WO2009094625A1

WO2009094625A1 - Operation pooling system and method

Info

Publication number: WO2009094625A1
Application number: PCT/US2009/031974
Authority: WO
Inventors: John Craig Robert Degruchy; Blair Daniel Leduc; James Monteiro Fernandes; Robert Dunn-Dufault; Bryan Greenway
Original assignee: Thermo Crs, Ltd.
Priority date: 2008-01-25
Filing date: 2009-01-26
Publication date: 2009-07-30
Also published as: CA2713226A1

Abstract

The present invention advantageously provides a system and method for pooling devices based on operation that includes determining respective operations performed by a plurality of devices, grouping devices that perform similar operations into respective operation pools, and selecting devices to perform a sequence of operations. If an operation within the sequence is associated with one of the operation pools, then the device is selected from the associated operation pool.

Description

OPERATION POOLING SYSTEM AND METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 61/023,641, entitled "Operation Pooling" and filed on January 25, 2008, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

[0002] The present invention relates generally to automation. More particularly, the present invention relates to processes, operations, tasks, etc., that are performed by a set of devices under the control of one or more computers or control systems.

BACKGROUND OF THE INVENTION

[0003] There has been an ever-increasing demand for automation within the public and private sectors of the economy, generally, as well as across many different technical fields, such as medical research, biological sample processing, chemical engineering, semiconductor manufacturing, etc. Automation may be thought of as the configuration, operation and control of a set of devices with reduced human intervention, which advantageously increases efficiency, allows processes, operations, tasks, etc., to be performed within controlled environments, reduces the burdens on the human workforce, increases throughput, reduces cost, etc. Specific technological challenges are always presented to the automation system developer, including the fundamental problem of how to control a set of devices in order to accomplish a specific objective in an efficient and timely manner.

[0004] One significant challenge faced by automation system developers is device failure; to wit, whether a failed device should be physically replaced by a new device, or whether a backup or redundant device within the system should be assigned to perform the operations of the failed device. Physical replacement of a failed device creates system "down time" that, depending on the severity of the failure and the complexity of the replacement, reduces system efficiency, throughput, temporal performance, etc. While the technique known as "hot swapping" tends to minimize failed device replacement time for some systems, this technique may not be adaptable to many types of technologies, such as biological sample processing. In some systems, an identical device within the system may be reassigned to perform the operations of the failed device, in addition to its own operations. Unfortunately, such simple resource reallocation techniques require that unused capacity be designed into the system a priori, which increases cost, reduces efficiency, etc. Furthermore, the reallocated device may not be identical to the failed device, or may perform the required operations in a different manner, both physically and temporally, such that the reallocation represents a less-than-ideal solution until such time as a physical replacement or repair of the failed device can be effected.

[0005] Another significant challenge faced by automation system developers is device loading; to wit, whether a particular device is operating at full capacity for as much time as possible. Generally, if a particular device is operating at less than full capacity, the throughput and efficiency of the system will be less that optimal. Further complicating both the failure and loading issues is the ability of many devices to perform more than one operation, such as temperature measurement and sample movement. Consequently, the loading of one device with respect to one particular operation, e.g., temperature measurement, may undesirably limit the ability of the device to perform the second operation, e.g., sample movement. Similarly, if a multi-function device fails with respect to one function, replacement of the entire device may be inefficient, as the device may still be capable of performing at least one operation. [0006] Accordingly, an improved automated system and concomitant method is needed to more effectively accommodate device failure as well as to more efficiently apportion device functionality within the system.

SUMMARY OF THE INVENTION

[0007] Embodiments of the present invention advantageously provide a system and method for pooling devices based on operation that includes determining respective operations performed by a plurality of devices, grouping devices that perform similar operations into respective operation pools, and selecting devices to perform a sequence of operations. If an operation within the sequence is associated with one of the operation pools, then the device is selected from the associated operation pool.

[0008] There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

[0009] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

[0010] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 depicts a block diagram of an automation system, in accordance with an embodiment of the present invention.

[0012] FIG. 2 depicts another block diagram of an automation system, in accordance with an embodiment of the present invention.

[0013] FIG. 3 depicts two automation system devices, in accordance with an embodiment of the present invention.

[0014] FIG. 4 presents an operation pool table, in accordance with an embodiment of the present invention.

[0015] FIG. 5 depicts a further block diagram of an automation system, in accordance with an embodiment of the present invention.

[0016] FIG. 6 presents a flow diagram of a sample process, in accordance with an embodiment of the present invention.

[0017] FIG. 7 depicts a block diagram of an automation system computer, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[0018] Embodiments of the present invention provide an automated system that includes a computer coupled to a plurality of processing devices, each of which performs at least one operation, as generally depicted in FIGS. 2, 3, and 7. The computer includes a memory that stores a plurality of operation pools, each of which includes a list of devices that have at least one similar operation, and a processor, coupled to the memory, that executes an inventive method that pools devices based on operation. The method generally includes selecting devices to perform a sequence of operations, and, if an operation within the sequence is associated with one of the operation pools, then the device is selected from the associated operation pool. The present invention more effectively accommodates device failure and more efficiently apportions device functionality within the automated system. Additional features and further embodiments of the inventive system and method are discussed below.

[0019] Operation pooling may be used in many different contexts, such as, for example, high throughput screening, high-content screening, various cellular assays, clinical processes, or any other process utilizing a suite of instruments for automation. Other examples also include protein crystallography, microplate stackers, devices for automation of assays, automated movers, etc. Further, operation pooling may also be used in other areas, such as semiconductor manufacturing, mechanical device manufacturing, etc. There is practically no limitation as to application of the present invention provided there is at least one sequence of operations to be performed.

[0020] Generally, an automation (or automated) system can vary in size and complexity, from a single instrument that performs an automated process, for example, to a group of such instruments or devices that are controlled by a computer or computer system. The instruments or devices may be, for example, a robotic arm or a conveyor system to move objects individually, an incubation system to control the environmental conditions of objects stored on plates within a stacker that can be moved by a robotic arm, etc. The instruments may also include screening devices or systems for high throughput screening of cellular and biochemical assays. Instruments may also include devices for high content screening and cellular imaging, such as automated microscopes, imaging analysis devices and robotics, etc. The instruments are mentioned only as a way of example and are without limitation. [0021] The present invention alleviates the dependency and reliance on certain specific devices, thus accommodating a greater freedom of choice for the user of the automation system, thereby allowing for a greater reliability and efficiency of the automation system. The dependency on a particular instrument, for example, can become very cumbersome and potentially expensive to an automation system that cannot repair or replace the particular device that is either not performing up to its specification or is completely malfunctioning. Further, the independence from a particular instrument allows greater latitude and flexibility in generating a sequence of device operations that performs a certain process.

[0022] FIG. 1 depicts a block diagram of an automation system, in accordance with an embodiment of the present invention. Automation system 10 includes at least one computer 20 to control and coordinate a set of devices 300, such as, for example, instruments, movers, etc. Additionally, automation system 10 can include a number of control computers 20 (represented as dashed box 200) that control a number of device sets 300 (represented as dashed box 400). For example, the total set of devices 400 can include up to "P" sets of devices 300, where P is an integer greater than zero. The connection from the control computers 200 to the "P" sets of devices 400 can be a wired connection, a wireless connection, a combination of the two, etc. The control computers 200 can be any number from 1 to M, where M is an integer greater than zero. The set of devices 300 can be anywhere from 1 to N, where N is an integer greater than zero.

[0023] FIG. 2 depicts another block diagram of an automation system, in accordance with an embodiment of the present invention. Automation system 10 includes a control computer 20 and a set of eight devices 22, 24, 26, 28, 30, 32, 34 and 36. Each device in system 10 can perform one or more operations; additionally, two or more devices may be needed to perform a "single" operation. Further, the operations may overlap, in which one device performs Operations A, B, C and another device performs Operations B and C.

[0024] For example, referring to FIG. 3, a robotic device 500 moves objects to and from other devices, such as an analytical instrument 600, which performs any number of operations upon the object or sample, including, for example, measuring the weight of the object, determining a chemical composition of the object, measuring the temperature of the object, etc. Therefore, each device adds to the overall capability of the system 10 by adding to the operations that system 10 can perform.

[0025] Devices 500 and 600 may also share a certain operation. For example, the robotic device 500 may have a sensor that detects the temperature of an object, while the analytic instrument 600 may also have a sensor that measures the temperature of the object. Therefore, this common operation, i.e., temperature measurement, may be pooled because the operation can be performed by either device. Generally, device 22 may perform operation A, while device 24, even though it is a different device from device 22, may also performs operation A. The devices 22 to 36 can be all different devices, or any one of them can be the same or similar devices.

[0026] In some situations, it is desirable to include multiple devices, such as devices 22 to 36, in a system that provides identical (or nearly identical) operations to an instant process. Providing such redundancy is important because the operation may not be identical (or nearly identical) to all the processes that may be accommodated by the system. This capability may be driven by a need for increased system throughput for that type of operation, for reliability concerns (i.e., the reliability of a device is lower than desired, so redundant devices are included in the system), etc. System throughput may be increased by having devices run similar, or the same, operations in parallel or in series, thus allowing rest time for a particular device to increase reliability, or to free up that particular device not being utilized for the particular operation to be potentially used for another operation. [0027] FIG. 4 presents an operation pool table, in accordance with an embodiment of the present invention. As depicted in the table, operation pools are shown across devices that have operations that are considered to be the same, similar, common, etc. Many permutations of device types may reside within any particular operation pool. For example, the devices may be exactly the same make, model and manufacturer, the devices may be the same make and model but made by different manufacturers, the devices may be completely different devices with at least one common operation, etc.

[0028] Of course, an important aspect of operation pooling is that one particular operation that a device provides is similar enough to an operation that another device provides, such that the devices can be pooled together based on the similarity of this particular operation. Accordingly, it is the operation that is noteworthy and not the device itself. In other words, the devices within a given pool are functionally equivalent with respect to a particular operation (e.g., temperature measurement), such that the control computer 20 is free to choose any device from within a given operation pool to perform that operation (e.g., measure the object temperature).

[0029] Operation pools are determined either by the automation system user (or automator), or by the automation system itself, using predetermined criteria and one or more rule sets. Importantly, a thorough understanding of the particular operations and operating parameters of each device is necessary in order to determine equivalence among devices.

[0030] For example, Operation A moves object A from position 0 to 1 traveling along the x axis, and then along the y axis, while Operation B moves object B from position 0 to 1 in the same manner, and Operation C moves object A from position 0 to 1, first along the y axis and then along the x axis. To a certain process AA with no limitation on the motion and object used, all Operations A, B and C are equivalent, while to a certain process AB that has no limitation on the motion, but a limitation on the object used, only Operations A and C are equivalent.

[0031] Since each device performing a specific operation may have different operating parameters, it is the automator's responsibility to ensure that each operation is functionally equivalent to the other operations within a pool. Additionally, each process accommodated by automated system 10 may have different operation pools, because a given operation pool that is valid for one process may not be valid for another process.

[0032] As depicted in FIG. 4, different devices provide common operations. For example, operation pool 1 was created, since devices 2 and 3 both provide Operation D. Similarly, operation pools 2 thru 5 were respectively created for Operations E, F, G, and I.

[0033] Control computer 20 executes software that controls and coordinates the system by initiating the execution of individual device operations at the appropriate times. Once the operation pools are created by the user, or autonomously, the control software can choose from all of the devices within an operation pool when that particular operation needed.

[0034] FIG. 6 presents a flow diagram of a sample process, in accordance with an embodiment of the present invention. In general, material flows from start to stop by passing either through Operations A, D, and E or through Operations A, F, and H. If Operation D needs to be performed, the control software may choose to perform that operation using device 2 or device 3. As stated earlier, the criteria upon which this choice is made varies.

[0035] As depicted in FIG. 4, operation pool 1 for Operation D may be performed using either device 2 or device 3; accordingly, operation pool 1 includes device 2 and device 3. Operation pool 2 for Operation E includes device 2 and device 4; operation pool 3 for Operation F includes device 2, device 3, and device 4; operation pool 4 for Operation G includes device 3 and device 4; finally, operation pool 5 for Operation I includes device 5 and 6.

[0036] FIG. 5 depicts a further block diagram of an automation system, in accordance with an embodiment of the present invention. Operation pool 450 and operation pool 460 are shown with respect to automated system 10. Operation pool 450 for operation D includes devices 2 and 3, while operation pool 460 for Operation G includes devices 3 and 4.

[0037] In addition, an operation pool can include multiple operations. For example, an operation pool can be a combination of Operations E and F; accordingly, the devices that perform Operations E and F is the intersecting subset of the set for operation E and F, which, in this example, would be device 2 and device 4.

[0038] Moreover, a single operation can also be performed by more than one device. For example, it may take both devices 22 and 24 to perform operation Z, and devices 26 and 28 together are needed to perform operation Z. Therefore, the pool will include the combination of device 22 and 24, and the combination of devices 26 and 28.

[0039] Referring again to FIG. 6, Operation A is first selected by the automation system 10 in step 500. Since Operation A has been explicitly identified in the process, the automation system 10 is limited to device 1 (e.g., FIG. 4). In one embodiment, an operation pool is not created for Operation A, and device 1 is simply selected directly by the automation system (as depicted in FIG. 4). In another embodiment, an operation pool is created for Operation A, but only includes a single device, i.e., device 1 (not shown).

[0040] The automation system 10 then takes the decision of whether to proceed to a primary process flow path. If the primary process flow path is decided in step 500, then Operation D is selected in step 504. For Operation D, the automation system can select either device 2 or device 3 from operation pool 1; alternatively, automation system 10 can use device 2 and device 3 in parallel for increased throughput, or automation system 10 can use device 2 and device 3 in serial to decrease the time of use for each device, thus decreasing the wear upon any one device, etc. After the initiation of Operation D, Operation E is selected in step 506. For Operation E, the automation system can select device 2 or device 4 from operation pool 2; alternatively, the automation system 10 can use device 2 and device 4 in parallel for increased throughput, etc.

[0041] If, however, in step 502, the decision of "no" is taken, then Operation F is selected in step 508. For Operation F, the automation system can select between device 2, device 3 or device 4 from operation pool 3; alternatively, automation system 10 can use device 2, device 3 and device 4 in parallel for increased throughput, etc. After initiation of Operation F, Operation H is selected in step 510 by. In the depicted embodiment, Operation H does not have an associated pool of operations, and, consequently, automation system 10 is limited to selecting device 6. Finally, after either Operation E or H is finished, the process is stopped in step 512.

[0042] Automation system 10 also provides robust error handling. The pooling or grouping of operations advantageously adds redundant behavior; accordingly, if there is an error in a particular instrument that has a pooled operation, the system itself will not halt. Instead, control computer 20 advantageously selects a different instrument from the operation pool to perform that particular operation.

[0043] The invention may be realized as computer-executable instructions in computer readable media. The computer readable media includes all possible kinds of media in which computer readable data is stored or included or can include any type of data that can be read by a computer or a processing unit. The computer readable media include for example and not limited to storing media, such as magnetic storing media (e.g., ROMs, floppy disks, hard disk, and the like), optical reading media (e.g., CD ROMs (compact disc-read-only memory), DVDs (digital versatile discs), re- writable versions of the optical discs, and the like), hybrid magnetic optical disks, organic disks, system memory (read- only memory, random access memory), non-volatile memory such as flash memory or any other volatile or non- volatile memory, other semiconductor media, electronic media, electromagnetic media, infrared, and other communication media such as carrier waves (e.g., transmission via the Internet or another computer).

[0044] Communication media generally embodies computer-readable instructions, data structures, program modules or other data in a modulated signal such as the carrier waves or other transportable mechanism including any information delivery media. Computer-readable media such as communication media may include wireless media such as radio frequency, infrared microwaves, and wired media such as a wired network. Also, the computer readable media can store and execute computer readable codes that are distributed in computers connected via a network. The computer readable medium also includes cooperating or interconnected computer readable media that are in the processing system or are distributed among multiple processing systems that may be local or remote to the processing system. The invention can include the computer-readable medium having stored thereon a data structure including a plurality of fields containing data representing the techniques of the invention.

[0045] FIG. 7 depicts a block diagram of an automation system computer, in accordance with an embodiment of the present invention. Computer 800 reads computer readable media 806 that includes computer-executable instructions of the invention. The computer 800 includes a processor 802 that uses the system memory 804 and a computer readable memory device 806 that includes certain computer readable recording media. A system bus connects the processor 802 to a network interface 808, modem 812 or other interface that accommodates a connection to another computer or network such as the Internet. The system bus may also include an input and output (I/O) interface 810 that accommodate connection to a variety of other devices. Furthermore, the computer 800 can output through, for example, the I/O 810, data for display on a display device 820. [0046] The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention.

Claims

What is claimed is:

1. A method for managing devices within an automated system, comprising: determining at least one operation performed by each of a plurality of devices; forming a plurality of operation pools, each including devices that perform a common operation; and selecting a device from one of the operation pools to perform the respective operation.

2. The method of claim I₅ further comprising: creating a sequence of operations to be performed; and selecting one of the devices to perform each operation within the sequence, wherein, if an operation within the sequence is associated with one of the operation pools, then the device is selected from the associated operation pool.

3. The method of claim 2, wherein each device performs at least one operation on at least one biological sample.

4. The method of claim 2, wherein at least one device is not assigned to an operation pool.

5. The method of claim 2, wherein each operation pool includes at least two devices.

6. The method of claim 5, wherein at least one device within each operation pool performs at least one additional operation.

7. The method of claim 2, wherein each device is assigned to each operation pool for which the device has a corresponding operation.

8. The method of claim 2, wherein the sequence of operations includes a primary operation sequence and at least one secondary operation sequence.

9. The method of claim 2, wherein the plurality of devices are geographically dispersed.

10. The method of claim 9, wherein at least one operation pool includes geographically dispersed devices.

11. A method for pooling devices based on operation, comprising: determining respective operations performed by a plurality of devices; grouping devices that perform similar operations into respective operation pools; and selecting devices to perform a sequence of operations, wherein, if an operation within the sequence is associated with one of the operation pools, then the device is selected from the associated operation pool.

12. The method of claim 11 , wherein each operation pool includes at least two devices.

13. The method of claim 12, wherein at least one device within each operation pool performs at least one additional operation.

14. The method of claim 11, wherein each device is assigned to each operation pool for which the device has a corresponding operation.

15. The method of claim 11, wherein the sequence of operations includes a primary operation sequence and at least one secondary operation sequence

16. An automated system, comprising: a plurality of devices, each performing at least one operation; and a computer, coupled to the devices, including: a memory storing a plurality of operation pools, each including a list of devices that have at least one similar operation; and a processor, coupled to the memory, adapted to perform a method for pooling devices based on operation, the method including selecting devices to perform a sequence of operations, and, if an operation within the sequence is associated with one of the operation pools, then the device is selected from the associated operation pool.

17. The automated system of claim 16, wherein each operation pool includes at least two devices.

18. The automated system of claim 17, wherein at least one device within each operation pool performs at least one additional operation.

19. The automated system of claim 16, wherein each device is assigned to each operation pool for which the device has a corresponding operation.

20. The automated system of claim 16, wherein the sequence of operations includes a primary operation sequence and at least one secondary operation sequence.