Chemical analyzer

• US 9,797,916 B2
• Filed: 01/08/2015
• Issued: 10/24/2017
• Est. Priority Date: 01/10/2014
• Status: Active Grant

• Current Assignee: IDEXX Laboratories Incorporated
• Original Assignee: IDEXX Laboratories Incorporated
• Inventors: Connolly, David Lance, Dumont, Mark Raymond, Griffin, Justin Jay, McGibbon, John Harvey, Misener, Garland Christian, Phelps, Jeffrey Eric, Rich, Carl Russell, Smith, Kenneth Eugene, Vidacic, Dragan
• Primary Examiner(s): Warden, Jill
• Assistant Examiner(s): Whatley, Benjamin R
• Application Number:
  US14/592,282
• Publication Number:
  US 20150226759A1
• Time in Patent Office: 1,020 Days
• Field of Search: None
• CPC Class Codes: B25J 19/021 Optical sensing devices
• CPC Class Codes: B25J 9/1697 Vision controlled systems
• CPC Class Codes: G01N 1/312 for samples mounted on planar substrates
• CPC Class Codes: G01N 2035/00039 Transport arrangements specific to flat sample substrates, e.g. pusher blade
• CPC Class Codes: G01N 2035/00079 Evaporation covers for slides
• CPC Class Codes: G01N 2035/00138 Slides
• CPC Class Codes: G01N 2035/00356 Holding samples at elevated temperature (incubation)
• CPC Class Codes: G01N 2035/0405 manipulating closing or opening means, e.g. stoppers, screw caps, lids or covers
• CPC Class Codes: G01N 2035/0449 using centrifugal transport of liquid
• CPC Class Codes: G01N 2035/103 using disposable tips
• CPC Class Codes: G01N 35/00029 provided with flat sample substrates, e.g. slides G01N35/028 takes precedence
• 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
• CPC Class Codes: G01N 35/025 having a carousel or turntable for reaction cells or cuvettes
• CPC Class Codes: G01N 35/04 Details of the conveyor system G01N35/021 - G01N35/028 take precedence
• CPC Class Codes: G01N 35/109 with two horizontal degrees of freedom
• CPC Class Codes: Y10S 901/09 Closed loop, sensor feedback controls arm movement
• CPC Class Codes: Y10S 901/41 Tool

Abstract

A medical apparatus for analyzing fluid samples includes an outer casing, a slide loading mechanism disposed within the outer casing for loading fluid analysis slides, a slide ejecting mechanism disposed within the outer casing for ejecting fluid analysis slides, an evaporation cap opening mechanism disposed within the outer casing for opening an evaporation cap, an evaporation cap closing mechanism disposed within the outer casing for closing an evaporation cap, a drawer locking mechanism disposed within the outer casing for locking a drawer associated with the outer casing, a camera disposed within the outer casing, and a robot disposed within the outer casing. The robot is movable in three dimensions and has means for conducting three or more of the following operations: slide loading; slide ejecting; evaporation cap opening; evaporation cap closing; drawer locking; and camera manipulation.

Claims

1. A medical apparatus for analyzing fluid samples comprising:

a. an outer casing, the outer casing defining an interior cavity;

b. a slide loading mechanism disposed within the interior cavity of the outer casing for loading fluid analysis slides;

c. a slide ejecting mechanism disposed within the interior cavity of the outer casing for ejecting fluid analysis slides;

d. an evaporation cap opening mechanism disposed within the interior cavity of the outer casing for opening an evaporation cap;

e. an evaporation cap closing mechanism disposed within the interior cavity of the outer casing for closing an evaporation cap;

f. a consumables manager drawer, the consumables manager drawer being received by an opening formed in the outer casing;

g. at least one camera disposed within the interior cavity of the outer casing;

h. a fluid handler unit disposed within the interior cavity of the outer casing, the fluid handler unit including a robot assembly having portions thereof which are movable within the interior cavity relative to the outer casing, the fluid handler unit further including a fluid pump assembly mounted on the robot assembly and at least one elongated robot arm coupled to the fluid pump assembly, the fluid pump assembly movable within the interior cavity of the outer casing, the movable portions of the robot assembly being movable in an X-Z plane and a Y-Z plane, and being arcuately movable in an angular direction theta within an X-Y plane, the at least one elongated robot arm moving at least arcuately with the fluid pump assembly and engaging at least two of;

i. the slide loading mechanism to load fluid analysis slides;

ii. the slide ejecting mechanism to eject fluid analysis slides;

iii. the evaporation cap opening mechanism to open the evaporation caps; and

iv. the evaporation cap closing mechanism to close the evaporation caps;

i. an optics module, the optics module being in optical communication with at least one fluid analysis slide and conducting at least one of reflectance and fluorescence measurements on the at least one fluid analysis slide; and

j. a controller, the controller including electronic circuitry, the electronic circuitry being in electrical communication with at least one of the optics module, the consumables manager drawer, the robot assembly and the fluid pump assembly.

2. The apparatus of claim 1, wherein the at least one camera is mounted on the robot assembly and movable therewith within the interior cavity of the outer casing to be positionable to view at least the consumables manager drawer and generating image signals thereof and providing the signals to the controller.

3. The apparatus of claim 1, wherein the at least one elongated robot arm engages at least one of the slide loading mechanism, the slide ejecting mechanism, the evaporation cap opening mechanism and the evaporation cap closing mechanism by moving in a linear, Z-axis motion.

4. The apparatus of claim 1,

wherein the optics module is disposed within the interior cavity of the outer casing;

and

wherein the optics module is a combined reflectometer and fluorometer and includes;

a housing, the housing defining an interior chamber;

a first photodiode sensor situated within the interior chamber of the housing, the first photodiode sensor measuring light reflected from or fluoresced by a fluid analysis slide in optical communication with the optics module;

a printed circuit board situated within the interior chamber of the housing, the printed circuit board having a frusto-conical shape and defining a central opening, the central opening being in axial alignment with the first photodiode sensor;

a plurality of light emitting diodes mounted on the printed circuit board, the light emitting diodes being selectively energizable to emit light and illuminate the fluid analysis slide in optical communication with the optics module; and

a notch filter, the notch filter being situated in optical alignment with the first photodiode sensor, the notch filter filtering out light emitted by at least one light emitting diode at a fluorescence excitation wavelength.

5. The apparatus of claim 4, wherein the notch filter filters out light at a fluorescence excitation wavelength of about 470 nanometers.

6. The apparatus of claim 4, wherein the optics module further includes:

a heating element, the heating element being situated within the interior chamber of the housing.

7. The apparatus of claim 4, wherein the optics module further includes:

at least one second photodiode sensor situated within the interior chamber of the housing, the at least one second photodiode sensor measuring the intensity of light emitted by the selectively energized light emitting diodes.

8. The apparatus of claim 4, wherein the optics module further includes:

a lens holder situated within the interior chamber of the housing and in optical alignment with the first photodiode sensor; and

a lens/filter assembly mounted on the lens holder, the lens/filter assembly including an upper lens, a lower lens and the notch filter interposed between the upper lens and the lower lens.

9. The apparatus of claim 4, wherein at least one light emitting diode emits light at a fluorescence excitation wavelength of about 470 nanometers;

and

wherein the optics module further includes a filter mounted directly on the at least one light emitting diode that emits light at the fluorescence excitation wavelength.

10. The apparatus of claim 9, wherein the filter which is mounted on the at least one light emitting diode is a colored glass filter;

and

wherein the colored glass filter is mounted on the at least one light emitting diode with an adhesive.

11. The apparatus of claim 4, which further comprises:

a normalizer casting plate disposed within the interior cavity of the outer casing, the optics module being adjustably mounted on the normalizer casting plate; and

wherein the optics module further includes;

an optics module plate, the optics module plate extending radially outwardly from the housing of the optics module, the optics module plate having a surface and including at least one set of parallel, spaced apart, elongated ribs protruding outwardly from the surface thereof, the normalizer casting plate having a surface and including at least one elongated projection situated on the surface thereof, the ribs of the at least one set of ribs of the optics module plate of the optics module receiving therebetween the at least one elongated projection of the normalizer casting plate, the at least one elongated projection being received by the ribs of the at least one set of ribs permitting adjustment of the position of the optics module with respect to the normalizer casting plate.

12. The apparatus of claim 1, wherein the robot assembly of the fluid handler unit includes:

a base, the base being disposed in an upper portion of the interior cavity of the outer casing, the base having a main portion which is generally planar in shape;

a pair of spaced apart, parallelly disposed linear rails mounted on the base near opposite sides thereof;

a bearing holder assembly, the bearing holder assembly being movably mounted on the pair of linear rails of the base in the X-direction; and

an X-direction motor assembly mounted on the base and coupled to the bearing holder assembly, the X-direction motor assembly causing the bearing holder to move in the X-direction on the pair of linear rails of the base, the pump assembly of the fluid handler unit being operatively coupled to the bearing holder assembly and movable therewith on the base in the X-direction.

13. The apparatus of claim 12, wherein the robot assembly of the fluid handler unit further includes a first linear potentiometer, the first linear potentiometer being mounted on the base, the first linear potentiometer providing a signal to the controller of the apparatus corresponding to the position of the robot assembly and the pump assembly of the fluid handler unit in an X-axis.

14. The apparatus of claim 12, wherein the X-direction motor assembly includes a motor having a motor shaft, a lead screw operatively linked to the motor shaft, and an anti-backlash coupling mounted on the lead screw and reciprocatingly movable thereon, the anti-backlash coupling being coupled to the bearing holder assembly such that the X-direction motor assembly effects movement of the bearing holder assembly in the X-direction.

15. The apparatus of claim 12, wherein the bearing holder assembly of the robot assembly of the fluid handler unit includes a worm wheel, a theta-direction motor operatively linked to the worm wheel to cause the worm wheel to rotate, and a robot center hub, the robot center hub being coupled to the worm wheel and rotating with the worm wheel, the pump assembly being mounted on the robot center hub.

16. The apparatus of claim 15, wherein the theta-direction motor assembly includes a motor having a motor shaft, and a worm gear mounted on the motor shaft, the worm gear engaging the worm wheel, the motor causing the worm wheel to rotate in the theta-direction within the X-Y plane.

17. The apparatus of claim 16, wherein the robot assembly of the fluid handler unit further includes a circular potentiometer, the circular potentiometer being mounted on the base, the circular potentiometer sensing the position of the robot assembly and the pump assembly of the fluid handler unit in the theta-direction, the circular potentiometer providing a signal corresponding to the position of the robot assembly and the pump assembly in the theta-direction to the controller of the apparatus.

18. The apparatus of claim 12, wherein the robot assembly of the fluid handler unit further includes a Z-direction motor assembly, the Z-direction motor assembly being mounted on the bearing holder assembly and effecting movement of the pump assembly in the Z-direction.

19. The apparatus of claim 18, wherein the Z-direction motor assembly includes a motor having a motor shaft, a lead screw operatively linked to the motor shaft and rotatable by the motor, and an anti-backlash coupling mounted on the lead screw and movable axially thereon, the anti-backlash coupling of the Z-direction motor assembly being operatively linked to the pump assembly such that the pump assembly is moved in the Z-direction with movement of the coupling on the lead screw of the Z-direction motor assembly.

20. The apparatus of claim 15, wherein the robot center hub includes a main body, and a bracket extending outwardly from the main body, the pump assembly being mounted on the bracket of the robot center hub.

21. The apparatus of claim 20, wherein the bracket of the robot center hub includes a linear potentiometer, the linear potentiometer of the robot center hub detecting the position in the Z-axis of the pump assembly, the linear potentiometer of the robot center hub providing a signal to the controller corresponding to the position in the Z-axis of the pump assembly mounted on the bracket of the robot center hub.

22. The apparatus of claim 1, wherein the pump assembly of the fluid handler unit includes:

a pump motor assembly, the pump motor assembly including a stepper motor having a motor shaft, and a lead screw operatively linked to the motor shaft;

a pump lower mounting plate, the pump motor being affixed to the pump lower mounting plate, the at least one elongated robot arm being affixed to the pump lower mounting plate and extending outwardly therefrom in the Z-direction;

a pump upper mounting plate, the pump upper mounting plate being spaced apart from the pump lower mounting plate and being movable relative thereto;

a pump spring, the pump spring being mounted between the pump lower mounting plate and the pump upper mounting plate;

a pump motor nut, the pump motor nut being secured to the pump upper mounting plate and receiving a portion of the lead screw of the pump motor assembly therethrough, whereby rotational movement of the lead screw caused by the pump motor will effect movement of the pump upper mounting plate toward and away from the pump lower mounting plate;

a linear rail, the linear rail having a first movable rail mount and a second movable rail mount, the pump upper mounting plate being mounted on the first movable rail mount, the pump lower mounting plate being mounted on the second movable rail mount; and

a pump sub-assembly, the pump sub-assembly including a cylinder and a movable piston within the cylinder, the pump sub-assembly being mounted on the pump lower mounting plate and being movable therewith on the linear rail, the pump sub-assembly including a proboscis on which may be removably mounted disposable pipette tips.

23. The apparatus of claim 1, wherein the at least one elongated robot arm of the robot assembly includes a first elongated robot arm and a second elongated robot arm, each of the first elongated robot arm and the second elongated robot arm being affixed to the fluid pump assembly, each of the first elongated robot arm and the second elongated robot arm having a free end, the free end of at least one of the first elongated robot arm and the second elongated robot arm being selectively engageable with at least one of the slide loading mechanism, the slide ejecting mechanism, the evaporation cap opening mechanism and the evaporation cap closing mechanism.

24. The apparatus of claim 1, wherein the at least one elongated robot arm of the robot assembly includes a free end, the free end having formed thereon a reduced diameter portion and an end plate mounted on the reduced diameter portion, the end plate of the at least one elongated robot arm being selectively engageable with at least one of the slide loading mechanism, the slide ejecting mechanism, the evaporation cap opening mechanism and the evaporation cap closing mechanism.

25. The apparatus of claim 1, wherein the at least one camera is mounted on the robot assembly and movable therewith.

26. The apparatus of claim 1, wherein the at least one camera includes a first camera and a second camera, the first camera being mounted on the robot assembly and being movable therewith within the interior cavity of the outer casing, the second camera being fixedly mounted within the interior cavity of the outer casing.