Robotic system and method for transport of materials with minimization of footprint size

• US 6,988,518 B2
• Filed: 06/02/2004
• Issued: 01/24/2006
• Est. Priority Date: 06/02/2004
• Status: Active Grant

• Current Assignee: Automation Techniques, Inc.
• Original Assignee: Automation Techniques, Inc.
• Inventors: Rackers, Kevin J.
• Primary Examiner(s): Walczak, David J.
• Assistant Examiner(s): DEVORE, PETER T
• Application Number:
  US10/858,700
• Publication Number:
  US 20050268987A1
• Time in Patent Office: 601 Days
• Field of Search: 141/1, 141/130, 422/65, 422/67, 422/100, 738/641.1, 738/641.6, 738/641.7, 738/642.4, 738/642.5
• US Class Current: 141/130
• CPC Class Codes: B01J 2219/00283 Reactor vessels with top opening
• CPC Class Codes: B01J 2219/00308 interchangeably mounted in racks or blocks
• CPC Class Codes: B01J 2219/0031 the racks or blocks being mounted in stacked arrangements
• CPC Class Codes: B01J 2219/0036 Nozzles
• CPC Class Codes: B01J 2219/00364 Pipettes
• CPC Class Codes: B01J 2219/00691 using robots
• CPC Class Codes: G01N 2035/0498 Drawers used as storage or dispensing means for vessels or cuvettes
• CPC Class Codes: G01N 35/028 having reaction cells in the form of microtitration plates
• CPC Class Codes: G01N 35/109 with two horizontal degrees of freedom

Abstract

A robotic system and method that provides three axes of movement to couple a robotic arm with a desired target for movement of materials, including but not limited to fluids. The robotic arm moves in two axes of direction only, and the targets move in the third axis of direction to couple the robotic arm with the desired target. The targets are contained on trays that are controlled to move linearly to accomplish the third axis of movement. Multiple trays each containing targets are provided and are vertically stacked on top of each other to increase the target handling capacity of the robotic system without increasing the footprint size of the robotic system. Each axis of motion is accomplished by control of an actuator by a control system and associated motion controller.

Claims

1. A robotic transfer system, comprising:

a control system;

a frame;

a plurality of first actuators attached to the frame;

a plurality of linear bearings attached to the frame wherein each of the plurality of linear bearings is controlled to be moveable to any position by one corresponding actuator in the plurality of first actuators only in a first axis of motion;

a plurality of shelves each containing a plurality of targets wherein each shelf in the plurality of shelves is attached to one corresponding bearing in the plurality of linear bearings and wherein each of said plurality of shelves is stacked in a vertical arrangement;

an arm attached to the frame and moveable only in two axes of motion both orthogonal to the first axis of motion, wherein the arm comprises;

a second actuator that moves only in one of the two axes of motion; and

a third actuator that moves only in the other of the two axes of motion; and

an end effector attached to the third actuator;

the control system electronically coupled to the plurality of first actuators and the second and third actuators, wherein the control system controls coupling the end effector to one of the plurality of targets by controlling an actuator in the plurality of first actuators corresponding to the shelf containing the one of the plurality of targets to independently move in the first axis of motion, and controlling the second and third actuators to move in the two axes of motion to align the end effector with the one of the plurality of targets, wherein said second and third actuators are not controllable to move in the first axis of motion.

2. The system of claim 1, wherein the end effector contains one or more nozzles for fluid transfer.

3. The system of claim 2, further comprising one or more pumps, wherein each of the one or more pumps is coupled individually to the one or more nozzles wherein the pump provides suction power to the nozzle for drawing in fluid.

4. The system of claim 1, wherein said plurality of targets comprises a plurality of glass tubes.

5. The system of claim 1, further comprising a wash station wherein said control system controls moving the end effector into the wash station by controlling the second and third actuators to move the end effector in two axes of motion.

6. The system of claim 1, wherein the plurality of targets on each shelf are contained in a container.

7. The system of claim 6, wherein the plurality of targets are arranged in the container in a row and column format.

8. The system of claim 6, wherein each of the plurality of shelves contains a plurality of platforms wherein each platform is designed to hold the container.

9. The system of claim 1, further comprising a user interface coupled to the control system for an operator to program the robotic system.

10. The system of claim 1, wherein the plurality of first actuators are each comprised of a mechanical actuator that rotates a spur gear wherein the spur gear is coupled to a gear rack attached to each of the plurality of shelves.

11. The system of claim 10, wherein the control system rotates the spur gear to move one of the plurality of shelves in the first axis of motion.

12. The system of claim 1, wherein the second actuator is comprised of an actuator housing attached to a belt wherein the control system causes a mechanical actuator coupled to the belt to rotate the belt thereby causing the actuator housing to move in the second axis of motion.

13. The system of claim 12, wherein the third actuator is comprised of a lead screw coupled to the end effector wherein the control system causes a mechanical actuator coupled to the lead screw to rotate the lead screw thereby causing the end effector to move in the third axis of motion.

14. A method of robotically transporting a material, comprising the steps of:

selecting a target containing a material to transfer from a plurality of shelves containing a plurality of targets wherein each of the plurality of shelves are stacked in a vertical arrangement with respect to one another;

moving a shelf containing the target from the plurality of shelves only in a first axis of motion by causing a first actuator coupled to the shelf to move the shelf in the first axis of motion to align an end effector with the target; and

coupling the end effector with the target comprised of;

moving an arm that is only moveable in two axes of motion both orthogonal to the first axis of motion, which is comprised of;

instructing a second actuator to move the arm in a second axis of motion from the two axes of motion; and

instructing a third actuator to move the arm in a third axis of motion from the two axes of motion in a different axis from the second axis of motion;

wherein said second and third actuators are not controllable to move in the first axis of motion.

15. The method of claim 14, further comprising coupling a pump to the end effector to provide suction to the end effector when the end effector is coupled with the target.

16. The method of claim 14, further comprising moving the end effector into a wash station by:

instructing a second actuator to move the arm in a second axis of motion from the two axes of motion to align end effector with the wash station in the second axis of motion; and

instructing a third actuator to move the arm in a third axis of motion from the two axes of motion in a different axis from the second axis of motion to align the end effector with the wash station in the third axis of motion.

17. The method of claim 14, wherein the step of moving the shelf is comprised of rotating a spur gear wherein the spur gear is coupled to a gear rack attached to the shelf.

18. The method of claim 14, wherein the step of instructing a second actuator to move the arm in a second axis of motion from the two axes of motion comprises moving a belt wherein the belt is attached to the arm thereby causing the arm to move in the second axis of motion.

19. The method of claim 14, wherein the step of instructing a third actuator to move the arm in a third axis of motion from the two axes of motion in a different axis from the second axis of motion, wherein the third actuator is comprised of rotating a lead screw wherein the lead screw is coupled to the end effector thereby causing the end effector to move in the third axis of motion.