 1, comprising at least one sample tube rack that comprises unique coded information on at least one side, wherein the sample tube rack and the vision system are configured such that the coded information is recorded by the vision system when the tube rack is positioned above the vision system.

7. A device according to claim 1, comprising a sample tube rack comprising a plurality of sample tubes to be sorted, wherein each sample tube comprises a top and a bottom, wherein the top of the tube is configured and of a dimension such that the tube will be held by suction when picked up by the end of arm tooling of the robotic arm when a vacuum is applied therethrough, and wherein each sample tube comprises unique coded information on the bottom of the tube, wherein the vision system is configured to read and convey information about the locations of the coded information to the control system before and after sorting to desired locations in one or more tube rack.

8. A device according to claim 1, wherein the vacuum source and the air source are produced with a vacuum pump that creates a vacuum through the venturi effect, wherein a vacuum is produced when compressed air flows through a venturi, and wherein positive air pressure is produced when the flow of compressed air is terminated.

9. A device according to claim 1, further comprising a tube sensor that senses whether a sample tube has been picked up by the end of arm tooling when the vacuum is applied.

10. A device according to claim 1, wherein the stage is in the form of a deck or a track on a conveyer belt.

11. A device according to claim 1, wherein the device is configured to sort 20 or more sample tubes per minute.

12. A device according to claim 1, further comprising a plurality of sample tubes in one or more tube racks, wherein each sample tube comprises a unique identification code that may be read by the vision system and conveyed to the control system.

13. A device according to claim 12, comprising a plurality of tube racks, wherein each tube rack comprises a unique identification code that may be read by the vision system and conveyed to the control system.

14. A device according to claim 1, wherein said plurality of openings is a ring of openings around the open column that extends through the interior of the tooling and are configured to expel air around a sample tube, preventing interference from surrounding tubes in the tube rack, if any, when the robotic arm picks up the sample tube.

15. A device according to claim 14, wherein the ring of openings is disposed in a substantially circular configuration around the open column, and wherein the ring of openings is configured to expel air in a substantially circular configuration around a sample tube.

16. A device according to claim 1, wherein the vision system comprises three vision camera systems that are aligned to read coded information from a sample tube or sample tube rack when it is located in a position above the vision system.

17. A device according to claim 16, comprising a vision system under each location on the stage on which a sample tube rack may be positioned.

18. A device according to claim 16, comprising a single vision system, and comprising a track to move sample tube racks into position above the vision system for reading of coded information on sample tubes and/or on the tube rack.

19. A device according to claim 1, wherein the control system comprises a laboratory information management system (LIMS).

20. A method for sorting sample tubes, comprising a device according to claim 1, and further comprising at least one sample tube rack that comprises sample tubes, wherein a sample tube in a first location is sorted to a second location on the same or different sample tube rack, said method comprising:

(a) moving the robotic arm via the control system to configure the end of arm tooling above the first location,

(b) applying a vacuum via the vacuum source, thereby providing a suction force through the end of arm tooling, wherein the sample tube is picked up from the first location and retained by the end of arm tooling via vacuum suction,

(c) moving the robotic arm via the control system to configure the end of arm tooling with the retained sample tube above the second location,

(d) terminating the vacuum and applying positive air pressure through the end of arm tooling to expel the sample tube in the second location, and

(e) determining the presence of the sample tube in the first location and/or second location by reading of coded information on the sample tube by the vision system.

21. A method according to claim 20, wherein the control system lowers the robotic arm before the sample tube is picked up, raises the robotic arm when it is moved to configure the end of arm tooling above the second location, and lowers the robotic arm before the sample tube is expelled in the second location.

22. A method according to claim 20, wherein the robotic arm is a SCARA, comprising:

a first horizontal arm segment comprising;

a first proximal end that is configured to be lifted by the lift shaft and is configured for pivotal movement around the base, and a first distal end;

a second horizontal arm segment comprising;

a second proximal end that is rotatably coupled to the first distal end, and a second distal end;

a third horizontal arm segment comprising;

a third proximal end that is rotatably coupled to the second distal end, and a third distal end; and

the end of arm tooling connected to the third distal end.

23. A method according to claim 20, wherein the vacuum source and air source run simultaneously, wherein a vacuum is pulled through the end of arm tooling through the open column when a sample tube is picked up, wherein the vacuum is shut off when the sample tube is above a desired location in a tube rack, and wherein air is expelled briefly through the column after the vacuum is shut off, depositing the sample tube into the desired location in the tube rack.

24. A method according to claim 20, wherein the vacuum source and the air source are produced with a vacuum pump that creates a vacuum through the venturi effect, wherein a vacuum is produced when compressed air flows through a venturi, providing a suction force whereby the sample tube is picked up from the first location, and wherein positive air pressure is produced when the flow of compressed air is terminated, thereby expelling the sample tube in the second location.

25. A method according to claim 20, wherein the coded information comprises one-dimensional, two-dimensional, or three-dimensional bar codes on sample tubes and/or on sample racks.

26. A method according to claim 20, wherein each sample tube in the tube rack comprises unique coded information on the bottom of the tube, wherein the tube rack comprises openings such that the coded information on the sample tubes is viewable through the bottom of the tube rack, wherein the vision system is configured beneath the bottom of the tube rack, and wherein the vision system records the locations of coded information when the tube rack is positioned above the vision system.

27. A method according to claim 20, wherein each sample tube rack comprises unique coded information on at least one side, wherein the sample tube rack and the vision system are configured such that the coded information is recorded by the vision system when the tube rack is positioned above the vision system.

28. A method according to claim 20, wherein the vision system comprises three vision camera systems that are aligned to read coded information from a sample tube or sample tube rack when it is located in a position above the vision system.

29. A method according to claim 20, wherein the device further comprises a tube sensor that senses whether a sample tube has been picked up by the end of arm tooling when the vacuum is applied.

30. A method according to claim 20, wherein 20 or more sample tubes per minute are sorted.

31. A method according to claim 20, wherein said plurality of openings is a ring of openings around the open column that extends through the interior of the tooling, wherein air is expelled around a sample tube, preventing interference from surrounding tubes in the tube rack, if any, when the robotic arm picks up the sample tube.

32. A method according to claim 31, wherein the ring of openings is disposed in a substantially circular configuration about the open column, and wherein air is expelled in a substantially circular configuration around the sample tube.