Laboratory sample distribution system, laboratory system and method of operating

• US 9,239,335 B2
• Filed: 04/28/2014
• Issued: 01/19/2016
• Est. Priority Date: 11/04/2011
• Status: Active Grant

• Current Assignee: Roche Diagnostics Operations Incorporated (Roche Holding AG)
• Original Assignee: Roche Diagnostics Operations Incorporated (Roche Holding AG)
• Inventors: Heise, Michael, Schneider, Hans
• Primary Examiner(s): Deuble, Mark A
• Application Number:
  US14/263,002
• Publication Number:
  US 20140234978A1
• Time in Patent Office: 631 Days
• Field of Search: 422 63- 67, 198/339.1, 198/349, 198/465.1, 198/619
• US Class Current: 1/1
• CPC Class Codes: B65G 2201/0261 Puck as article support
• CPC Class Codes: B65G 37/00 Combinations of mechanical conveyors of the same kind, or of different kinds, of interest apart from their application in particular machines or use in particular manufacturing processes series of co-operating belt conveyor units B65G15/22; series of co-operating chain conveyor units B65G17/26; sequence control of combined conveyors B65G43/10
• CPC Class Codes: B65G 54/02 electrostatic, electric, or magnetic
• CPC Class Codes: G01N 2035/00752 bar codes
• CPC Class Codes: G01N 2035/0406 Individual bottles or tubes
• CPC Class Codes: G01N 2035/0465 Loading or unloading the conveyor
• CPC Class Codes: G01N 2035/0477 Magnetic
• CPC Class Codes: G01N 35/04 Details of the conveyor system G01N35/021 - G01N35/028 take precedence
• CPC Class Codes: Y10T 436/114165 with step of insertion or removal from test line

Abstract

A laboratory sample distribution system is presented. The laboratory sample distribution system comprises a plurality of container carriers. The container carriers each comprise at least one magnetically active device such as, for example, at least one permanent magnet, and carry a sample container containing a sample. The system further comprises a transport plane to carry the multiple container carriers and a plurality of electro-magnetic actuators stationary arranged below the transport plane. The electro-magnetic actuators move a container carrier on top of the transport plane by applying a magnetic force to the container carrier. The system also comprises at least one transfer device to transfer a sample item, wherein the sample item is a container carrier, a sample container, part of the sample and/or the complete sample, between the transport plane and a laboratory station such as, for example, a pre-analytical, an analytical and/or a post-analytical station.

Claims

1. A laboratory sample distribution system, the laboratory sample distribution system comprising:

a plurality of container carriers, wherein each container carriers comprises at least one magnetically active device and carries a sample container containing a sample;

a transport plane to carry the plurality of container carriers;

a plurality of electro-magnetic actuators stationary arranged below the transport plane, wherein the plurality of electro-magnetic actuators moves a container carrier on top of the transport plane from a start location to a designation location by applying a magnetic force to the container carrier; and

at least one transfer device arranged to transfer a sample item between the transport plane and a laboratory station adjacent to the destination location,

wherein the laboratory station is a pre-analytical, an analytical and/or a post-analytical station and wherein the sample container containing the sample is fed into the laboratory sample distribution system and moved to and processed by laboratory stations determined to be the processing laboratory stations for the sample contained in the sample container.

2. The laboratory sample distribution system according to claim 1, wherein the at least one magnetically active device is a permanent magnet.

3. The laboratory sample distribution system according to claim 1, wherein the sample item is a container carrier, a sample container, part of the sample and/or the complete sample.

4. The laboratory sample distribution system according to claim 1, wherein the at least one transfer device transfers the sample item along two axes.

5. The laboratory sample distribution system according to claim 1, wherein the at least one transfer device transfers more than one sample item in parallel.

6. The laboratory sample distribution system according to claim 1, wherein the transport plane comprises at least one transfer location located adjacent to the at least one transfer device, wherein the at least one transfer device is arranged to transfer the sample item between the at least one transfer location and the laboratory station.

7. The laboratory sample distribution system according to claim 6, wherein the transport plane comprises at least one transfer area located adjacent to the at least one transfer device and stores a plurality of container carriers, wherein the at least one transfer location is located within the at least one transfer area.

8. The laboratory sample distribution system according to claim 7, wherein the at least one transfer area comprises priority areas and wherein the at least one transfer device transfers the sample item between at least one specific priority location of the priority area and the laboratory station with priority.

9. The laboratory sample distribution system according to claim 1, wherein the transport plane comprises at least one buffer area to store container carriers actually not carrying a sample container.

10. The laboratory sample distribution system according to claim 1, further comprising,

a container carrier conveyor functionally coupled to the transport plane, wherein the container carrier conveyor conveys container carriers not placed on top of the transport plane.

11. The laboratory sample distribution system according to claim 1, further comprising,

at least one RFID reader, wherein each container carrier comprises a RFID tag storing a unique ID corresponding to the container carrier.

12. The laboratory sample distribution system according to claim 1, further comprising,

at least one barcode reader for reading barcodes on sample containers.

13. The laboratory sample distribution system according to claim 12, wherein the barcode reader is in the at least one transfer device.

14. The laboratory sample distribution system according to claim 1, wherein the transfer device comprises a pick-and-place device to pick a sample container from a container carrier placed on the transport plane and place the sample container in a sample container rack and/or pick a sample container from a sample container rack and place the sample container in a container carrier placed on the transport plane.

15. The laboratory sample distribution system according to claim 1, wherein the transfer device comprises at least one conveyor to move a sample container rack towards a laboratory station and/or to move a sample container rack from a laboratory station towards the transport plane.

16. The laboratory sample distribution system according to claim 1, wherein the transfer device comprises a sample container rack storage device to store sample container racks.

17. The laboratory sample distribution system according to claim 16, wherein the sample container rack storage device stores sample container rack trays.

18. The laboratory sample distribution system according to claim 16, wherein the sample container rack trays stores a plurality of sample container racks.

19. The laboratory sample distribution system according to claim 16, wherein the sample container rack storage device comprises a push loading drawer, the push loading drawer having an open and a closed state, wherein in the open state, the push loading drawer is filled with sample container racks and/or sample container rack trays.

20. The laboratory sample distribution system according to claim 16, wherein the sample container rack storage device stores sample container racks or sample container rack trays in at least one a storage level below a transport plane level of the transport plane and wherein the sample container rack storage device comprises an elevator device to lift a sample container rack or a sample container rack tray from the at least one storage level to the transport plane level.

21. The laboratory sample distribution system according to claim 16, wherein the transfer device removes a sample container rack from the sample container rack storage device, takes a plurality of sample containers to be transferred from the transport plane and inserts them into the sample container rack and provides the sample container rack including the inserted sample containers to the laboratory station.

22. A laboratory system, the laboratory system comprising:

at least one laboratory station; and

a laboratory sample distribution system according to claim 1.

23. The laboratory system according to claim 22, wherein the at least one laboratory station is a pre-analytical, an analytical and/or a post-analytical station.

24. The laboratory system according to claim 22, wherein the at least one laboratory station is a decapping station, a recapping station, a labeling station, an aliquot station, a centrifugation station, an archiving station, a pipetting station, a sorting station, a tube type identification station, a sample quality determining station or a combination thereof.

25. The laboratory system according to claim 22, further comprising, a memory device for storing matching pairs of a unique ID corresponding to a container carrier and an ID corresponding to a container being carried by the container carrier.