US20070225857A1 - Specimen carrier transfer apparatus - Google Patents
Specimen carrier transfer apparatus Download PDFInfo
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- US20070225857A1 US20070225857A1 US11/304,108 US30410806A US2007225857A1 US 20070225857 A1 US20070225857 A1 US 20070225857A1 US 30410806 A US30410806 A US 30410806A US 2007225857 A1 US2007225857 A1 US 2007225857A1
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- shuttle
- conveyor
- conveyors
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- specimen
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J18/00—Arms
- B25J18/02—Arms extensible
- B25J18/04—Arms extensible rotatable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G21/00—Supporting or protective framework or housings for endless load-carriers or traction elements of belt or chain conveyors
- B65G21/20—Means incorporated in, or attached to, framework or housings for guiding load-carriers, traction elements or loads supported on moving surfaces
- B65G21/22—Rails or the like engaging sliding elements or rollers attached to load-carriers or traction elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G23/00—Driving gear for endless conveyors; Belt- or chain-tensioning arrangements
- B65G23/02—Belt- or chain-engaging elements
- B65G23/04—Drums, rollers, or wheels
- B65G23/08—Drums, rollers, or wheels with self-contained driving mechanisms, e.g. motors and associated gearing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G23/00—Driving gear for endless conveyors; Belt- or chain-tensioning arrangements
- B65G23/24—Gearing between driving motor and belt- or chain-engaging elements
- B65G23/30—Variable-speed gearing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G37/00—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
- B65G37/005—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 comprising two or more co-operating conveying elements with parallel longitudinal axes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G37/00—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
- B65G37/02—Flow-sheets for conveyor combinations in warehouses, magazines or workshops
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/52—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
- B65G47/76—Fixed or adjustable ploughs or transverse scrapers
- B65G47/763—Fixed ploughs or transverse scrapers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
- B65G47/90—Devices for picking-up and depositing articles or materials
- B65G47/902—Devices for picking-up and depositing articles or materials provided with drive systems incorporating rotary and rectilinear movements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
- B65G47/90—Devices for picking-up and depositing articles or materials
- B65G47/91—Devices for picking-up and depositing articles or materials incorporating pneumatic, e.g. suction, grippers
- B65G47/914—Devices for picking-up and depositing articles or materials incorporating pneumatic, e.g. suction, grippers provided with drive systems incorporating rotary and rectilinear movements
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/0099—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor comprising robots or similar manipulators
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/02—Articles
- B65G2201/0235—Containers
- B65G2201/0261—Puck as article support
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
- G01N2035/0401—Sample carriers, cuvettes or reaction vessels
- G01N2035/0406—Individual bottles or tubes
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
- G01N2035/046—General conveyor features
- G01N2035/0462—Buffers [FIFO] or stacks [LIFO] for holding carriers between operations
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
- G01N2035/046—General conveyor features
- G01N2035/0465—Loading or unloading the conveyor
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
- G01N2035/046—General conveyor features
- G01N2035/0467—Switching points ("aiguillages")
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
- G01N2035/046—General conveyor features
- G01N2035/0467—Switching points ("aiguillages")
- G01N2035/047—Switching points ("aiguillages") diverging, e.g. sending carriers to different analysers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/02—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor using a plurality of sample containers moved by a conveyor system past one or more treatment or analysis stations
- G01N35/04—Details of the conveyor system
- G01N2035/0474—Details of actuating means for conveyors or pipettes
- G01N2035/0482—Transmission
- G01N2035/0484—Belt or chain
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T436/00—Chemistry: analytical and immunological testing
- Y10T436/11—Automated chemical analysis
- Y10T436/113332—Automated chemical analysis with conveyance of sample along a test line in a container or rack
Definitions
- the present invention relates generally to track utilized in an automated clinical laboratory conveyor system, and more particularly to an improved specimen carrier transfer apparatus for transferring specimen carriers from one track loop to another in a dual track system.
- Clinical laboratory testing has changed and improved remarkably over the past 80 years. Initially, tests or assays were performed manually and generally utilized large quantities of serum, blood or other materials and/or body fluids. As mechanical technology developed in the industrial work place, similar technology was introduced into the clinical laboratory. With the introduction of new technology, methodologies were also improved in an effort to improve the quality of the results produced by the individual instruments, and to minimize the amount of physical specimen required to perform a particular test.
- Instruments have been developed to increase the efficiency of testing procedures by reducing turnaround time and decreasing the volumes necessary to perform various assays.
- Robotic engineering has evolved to such a degree that various types of robots have been applied in the clinical laboratory setting.
- Track devices form the physical interface between the specimen samples in carriers being directed throughout the system, while the Laboratory Automation System (LAS) database provides direction for the system through its command and control features.
- the LAS and the various track devices work in combination to direct, manage and track all specimens throughout the system.
- the dual-lane conveyors used in the present invention utilize table top chain to transport specimen carriers about a closed loop among various stations.
- the inside lane of the dual lane conveyor acts as a highway to rapidly transport specimens to their proper destination.
- the outside lane accepts specimens diverted to it from the inside lane, and queues them for processing at one of the automation system modules or laboratory instruments.
- the continuous loop dual lane design means that specimens will quickly circulate back to any module or instrument on the system without operator intervention. Rules based processing guidelines determine all specimen actions, including routing changes for additional testing or modified processing.
- the transfer apparatus of the present invention includes a shuttle depending from an overhead support with a pair of arms for receiving and shifting a specimen carrier from one conveyor to a second conveyor of a dual-conveyor track.
- the shuttle is operable to retain a specimen carrier along either the first or second conveyor and to release a specimen carrier along either the first or second conveyor.
- Sensors are located to detect the presence of a specimen carrier at each of the retention locations, and to confirm the release of a specimen carrier from the shuttle along each of the conveyors.
- a drive motor for moving the shuttle between the retention and release positions is electrically connected to a command module with a processor, for receiving instructions as to the position of the shuttle.
- the sensors are also connected to the processor to transmit detection data to the processor.
- a queue is positioned upstream of the shuttle and is electrically connected to the processor.
- the queue includes retractable shafts, sensors and scanners for selectively retaining, detecting and scanning identification data from a specimen carrier on either of the conveyors, upstream of the shuttle, and transmitting the information to the processor.
- FIG. 1 is a perspective view of a transfer apparatus of the present invention installed along a dual lane conveyor track;
- FIG. 2 is a top plan view of the transfer apparatus module, showing various possible positions of a specimen carrier as the transfer apparatus operates;
- FIG. 3 is a front elevational view of the transfer apparatus
- FIG. 4 is a side elevational view of the transfer apparatus
- FIG. 5 is a bottom view of the drive assembly of the transfer apparatus
- FIG. 6 is a front elevational view of the transfer apparatus showing the shuttle in a first position
- FIG. 7 is a front elevational view of the transfer apparatus showing the shuttle in a second position
- FIG. 8 is a front elevational view of the transfer apparatus showing the shuttle in a third position.
- Transfer apparatus 10 includes three general components: a queue 20 , a lane changer 22 and a command module 24 .
- Queue 20 serves to stop each specimen carrier 18 that travels by the queue, identify the carrier 18 and then release the carrier at a time determined by the command module 24 .
- Lane changer 22 is operated by the command module 24 to receive and shift a specimen carrier 18 from one of conveyors 12 or 14 , to the other.
- the command module 24 serves as the “brain” of the transfer apparatus 10 and interacts with the Laboratory Automation System (LAS) to identify, track and direct specimen carriers 18 through the transfer apparatus 10 .
- LAS Laboratory Automation System
- each table top chain includes a plurality of plates 26 , each having a flat upper surface or “table top” for moving carriers 18 .
- Plates 26 are interconnected by links, which permit plates 26 to pivot about the links within a horizontal plane.
- the links are engaged by a drive mechanism to pull the chain along track 16 and thereby move carriers 18 supported on the track.
- the upper surfaces of plates 26 form a flat planar surface identified throughout this specification as a drive plane.
- a pair of elongated guide rails 28 and 30 are disposed along the lengths of each conveyor 12 and 14 on opposing sides of plates 26 to guide specimen carriers 18 therebetween.
- specimen carriers 18 One embodiment of specimen carriers 18 is disclosed throughout this specification, but it should be understood that many other sizes and shapes of carriers for specimens could be utilized with the present invention.
- Each specimen carrier 18 includes a generally rectangular body with a forward wall and a top surface. A plurality of openings are formed in the top surface and extend into the interior of the body for receiving and supporting a specimen tube, slide, or other specimen container in an upright position.
- Conveyors 12 and 14 operate in the same direction, designated generally by arrow 32 , although they may be operated at different speeds.
- Queue 20 includes a housing 34 positioned between conveyors 12 and 14 and located upstream of lane changer 22 .
- a pair of forward and rearward retractable shafts 36 and 38 extend transversely outwardly from a first side 20 a of queue 20 , and project over conveyor 12 to restrain a specimen carrier 18 from passing by shaft 36 or 38 .
- Forward and rearward sensors 40 and 42 are positioned adjacent each shaft 36 and 38 , respectively, to detect the presence of a specimen carrier 18 at the associated shaft.
- a second pair of forward and rearward retractable shafts 44 and 46 extend transversely outwardly from the opposing second side 20 b of queue 20 , and project over conveyor 14 to restrain a specimen carrier 18 from passing by shaft 44 or 46 .
- Forward and rearward sensors 48 and 50 are positioned adjacent each shaft 44 and 46 , respectively, to detect the presence of a specimen carrier 18 at the associated shaft.
- forward shafts 36 and 44 are the projecting ends of a single shaft. In this way, only one carrier 18 is permitted to continue downstream at a time, since the retraction of one end of the shaft would cause the other end to project farther over the opposing track.
- rearward shafts 38 and 46 are preferably the projecting ends of a second single shaft. Again, only one carrier is permitted to advance downstream from queue 20 along the conveyors 12 and 14 .
- the inward guide rails 30 of conveyors 12 and 14 are removed from between the downstream end of queue 20 and lane changer 22 , and a platform 52 is installed with its top surface coplanar with the drive plane of conveyors 12 and 14 .
- carriers 18 may be moved off of one conveyor and onto the other by sliding the carrier across platform 52 .
- lane changer 22 includes a lower housing 54 mounted between conveyors 12 and 14 and depending below the drive plane “P”.
- a rigid upright back 56 is connected at its lower end to housing 54 and projects upwardly between conveyors 12 and 14 .
- a support plate 58 projects forwardly and transversely outwardly from the top of back 56 , and serves as the frame for supporting the shuttle 60 , the shuttle drive assembly 62 and sensors 64 and 66 , all of which are described in more detail hereinbelow.
- Shuttle 60 serves to receive a specimen carrier 18 between a pair of arms 68 and 70 and transversely move carrier 18 between conveyors 12 and 14 , and includes a base plate 72 connecting the upper ends of arms 68 and 70 to form an inverted U-shaped structure.
- Base plate 72 is mounted to the bottom of a slide 74 which in turn is slidably connected to a linear rail 76 on the bottom of support plate 58 .
- linear rail 76 extends transversely over both conveyors 12 and 14 , thereby permitting movement of shuttle 60 over both conveyors.
- An encoder-monitored DC stepper motor 78 selectively drives a drive belt 80 connected to slide 74 to precisely position shuttle 60 where desired along rail 76 .
- the lower ends of arms 68 and 70 on shuttle 60 each have a guide blade 82 and 84 , respectively, mounted thereon. Blades 82 and 84 diverge outwardly as they project forwardly from the arms 68 and 70 , to thereby shift a specimen carrier 18 transversely into alignment between the arms 68 and 70 . Blades 82 and 84 are preferably formed of a resilient and flexible material so that shuttle 60 can shift fully against the outside guide rails 28 (see FIG. 2 ) to release a carrier 18 onto either conveyor 12 or 14 .
- a presence sensor 86 is positioned adjacent each outward extent of shuttle 60 to detect the presence of a carrier 18 within shuttle 60 on either conveyor 12 or 14 .
- An exit sensor 88 is positioned downstream of shuttle 60 along each conveyor 12 and 14 , to detect the presence of a carrier that has exited the shuttle along either conveyor.
- a pair of carrier stop arms 90 and 92 project transversely outwardly from back 56 and extend partially over conveyors 12 and 14 , respectively. However, stop arms 90 and 92 do not project far enough to prevent a carrier 18 from passing between the stop arm and the associated outside guide rail 28 , if aligned with the opening therebetween by carrier shuttle 60 .
- transfer apparatus 10 the operation of transfer apparatus 10 is as follows. While specimen carriers 18 travel along both conveyors 12 and 14 during operation the description of the operation of the transfer apparatus will assume that a carrier 18 first reaches queue 20 along conveyor 12 . The rest position of all four shafts 36 , 38 , 44 and 46 of queue 20 are in an extended position, so that a carrier 18 is prevented from advancing beyond the associated shaft until the particular shaft is retracted. Thus, carrier 18 , on conveyor 12 will first contact extended shaft 36 and stop in position “A”. Sensor 40 detects the presence of carrier 18 , and retracts shaft 36 to permit the carrier to proceed downstream. Carrier 18 is then stopped by extended shaft 38 .
- a barcode scanner 94 is turned on to scan the barcode label on the side of carrier 18 . This data is then transmitted to the command module 24 , which will determine the appropriate action to take, based upon priority rules and guidelines set up by the LAS.
- shaft 42 is retracted, and carrier 18 proceeds to a “hold” position “C” on conveyor 12 .
- the “hold” position locates shuttle 60 slightly inwardly from the lane of conveyor 12 , so that blade 82 directs the carrier between arms 68 and 70 , and into contact with stop 90 .
- command module 24 will instruct lane changer 22 to move shuttle 60 across platform 52 , as shown in FIG. 7 , to the “release” position “D” on conveyor 14 .
- the release position “D” locates carrier 18 on conveyor 14 so that it bypasses stop 92 , to permit the carrier to proceed downstream, as shown in FIG. 8 .
- As the carrier leaves lane changer 22 it will pass exit sensor 88 at position “E”, which will confirm that the desired action has occurred.
- shuttle 60 will be instructed to move outwardly from the “hold” position to the “release” position. This movement will cause carrier 18 to be moved outwardly beyond the end of stop 90 , permitting the carrier to proceed downstream on conveyor 12 . As the carrier leaves lane changer 22 , it will pass exit sensor 88 at position “F”, which will confirm that the desired action has been taken.
- This same sequence of actions occurs with a carrier 18 that approaches queue 20 along conveyor 14 , with the same options of releasing the carrier on the same conveyor, or diverting the carrier to conveyor 12 .
Abstract
A transfer apparatus includes a shuttle depending from an overhead support with a pair of arms for receiving and shifting a specimen carrier from one conveyor to a second conveyor of a dual-conveyor track. The shuttle is operable to retain a specimen carrier along either the first or second conveyor and to release a specimen carrier along either the first or second conveyor. Sensors are located to detect the presence of a specimen carrier at each of the retention locations, and to confirm the release of a specimen carrier from the shuttle along each of the conveyors. A drive motor for moving the shuttle between the retention and release positions is electrically connected to a command module with a processor, for receiving instructions as to the position of the shuttle. The sensors are also connected to the processor to transmit detection data to the processor. A queue is positioned upstream of the shuttle and is electrically connected to the processor. The queue includes retractable shafts, sensors and scanners for selectively retaining, detecting and scanning identification data from a specimen carrier on either conveyor upstream of the shuttle, and transmitting the information to the processor.
Description
- This is a Continuation of Ser. No. 10/626,466, filed Jul. 24, 2003, which claims the benefit of U.S. Provisional Application Ser. No. 60/398,893, filed Jul. 26, 2002.
- (Not applicable)
- (Not applicable)
- 1. Field of the Invention
- The present invention relates generally to track utilized in an automated clinical laboratory conveyor system, and more particularly to an improved specimen carrier transfer apparatus for transferring specimen carriers from one track loop to another in a dual track system.
- 2. Description of Related Art Including Information Disclosed under 37 CFR 1.97, 1.98
- Clinical laboratory testing has changed and improved remarkably over the past 80 years. Initially, tests or assays were performed manually and generally utilized large quantities of serum, blood or other materials and/or body fluids. As mechanical technology developed in the industrial work place, similar technology was introduced into the clinical laboratory. With the introduction of new technology, methodologies were also improved in an effort to improve the quality of the results produced by the individual instruments, and to minimize the amount of physical specimen required to perform a particular test.
- Instruments have been developed to increase the efficiency of testing procedures by reducing turnaround time and decreasing the volumes necessary to perform various assays. Robotic engineering has evolved to such a degree that various types of robots have been applied in the clinical laboratory setting.
- The main focus of prior art laboratory automation relied on the implementation of conveyor systems to connect areas of a clinical laboratory. Known conveyor systems in the laboratory setting utilize separate conveyor segments to move specimens from a processing station to a specific laboratory work station. In order to obtain cost savings, one typical scenario called for specimens to be sorted manually and grouped together in a carrier rack to be conveyed to a specific location. In this way, a carrier would move a group of 5-20 specimens from the processing location to the specific work station for the performance of a single test on each of the specimens within the carrier rack.
- With the development of new and improved automatic conveyor systems for laboratories and other environments, it is possible to select, track, and convey individual specimens throughout a laboratory for a variety of different testing, while maintaining a priority system for certain types of testing or special urgent requests for a time-specific response. These new automated conveyor systems are of various types and design, but the inventors herein have found that a dual conveyor system, using a pair of parallel conveyor tracks circulating throughout a laboratory, provides the greatest flexibility and versatility. The integration of various track devices with software directing the operation of the conveyor system and the various automated testing stations, has improved both the speed and capability of automated conveyor systems in recent years.
- Track devices form the physical interface between the specimen samples in carriers being directed throughout the system, while the Laboratory Automation System (LAS) database provides direction for the system through its command and control features. The LAS and the various track devices work in combination to direct, manage and track all specimens throughout the system.
- The dual-lane conveyors used in the present invention utilize table top chain to transport specimen carriers about a closed loop among various stations. Typically, the inside lane of the dual lane conveyor acts as a highway to rapidly transport specimens to their proper destination. The outside lane accepts specimens diverted to it from the inside lane, and queues them for processing at one of the automation system modules or laboratory instruments. The continuous loop dual lane design means that specimens will quickly circulate back to any module or instrument on the system without operator intervention. Rules based processing guidelines determine all specimen actions, including routing changes for additional testing or modified processing.
- In order to effectively manage, track and route specimens throughout a clinical laboratory, it is necessary to maintain constant “awareness” of the location of every specimen throughout the system, and be able to direct each specimen to the appropriate location at the most appropriate time for storage, testing or other processing. This in turn is accomplished, in part, by one or more transfer apparatus for selectively shifting a specimen carrier between the inside and outside lanes of the dual lane conveyor.
- It is therefore a general object of the present invention to provide an improved transfer apparatus for selectively moving specimen carriers between the lanes of a dual lane, closed loop conveyor in an automated conveyor system.
- These and other objects will be apparent to those skilled in the art.
- The transfer apparatus of the present invention includes a shuttle depending from an overhead support with a pair of arms for receiving and shifting a specimen carrier from one conveyor to a second conveyor of a dual-conveyor track. The shuttle is operable to retain a specimen carrier along either the first or second conveyor and to release a specimen carrier along either the first or second conveyor. Sensors are located to detect the presence of a specimen carrier at each of the retention locations, and to confirm the release of a specimen carrier from the shuttle along each of the conveyors. A drive motor for moving the shuttle between the retention and release positions is electrically connected to a command module with a processor, for receiving instructions as to the position of the shuttle. The sensors are also connected to the processor to transmit detection data to the processor. A queue is positioned upstream of the shuttle and is electrically connected to the processor. The queue includes retractable shafts, sensors and scanners for selectively retaining, detecting and scanning identification data from a specimen carrier on either of the conveyors, upstream of the shuttle, and transmitting the information to the processor.
- The preferred embodiment of the invention is illustrated in the accompanying drawings, in which similar or corresponding parts are identified with the same reference numeral throughout the several views, and in which:
-
FIG. 1 is a perspective view of a transfer apparatus of the present invention installed along a dual lane conveyor track; -
FIG. 2 is a top plan view of the transfer apparatus module, showing various possible positions of a specimen carrier as the transfer apparatus operates; -
FIG. 3 is a front elevational view of the transfer apparatus; -
FIG. 4 is a side elevational view of the transfer apparatus; -
FIG. 5 is a bottom view of the drive assembly of the transfer apparatus; -
FIG. 6 is a front elevational view of the transfer apparatus showing the shuttle in a first position; -
FIG. 7 is a front elevational view of the transfer apparatus showing the shuttle in a second position; and -
FIG. 8 is a front elevational view of the transfer apparatus showing the shuttle in a third position. - Referring now to the drawings, in which similar or corresponding parts are identified with the same reference numeral, and more particularly to
FIG. 1 , the transfer apparatus of the present invention is designated generally at 10, and is shown installed between twoconveyors conveyor transport track 16, to selectively transfer aspecimen carrier 18 betweenconveyors Transfer apparatus 10 includes three general components: aqueue 20, alane changer 22 and acommand module 24.Queue 20 serves to stop eachspecimen carrier 18 that travels by the queue, identify thecarrier 18 and then release the carrier at a time determined by thecommand module 24.Lane changer 22 is operated by thecommand module 24 to receive and shift aspecimen carrier 18 from one ofconveyors command module 24 serves as the “brain” of thetransfer apparatus 10 and interacts with the Laboratory Automation System (LAS) to identify, track anddirect specimen carriers 18 through thetransfer apparatus 10. - Referring now to
FIG. 2 ,conveyors specimen carriers 18. Each table top chain includes a plurality ofplates 26, each having a flat upper surface or “table top” for movingcarriers 18.Plates 26 are interconnected by links, which permitplates 26 to pivot about the links within a horizontal plane. The links are engaged by a drive mechanism to pull the chain alongtrack 16 and thereby movecarriers 18 supported on the track. The upper surfaces ofplates 26 form a flat planar surface identified throughout this specification as a drive plane. - A pair of
elongated guide rails conveyor plates 26 to guidespecimen carriers 18 therebetween. One embodiment ofspecimen carriers 18 is disclosed throughout this specification, but it should be understood that many other sizes and shapes of carriers for specimens could be utilized with the present invention. Eachspecimen carrier 18 includes a generally rectangular body with a forward wall and a top surface. A plurality of openings are formed in the top surface and extend into the interior of the body for receiving and supporting a specimen tube, slide, or other specimen container in an upright position. -
Conveyors arrow 32, although they may be operated at different speeds.Queue 20 includes ahousing 34 positioned betweenconveyors lane changer 22. A pair of forward and rearwardretractable shafts first side 20 a ofqueue 20, and project overconveyor 12 to restrain aspecimen carrier 18 from passing byshaft rearward sensors shaft specimen carrier 18 at the associated shaft. - A second pair of forward and rearward
retractable shafts second side 20 b ofqueue 20, and project overconveyor 14 to restrain aspecimen carrier 18 from passing byshaft rearward sensors shaft specimen carrier 18 at the associated shaft. - In the preferred embodiment of the invention,
forward shafts carrier 18 is permitted to continue downstream at a time, since the retraction of one end of the shaft would cause the other end to project farther over the opposing track. Similarly,rearward shafts queue 20 along theconveyors - The
inward guide rails 30 ofconveyors queue 20 andlane changer 22, and aplatform 52 is installed with its top surface coplanar with the drive plane ofconveyors carriers 18 may be moved off of one conveyor and onto the other by sliding the carrier acrossplatform 52. - As shown in
FIGS. 3 and 4 ,lane changer 22 includes alower housing 54 mounted betweenconveyors housing 54 and projects upwardly betweenconveyors support plate 58 projects forwardly and transversely outwardly from the top of back 56, and serves as the frame for supporting theshuttle 60, theshuttle drive assembly 62 and sensors 64 and 66, all of which are described in more detail hereinbelow. -
Shuttle 60 serves to receive aspecimen carrier 18 between a pair ofarms transversely move carrier 18 betweenconveyors base plate 72 connecting the upper ends ofarms Base plate 72 is mounted to the bottom of aslide 74 which in turn is slidably connected to alinear rail 76 on the bottom ofsupport plate 58. As shown inFIG. 3 ,linear rail 76 extends transversely over bothconveyors shuttle 60 over both conveyors. An encoder-monitoredDC stepper motor 78 selectively drives adrive belt 80 connected to slide 74 to precisely positionshuttle 60 where desired alongrail 76. - The lower ends of
arms shuttle 60 each have aguide blade Blades arms specimen carrier 18 transversely into alignment between thearms Blades shuttle 60 can shift fully against the outside guide rails 28 (seeFIG. 2 ) to release acarrier 18 onto eitherconveyor - A
presence sensor 86 is positioned adjacent each outward extent ofshuttle 60 to detect the presence of acarrier 18 withinshuttle 60 on eitherconveyor exit sensor 88 is positioned downstream ofshuttle 60 along eachconveyor - A pair of carrier stop
arms conveyors arms carrier 18 from passing between the stop arm and the associatedoutside guide rail 28, if aligned with the opening therebetween bycarrier shuttle 60. - Referring once again to
FIG. 2 , the operation oftransfer apparatus 10 is as follows. Whilespecimen carriers 18 travel along bothconveyors carrier 18first reaches queue 20 alongconveyor 12. The rest position of all fourshafts queue 20 are in an extended position, so that acarrier 18 is prevented from advancing beyond the associated shaft until the particular shaft is retracted. Thus,carrier 18, onconveyor 12 will first contact extendedshaft 36 and stop in position “A”.Sensor 40 detects the presence ofcarrier 18, and retractsshaft 36 to permit the carrier to proceed downstream.Carrier 18 is then stopped byextended shaft 38. Whenrearward sensor 42 detects the presence ofcarrier 18 at position “B”, abarcode scanner 94 is turned on to scan the barcode label on the side ofcarrier 18. This data is then transmitted to thecommand module 24, which will determine the appropriate action to take, based upon priority rules and guidelines set up by the LAS. - Once the command module has determined the action to be taken,
shaft 42 is retracted, andcarrier 18 proceeds to a “hold” position “C” onconveyor 12. As shown inFIG. 6 , the “hold” position locatesshuttle 60 slightly inwardly from the lane ofconveyor 12, so thatblade 82 directs the carrier betweenarms stop 90. Ifcarrier 18 is to be diverted toconveyor 14, thencommand module 24 will instructlane changer 22 to moveshuttle 60 acrossplatform 52, as shown inFIG. 7 , to the “release” position “D” onconveyor 14. The release position “D” locatescarrier 18 onconveyor 14 so that it bypassesstop 92, to permit the carrier to proceed downstream, as shown inFIG. 8 . As the carrier leaveslane changer 22 it will passexit sensor 88 at position “E”, which will confirm that the desired action has occurred. - In the alternative, if
carrier 18 is to be released alongconveyor 12 rather than diverted toconveyor 14, then shuttle 60 will be instructed to move outwardly from the “hold” position to the “release” position. This movement will causecarrier 18 to be moved outwardly beyond the end ofstop 90, permitting the carrier to proceed downstream onconveyor 12. As the carrier leaveslane changer 22, it will passexit sensor 88 at position “F”, which will confirm that the desired action has been taken. - This same sequence of actions occurs with a
carrier 18 that approachesqueue 20 alongconveyor 14, with the same options of releasing the carrier on the same conveyor, or diverting the carrier toconveyor 12. - Whereas the invention has been shown and described in connection with the preferred embodiment thereof, many modifications, substitutions and additions may be made which are within the intended broad scope of the appended claims.
Claims (3)
1. In combination:
a dual conveyor track having first and second parallel, spaced apart conveyors with upper surfaces within a single plane, the conveyors operable in the same longitudinal direction;
a plurality of specimen carriers carried on said first and second conveyors of said track; and
a transfer apparatus located between the first and second conveyors, with downstream portions extending past the transfer apparatus to carry specimen carriers to separate, predetermined locations, the transfer apparatus comprising:
a frame connected to the track for supporting an operable shuttle;
a shuttle operably connected to the frame for transverse movement between the conveyors generally perpendicular to the movement the specimen carriers on the conveyors;
a first stop member on said frame, projecting partially over the first conveyor;
a second stop member on said frame, projecting partially over the second conveyor;
said shuttle having a pair of parallel arms spaced apart a distance to receive a specimen carrier therebetween;
said shuttle operable to a first “hold” position with the shuttle arms located such that a specimen carrier therebetween is in contact with the first stop member, to thereby prevent downstream movement of a carrier on the first conveyor;
said shuttle operable to a first “release” position with the shuttle arms located such that a specimen carrier therebetween bypasses the first stop member and moves downstream through the shuttle arms on the first conveyor;
said shuttle operable to a second “release” position with the shuttle arms located such that a specimen carrier therebetween bypasses the second stop member and moves downstream through the shuttle arms on the second conveyor; and
a drive assembly on the frame for selectively moving the shuttle among the first “hold” position, the first “release” position and the second “release” position.
2. The combination of claim 1 , wherein said shuttle is operable to a second “hold” position with the shuttle arms located such that a specimen carrier located therebetween contacts the second stop member to thereby prevent downstream movement the carrier on the second conveyor, and wherein said drive assembly additionally selectively moves the shuttle to the second “hold” position.
3. The combination of claim 1 , wherein said frame further includes a platform thereon extending between the conveyors, the platform coplanar with the conveyors such that movement of the shuttle between the conveyors moves a specimen carrier located within the arms of the shuttle across the platform to the opposing conveyor.
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