Modular and Scalable Apparatus for Process Automation

• US 20070123999A1
• Filed: 11/06/2006
• Published: 05/31/2007
• Est. Priority Date: 11/07/2005
• Status: Active Grant

• Current Assignee: Charles Boone, Sasan Raghibizadeh
• Original Assignee: Charles Boone, Sasan Raghibizadeh
• Inventors: BOONE, CHARLES, RAGHIBIZADEH, SASAN
• Granted Patent: US 8,150,548 B2
• Time in Patent Office: Days
• US Class Current: 700/1
• CPC Class Codes: A61L 2/24 Apparatus using programmed or automatic operation
• CPC Class Codes: B01L 13/02 for receptacle or instruments
• CPC Class Codes: B01L 2300/0819 Microarrays; Biochips
• CPC Class Codes: B01L 9/52 Supports specially adapted for flat sample carriers, e.g. for plates, slides, chips
• CPC Class Codes: B01L 9/543 for disposable pipette tips, e.g. racks or cassettes
• CPC Class Codes: B01L 9/547 for dispensing pins
• CPC Class Codes: G01N 2035/00326 Analysers with modular structure
• CPC Class Codes: G01N 2035/042 moved independently, e.g. by fork manipulator
• CPC Class Codes: G01N 2035/1037 Using surface tension, e.g. pins or wires
• CPC Class Codes: G01N 35/0099 comprising robots or similar manipulators robots per se B25J
• CPC Class Codes: G01N 35/1011 Control of the position or alignment of the transfer device
• CPC Class Codes: G01N 35/1074 arranged in a two-dimensional array

Abstract

An apparatus comprises one or more functional modules, conveyers, tools, and sub-modules. A functional module comprises at least one general-purpose tool interface and a device for moving the tool interface in one or more directions. A functional module may include a rotary positioning device, which rotates the tool interface about an axis. At least one functional module is used in an apparatus, and at least one tool is attached to the tool interface of a functional module. A tool performs a specific operation on a work sample. For example, a gripping tool is used to hold and release a sample container, or a scanning tool is used to scan multiple work samples. At least one conveyer is used to transfer work sample containers from one functional module to another. In addition to functional modules, conveyers, and tools, an apparatus may include one or more sub-modules. A sub-module can be a shelf for stacking sample containers, a carousel, a wash tower for sterilizing and cleaning a tool, a centrifuge device, a shaker, an incubator, a plate sealer, etc. A functional module uses one or more tools and one or more sub-modules to complete an operation. A base is provided for installing and integrating the functional modules, conveyers, tools, and sub-modules of an apparatus. At least one Computer Processing Unit (CPU) with a Human-Machine Interface (HMI) is used to control, synchronize, and integrate the operation of functional modules, conveyers, tools, and sub-modules and to provide a Graphical User Interface (GUI) through which the user can define and run a procedure.

Claims

1. An apparatus, comprising:

a plurality of functional modules, each functional module comprising a tool interface capable of moving independently and along a first and second axes, each tool interface to interface with a tool to operate on work samples;

a conveyer to transfer work samples from one functional module to another, the conveyor capable of movement along a third axis perpendicular to the first and second axes; and

a controller for coordinating the operation of the functional modules and the conveyer;

wherein the functional modules are substantially identical.

2. The apparatus of claim 1, wherein the third axis is a horizontal axis and the second axis is a vertical axis, thereby taking advantage of vertical space and minimizing apparatus footprint.

3. The apparatus of claim 1, further comprising:

a first tool to interface with a first functional module of the plurality of functional modules, the first tool comprising a gripper, a pipettor, a pinhead, a bar-code reader, a charge-coupled device camera, a re-arrayer pinhead, a magnetic pinhead, or a micro-arraying print-head.

4. The apparatus of claim 1, further comprising:

a first sub-module to cooperatively operate on work samples with the first functional module.

5. The apparatus of claim 4, the first sub-module comprising a stacker, a carousel, a stacker with incubator, a carousel with incubator, an incubator, a wash tower, a shaker, a centrifuge, a vacuum filtration manifold, a plate reader, a slide scanner, a gel reader, a magnetic stirrer, a piercer, a thermocycler, a plate reader, or a reagent library.

6. The apparatus of claim 4, wherein the conveyer comprises a tray, the tray comprising at least one sample plate holder, the sample plate holder comprising locating pins and one or more locking actuators for locating and locking a sample plate on the tray.

7. An apparatus, comprising:

a plurality of devices arranged vertically, each device to complete one step of a plurality of cleaning or sterilization steps of a tool;

the apparatus to serve in an automation apparatus, whereby the vertical arrangement of the plurality of devices takes advantage of vertical space and minimizes apparatus footprint.

8. The apparatus of claim 7, wherein a device of the plurality of devices is a circular wash station, the circular wash station to hold a wash solution and capable of automatic draining, rinsing and refilling.

9. The apparatus of claim 7, wherein a device of the plurality of devices is a circular brush station comprising a rotating brush, the rotating brush to submerge in a wash solution during operation of the circular brush station.

10. The apparatus of claim 7, wherein a device of the plurality of devices is an ultrasonic cleaner, the ultrasonic cleaner to hold a wash solution and generate high-frequency mechanical waves in the wash solution for cleaning and sterilization.

11. The apparatus of claim 7, wherein a device of the plurality of devices is a wash basin, the wash basin comprising a container to hold a wash solution.

12. The apparatus of claim 7, wherein a device of the plurality of devices is a dryer capable of generating a cold or warm flow of air for drying.

13. The apparatus of claim 7, wherein a device of the plurality of devices is a pre-wetting station comprising a lidded container and a lid lifting mechanism, the lidded container to hold a sterilized solution and to pre-wet a replicating pinhead before replication.

14. An apparatus, comprising:

a circular brush for cleaning a tool surface;

a container to hold the circular brush and a wash solution; and

a rotating mechanism to rotate the container and the circular brush with respect to the tool, thereby cleaning the tool surface.

15. An apparatus, comprising:

a circular or oval container to hold a wash solution for washing a tool surface;

a drain valve to allow draining of the wash solution from a bottom of the container; and

a tangential side port to fill the container or rinse the surface of the container after a drain and before a refill;

thereby allowing for automatic drain, rinse and refill of the apparatus.

16. The apparatus of claim 15, further comprising:

a center piece, the center piece to improve draining speed when vacuum is applied to the drain valve.

17. The apparatus of claim 16, further comprising:

a ball inside the container, the ball to further improve draining speed when vacuum is applied to the drain valve.

18. An apparatus, comprising:

a plurality of bushings arranged and held together in an array; and

a plurality of pins residing in the plurality of bushings, the plurality of pins for transferring samples;

wherein manufacturing tolerances for inside diameters of the bushings and outside diameters of the pins substantially match, thereby allowing the pins to slide freely within the bushings.

19. The apparatus of claim 18, further comprising:

a plate comprising a plurality of holes in which the plurality of bushings reside and whereby the plurality of bushings are held together in the array.

20. An apparatus, comprising:

a pin array comprising rows and columns of pins, the pins for transferring samples; and

an actuation element capable of moving across the pin array and comprising a plurality of actuators, the actuators to cause the pins to move;

wherein movement of the actuation element across the pin array allows for the pins to be separately indexable.

21. The apparatus of claim 20, wherein movement of the actuation element is along the direction of the rows and the actuators are arranged linearly and in parallel to the columns.

22. The apparatus of claim 20, wherein the pins float freely inside bushings, allowing the pins to float up inside the bushings when the pins touch a solid sample or work surface as the bushing are pushed down by the actuators, thereby preventing damage to the sample or work surface.

23. An apparatus, comprising:

a pin array comprising rows and columns of pins floating freely inside bushings, the pins for transferring samples; and

an actuation element comprising a plurality of actuators, the actuators to cause the pins to move;

wherein the pins float up inside the bushings when the pins touch a solid sample or work surface as the bushings are pushed down by the actuators, thereby preventing damage to the sample or work surface.