AUTOMATED LIQUID DISPENSING SYSTEMS

The present disclosure provides an apparatus for dispensing fluid from a reagent container having a pump comprising a control and an outlet whereby moving the control causes fluid to flow from the outlet. The apparatus comprises a pump actuator assembly comprising a first bracket configured to be mounted on the reagent container, a second bracket configured to engage the control, and a pump actuator connected to move the second bracket relative to the first bracket; a dispenser assembly comprising a dispensing nozzle, a nozzle positioning mechanism configured to move the dispensing nozzle through a plurality of positions, and a flexible tube having a first end connected to the dispensing nozzle and a second end connectible to the outlet of the pump; and a controller in communication with the dispenser assembly and the pump actuator assembly for controlling the pump actuator and the nozzle positioning mechanism.

TECHNICAL FIELD

The present disclosure relates to dispensing liquids. Particular embodiments relate to apparatus, methods and systems for safely and precisely dispensing controlled amounts of liquids.

BACKGROUND

There are a number of situations where liquids need to be dispensed into containers repeatedly and in controlled amounts. For example, many laboratory tests involve adding reagents to samples held in a plurality of test tubes in racks. Some reagents, such as strong industrial acids, can be highly corrosive, hazardous and produce toxic fumes, and subject to stringent safety regulations.

The inventors have determined a need for improved apparatus, methods and systems for safely and precisely dispensing controlled amounts of liquids.

SUMMARY

One aspect provides an apparatus for dispensing fluid from a reagent container having a pump comprising a control and an outlet whereby moving the control causes fluid to flow from the outlet. The apparatus comprises a pump actuator assembly comprising a first bracket configured to be mounted on the reagent container, a second bracket configured to engage the control, and a pump actuator connected to move the second bracket relative to the first bracket; a dispenser assembly comprising a dispensing nozzle, a nozzle positioning mechanism configured to move the dispensing nozzle through a plurality of positions, and a flexible tube having a first end connected to the dispensing nozzle and a second end connectible to the outlet of the pump; and a controller in communication with the dispenser assembly and the pump actuator assembly for controlling the pump actuator and the nozzle positioning mechanism.

Another aspect provides an apparatus for dispensing fluid from a reagent container, the apparatus comprising, a pump actuator assembly configured to actuate a pump to cause fluid from the reagent container to flow from an outlet, a dispenser assembly comprising a dispensing nozzle, a nozzle positioning mechanism configured to move the dispensing nozzle through a plurality of positions, and a flexible tube having a first end connected to the dispensing nozzle and a second end connectible to the outlet of the pump, and a controller in communication with the dispenser assembly and the pump actuator assembly for controlling the pump actuator assembly and the nozzle positioning mechanism.

Another aspect provides a method for dispensing fluid from a reagent container having a pump comprising a control and an outlet whereby moving the control causes fluid to flow from the outlet. The method comprises: mounting a pump actuator assembly on the pump of the reagent container, the pump actuator assembly comprising a first bracket configured to be mounted on the reagent container, a second bracket configured to engage the control, and a pump actuator connected to move the second bracket relative to the first bracket; connecting a first end of a flexible tube to the outlet of the pump and a second end of the flexible tube to a dispensing nozzle of a dispenser assembly comprising a nozzle positioning mechanism; and controlling the nozzle positioning mechanism to move the dispensing nozzle through a plurality of predetermined positions, and pause at each predetermined position while actuating the pump actuator assembly to dispense a predetermined amount of fluid from the reagent container.

Further aspects of the present disclosure and details of example embodiments are set forth below.

DETAILED DESCRIPTION

The following describes apparatus, methods and systems for safely, and precisely, dispensing controlled amounts of liquids or other fluids. In preferred embodiments, the present disclosure provides apparatus configured to be used with existing containers and pump dispensers commonly used in laboratory settings.

For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practiced without these details. In other instances, well-known methods, procedures, and components are not described in detail to avoid obscuring the examples described. The description is not to be considered as limited to the scope of the examples described herein.

FIG.1shows an example liquid dispensing system10according to one embodiment of the present disclosure. The system10comprises a dispenser assembly100, a pump actuator assembly200, and a controller300. As discussed further below, the system10may be activated by a user interacting with the controller300. In some embodiments, once activated, the controller300causes a nozzle positioning mechanism of the dispenser assembly100to move a dispensing nozzle112through a plurality of positions above a rack of test tubes T, and while the nozzle112is over each test tube, causes the pump actuator assembly200to eject a precisely controlled volume of liquid.

In the example illustrated inFIG.1, the pump actuator assembly200is configured to be mounted on standard laboratory reagent bottle B with a bottle-top dispenser pump P. The pump P has a plunger which, when depressed, causes liquid to flow from an outlet O. The pump actuator assembly200comprises a body202having a first bracket204configured to be mounted on the reagent container. The body202houses a motor or other actuator (not shown) connected (e.g. by a rack and pinion mechanism or other suitable gearing) to move a rod206in and out of the body202, and the rod206has a second bracket208configured to engage the plunger of the dispenser pump P.

The pump actuator assembly200may be differently configured than the example shown inFIG.1in other embodiments. For example, in some embodiments, the pump actuator assembly200is configured to be mounted on other types of containers/dispensers, and engage other types of pumps, so long as the pump has an outlet to which a flexible tube (as described below) of the dispensing assembly100may be attached, and some type of control to move to cause liquid or fluid to flow from the outlet. In the illustrated example, the control is a plunger of a pump, but in other embodiments the control could be, for example, a lever, dial, switch, button, squeezable bulb or other mechanism for causing fluid to flow from the outlet.

In some embodiments, the pump actuator assembly200comprises a motor-controlled pump which directly pumps liquid from a variety of types of reservoirs from an outlet to which a flexible tube may be attached. When dispensing hazardous liquids such as acids, there may be safety benefits in using a mechanical pumping mechanism of the type shown inFIG.1, but such safety benefits may not be present when dispensing less-hazardous liquids or other fluids, and thus another form of motor-controlled liquid pump may be substituted and/or preferable in some embodiments.

In the illustrated example, the nozzle positioning mechanism of the dispenser assembly100comprises a rotatable turret102mounted on a base104. In the illustrated example, the base104is mounted on a tray106with a raised edge107to contain any spills. The tray106also has a recess108for holding a rack of test tubes and a recess109for holding a drip container.

The turret102has an extendible arm110extending therefrom, at the end of which is a dispensing nozzle112. In the example illustrated inFIG.1, the dispensing nozzle112comprises a tube at the end of the arm110. A flexible tube120is connected to the top of the dispensing nozzle112, and the other end of the flexible tube120is connected to the outlet O of the pump P. An eyelet114is mounted on the turret102near the base of the arm110for holding the flexible tube120up away from the nozzle112.

In some embodiments the internal diameter of the flexible tube120and dispensing nozzle112is selected based on the characteristics of the liquid being dispensed. In some embodiments the diameter is sufficiently large, given the viscosity of the liquid being dispensed, to allow pump P to dispense the liquid from the dispensing nozzle112, and sufficiently narrow, given the surface tension of the liquid being dispensed, such that when pump P ceases its pumping action, entry of gas into, or further flow of liquid from, the dispensing nozzle112is prevented due to the formation of a static meniscus at the dispensing nozzle112.

As shown inFIG.2, the base104of dispenser assembly100has a mounting plate130therein that holds yaw gears132driven by a yaw motor134. The mounting plate130is raised up from the bottom of the base104so that any liquids that might fall onto the tray106and seep into base104do not come into contact with the internal components of dispenser assembly100. The yaw motor134is mounted on another mounting plate136at the bottom of turret102, such that the whole turret102rotates when the yaw motor134is activated. An advancement motor138is also mounted on mounting plate136, and engages teeth140on the extendible arm110, such that the arm110can be moved inwardly and outwardly from the turret102by activating the advancement motor138.

In some embodiments, the arm110may be configured to have more than one dispensing nozzle. For example,FIG.3shows an example liquid dispensing system10A with three dispensing nozzles112A (in the illustrated example ofFIG.3, all three nozzles112A are formed in a single component, but in other embodiments the nozzles112A could be formed by different components, such as three separate tubes at different angles at the end of arm110). A separate flexible tube120-1,120-2,120-3is connected between each of the nozzles112A and one of three separate reagent bottles B-1, B-2, B-3, and each of the bottles B-1, B-2, B-3has its own dispenser pump P with a pump actuator200coupled thereto. In some such embodiments, in addition to being extendible, the arm110is also rotatable about its longitudinal axis. Referring back toFIG.2, in some embodiments rotation of the arm110is effected by a roll slot142in the arm that is engaged by a pin connected to a roll gear mechanism144engaged by a roll motor146. A roll angle sensor148measures the roll angle of the arm110and provides feedback to the controller300. The arm110may be controlled to dispense any one of the different reagents by rotating the arm110to place the bottom of the nozzle connected to the desired reagent bottle at the bottom of the arm110. For example, in some embodiments, the arm110rotates around its horizontal axis (roll) to position a selected one of the nozzles112A over a test tube T, to accommodate different reagent to be dispensed in that tube without potential of misalignment or contamination.

In some embodiments, the arm110is also moveable to adjust the height of the nozzle112. For example, in some embodiments the arm110is connected to pivot about a horizontal axis through its interior end, such that the height of the nozzle112can be adjusted by pivoting the arm110.

In some embodiments, the dispenser assembly100is adaptable for use with differing test tube heights by other means. For example, in some embodiments, fixed-height spacer rings are provided, having the same outer diameter as base104, and configured to be inserted between the base104and the tray106to raise the dispenser assembly100. In some embodiments a variable-height spacer ring (either motor-actuated or manually-adjustable) is provided between the base104and the tray106to raise the dispenser assembly100. In some embodiments, the tray106has a variable depth recess (for example by having a moveable bottom, or providing spacers).

In some embodiments, all of the exposed portions of the dispenser assembly100and pump actuator assembly200are constructed from corrosion resistant materials (such as, for example PVC or other plastics). For example, in some embodiments, the components are 3D printed using acid resistant plastic, and are connected using fasteners constructed from polyether ether ketone (PEEK).

The controller300comprises a housing302containing drivers for the motors of the dispenser assembly100and pump actuator assembly200. The controller also comprises a microcontroller or other processor connected to the motor drivers.

In the illustrated example, the controller300comprises a user interface consisting of a display304, an on/off switch306, and an emergency stop308. In other embodiments, the controller300may have different user interfaces. For example, in some embodiments, the controller300may have inputs allowing a user to select from one of a plurality of predetermined dispensing sequences. In some embodiments, the controller300is configured to provide pulse width modulation (PWM) signals to the drivers for the pump actuator and the motors of the nozzle positioning mechanism.

In some embodiments, the system10comprises a pressure sensor embedded in or mounted on tray106, an optical sensor near tray106, or other sensor configured to detect the presence of a rack of test tubes T. In such embodiments, the controller300receives signals from such sensors and is configured to prevent dispensing of liquids if the signals indicate that there are no test tubes present.

In some embodiments, the controller300is programmed to cause the dispenser assembly100and pump actuator assembly200to execute a predetermined sequence of actions. For example, with reference to theFIG.1example, in some embodiments, once activated by a user, the controller300is programmed to execute a sequence for filling a rack of test tubes T in a 7×12 rectangular array, wherein the nozzle positioning mechanism is actuated to move the dispensing nozzle112over each of the 84 individual test tubes sequentially, and while the nozzle112is over each test tube the pump actuator is activated. The controller300can be configured for any standard racks (e.g., 21 positions (3×7), 40 positions (4×10), 60 positions (5×12) and 90 positions (6×15)), or custom racks, by reprogramming with the desired tube coordinates. Similarly, in some embodiments the controller300is configured for use with a pump actuator assembly200adapted for a particular type of bottle B/pump P, and in some embodiments the controller300may be reprogrammed and/or recalibrated for use with a differently configured pump actuator assembly adapted for a different type of pump or container, or preprogrammed with a variety of different settings for controlling pump actuator assemblies for different types of pumps. In some embodiments the controller300is configured to move the nozzle over a drip container in recess109and cause the pump actuator to move through one or more strokes before executing a filling sequence to ensure the flexible tube is full of liquid.

In some embodiments, the amount of liquid dispensed from the pump P can be affected by not only the length of travel but also the speed and acceleration of the plunger of the pump, and the controller300is configured to precisely control the motion of the plunger and thus the amount of liquid dispensed into each test tube. For example,FIG.4shows an example PWM curve for driving the pump actuator according to some embodiments. Once a triggering event occurs (e.g. the controller has moved the dispensing nozzle over a test tube and determined that the nozzle is in the correct position), there is a short delay, then the pump actuator accelerates the plunger upwardly, then moves the plunger upwardly at a steady speed, then decelerates until the pump actuator has moved through a predetermined upward distance for priming the pump. At the top of the stroke there is another short delay, then the pump actuator accelerates the plunger downwardly, then moves the plunger downwardly at a steady speed, then decelerates until the pump actuator has moved back to the bottom of its stroke and the desired amount of liquid has been dispensed.FIG.5shows an example output signal from the microcontroller of the controller300to the pump actuator driver.

The embodiments of the systems and methods described herein may be implemented in a combination of both hardware and software. These embodiments may be implemented on programmable computers, each computer including at least one processor, a data storage system (including volatile memory or non-volatile memory or other data storage elements or a combination thereof), and at least one communication interface. For example, the programmable computers may be a server, network appliance, set-top box, embedded device, computer expansion module, personal computer, laptop, personal data assistant, connected or autonomous vehicle, cloud computing system or mobile device. A cloud computing system is operable to deliver computing service through shared resources, software and data over a network.

Program code is applied to input data to perform the functions described herein and to generate output information. The output information is applied to one or more output devices to generate a discernable effect. In some embodiments, the communication interface may be a network communication interface. In embodiments in which elements may be combined, the communication interface may be a software communication interface, such as those for inter-process communication. In still other embodiments, there may be a combination of communication interfaces implemented as hardware, software, and combination thereof.

Furthermore, the system, processes and methods of the described embodiments are capable of being distributed in a computer program product including a physical non-transitory computer readable medium that bears computer usable instructions for one or more processors. The medium may be provided in various forms, including one or more diskettes, compact disks, tapes, chips, magnetic and electronic storage media, and the like. The computer useable instructions may also be in various forms, including compiled and non-compiled code.

Embodiments described herein may relate to various types of computing applications, such as image processing and generation applications, computing resource related applications, speech recognition applications, video processing applications, semiconductor fabrication, and so on. By way of illustrative example embodiments may be described herein in relation to image-related applications.

The embodiments described herein are implemented by physical computer hardware, including computing devices, servers, receivers, transmitters, processors, memory, displays, and networks. The embodiments described herein provide useful physical machines and particularly configured computer hardware arrangements.

As will be apparent to those skilled in the art in light of the foregoing disclosure, many alterations and modifications are possible to the methods and systems described herein. While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as may reasonably be inferred by one skilled in the art. The scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the foregoing disclosure.

The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive.