Method of operating a laboratory sample distribution system, laboratory sample distribution system and a laboratory automation system

A method of operating a laboratory sample distribution system is disclosed. The laboratory sample distribution system comprises a plurality of sample container carriers. The sample container carriers carry one or more sample containers. The sample containers comprise samples to be analyzed by a plurality of laboratory stations. The system also comprises a transport plane. The transport plane supports the sample container carriers. The transport plane comprises a plurality of transfer locations. The transfer locations are assigned to corresponding laboratory stations. The system also comprises a drive. The drive moves the sample container carriers on the transport plane. The method comprises, during an initialization of the laboratory sample distribution system, pre-calculating routes depending on the transfer locations and, after the initialization of the laboratory sample distribution system, controlling the drive such that the sample container carriers move along the pre-calculated routes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to EP 15168780.3, filed May 22, 2015, which is hereby incorporated by reference.

BACKGROUND

The present disclosure relates to a method of operating a laboratory sample distribution system, a laboratory sample distribution system, and a laboratory automation system.

Laboratory sample distribution systems can be used in order to distribute samples between pluralities of laboratory stations in a laboratory automation system. For example, a two-dimensional laboratory sample distribution system providing high throughput is known. Electro-magnetic actuators are disposed below a transport plane in order to drive sample container carriers carrying sample containers on the transport plane.

There is a need for a method of operating a laboratory sample distribution system, a laboratory sample distribution system and a laboratory automation system enabling an efficient and reliable distribution of samples between different laboratory stations.

SUMMARY

According to the present disclosure, a method and a laboratory sample distribution system are presented. The laboratory sample distribution system can comprise a plurality of sample container carriers. The sample container carriers can be adapted to carry one or more sample containers. The sample containers can comprise samples to be analyzed by a plurality of laboratory stations. The system can further comprise a transport plane. The transport plane can be adapted to support the sample container carriers. The transport plane can comprise a plurality of transfer locations. The transfer locations can be assigned to corresponding laboratory stations. The system can also comprise a drive. The drive can be adapted to move the sample container carriers on the transport plane. The system can also comprise a control unit. The control unit can be adapted to pre-calculate routes depending on the transfer locations during an initialization of the laboratory sample distribution system and to control the drive such that the sample container carriers can move along the pre-calculated routes after the initialization of the laboratory sample distribution system.

Accordingly, it is a feature of the embodiments of the present disclosure to provide for a method of operating a laboratory sample distribution system, a laboratory sample distribution system and a laboratory automation system enabling an efficient and reliable distribution of samples between different laboratory stations. Other features of the embodiments of the present disclosure will be apparent in light of the description of the disclosure embodied herein.

DETAILED DESCRIPTION

The method can be adapted to operate a laboratory sample distribution system. The laboratory sample distribution system can comprises a number (e.g., 10 to 10000) of sample container carriers. The sample container carriers can be respectively adapted to carry one or more sample containers. The sample containers can respectively comprise samples to be analyzed by a plurality (e.g., 2 to 50) of laboratory stations.

The laboratory sample distribution system can further comprise a, substantially planar, transport plane. The transport plane can be adapted to support the sample container carriers, i.e. the sample container carriers can be placed on top of the transport plane and can be moved on top of and over the transport plane.

The transport plane can comprise a plurality (e.g., 2 to 100) of transfer locations, or nodes. The transfer locations, or nodes, can be assigned to corresponding laboratory stations. For example, each laboratory station may have a single corresponding transfer location, or node. Alternatively, more than one transfer location, or node, may be assigned to a corresponding laboratory station. The transfer locations, or nodes, may be statically, or dynamically, assigned to the laboratory stations. In other words, during operation, the transfer locations may be changed, if necessary.

The laboratory sample distribution system can further comprise a drive. The drive can be adapted to move the sample container carriers on and over the transport plane.

The operating method can comprise, during an initialization (i.e., starting and/or booting) of the laboratory sample distribution system e.g., fixed routes extending over the transport plane can be pre-calculated depending on, e.g., between, the different transfer locations. In other words, the pre-calculated routes can be provided on the transport plane between the transfer locations. The transfer locations may represent initial, or goal, nodes in the sense of Graph theory.

After the initialization of the laboratory sample distribution system during a normal operational mode, the drive can be controlled such that the sample container carriers can move along the pre-calculated routes over the transport plane, if and when the sample container carriers are to be distributed between the different laboratory stations. In other words, after the initialization of the laboratory sample distribution system during a normal operational mode, the drive can be controlled such that the sample container carriers can repeatedly move, for example, only, along the pre-calculated fixed routes over the transport plane, if and when the sample container carriers are to be distributed between the different laboratory stations. The term “fixed” can denote that the routes can be statically calculated (i.e. not recalculated) and that the calculated routes can be used by several sample container carriers and may not be calculated for each sample container carrier individually. Self-evidently, in specific use scenarios, the sample container carriers may move apart from the pre-calculated routes, e.g., in case the sample container carriers have to be removed from the transport plane and/or in error conditions. Further, empty sample container carriers may move along different routes and/or apart from the pre-calculated routes.

The routes can be calculated using an informed search algorithm such as, for example, an A*-algorithm or a D*-algorithm. The A*-algorithm is an algorithm that can be used in path finding and graph traversal to efficiently calculate a traversable path between different nodes, e.g., in the form of the transfer locations. The A*-algorithm uses a best-first search and can find a least-cost path from a given initial node to one goal node (out of one or more possible goals). As the A*-algorithm traverses the graph, it can follow a path of the lowest expected total cost or distance, keeping a sorted priority queue of alternate path segments along the way. The D*-algorithm is a refined A*-algorithm.

The routes can be calculated such that a number of intersections between different routes can be minimized.

During the initialization of the laboratory sample distribution system, respective buffer areas located on the transport plane can be logically allocated to the laboratory stations. Samples waiting to be analyzed by the laboratory stations can be buffered in the buffer areas. For example, each laboratory station may have a single corresponding buffer area on the transport plane. Alternatively, more than one buffer area may be assigned to a corresponding laboratory station on the transport plane. The buffer areas can be allocated such that the pre-calculated routes do not intersect the buffer areas.

The sample container carriers can be entered into the buffer areas or can be removed from the buffer areas exclusively over (passing) the transfer locations, i.e., the transfer locations can serve as a gate (entrance/exit) to the buffer areas.

The transport plane can be segmented into logical fields, e.g., square shaped logical fields of substantially identical size and outline. The logical fields can be arranged in a chess board manner. In a time-prioritized reservation scheme, an adjustable number (e.g., 1 to 100) of logical fields positioned on or lying on a pre-calculated route can respectively be reserved for sample container carriers to be moved. In other words, the logical fields can be reserved in a first come, first serve manner for each sample container carrier to be moved. The logical fields can typically be reserved before starting a movement of a sample container carrier. Nevertheless, the logical fields can be reserved during a movement of a sample container carrier, if the sample container carrier has not yet reached the logical fields to be reserved. A sample container carrier moving on a route comprising logical fields being reserved for another sample container carrier with a higher time priority, i.e., the logical fields have been reserved for the other sample container carrier prior to the reservation for the moving sample container, can be stopped before the reserved field or may not be started. The reserved fields can be released when the sample container carrier has passed the reserved field(s).

After the initialization of the laboratory sample distribution system, operating data of the laboratory sample distribution system can be collected and stored. During a next initialization of the laboratory sample distribution system, the routes can be pre-calculated depending on the transfer locations and depending on the operating data.

The operating data can comprise information regarding a volume of traffic on the routes. The information regarding the volume of traffic can comprise information of the number of sample container carriers being moved on the route per time unit (e.g., per minute/hour/day etc.). A time profile of the volume of traffic over the operating time may be determined.

The step of pre-calculating the routes can comprise that a number of lanes assigned to the routes can be determined depending on the volume of traffic. For example, in case of low volume of traffic, a single lane may be assigned to a route. In case of increasing volume of traffic, two or more lanes may be assigned to the route. The routes can be, in one embodiment, one-way lanes.

Samples, and/or sample containers, and/or the sample container carriers can be transferred to/from the laboratory stations using the transfer locations. For example, a pick-and-place device can pick a sample container comprised in a sample container carrier located at one of the transfer locations and can transfer the sample container to the laboratory station. Accordingly, a sample container can be transferred from one of the laboratory stations to an empty sample container carrier located on the transfer location.

During the initialization of the laboratory sample distribution system, the routes can be pre-calculated between the transfer locations, i.e., the end points, or end nodes, of the routes can be formed by the transfer locations. If, for example, a first, a second, and a third transfer location are given, a route between the first and the second transfer location, a route between the first and the third transfer location, and a route between the second and the third transfer location can be pre-calculated.

The laboratory sample distribution system can be adapted to perform the method as described above.

The laboratory sample distribution system can comprise a plurality of sample container carriers. The sample container carriers can be adapted to carry one or more sample containers. The sample containers can comprise samples to be analyzed by a plurality of laboratory stations. The system can also comprise a transport plane. The transport plane can be adapted to support the sample container carriers. The transport plane can comprise a plurality of transfer locations The transfer locations can be assigned to corresponding laboratory stations. The system can also comprise a drive. The drive can be adapted to move the sample container carriers on the transport plane. The system can also comprise a control unit such as, for example, in the form of a microprocessor and program storage. The control unit can be adapted to control the laboratory sample distribution system such that the method as described above can be performed. The control unit can be adapted to pre-calculate routes depending on the transfer locations during an initialization of the laboratory sample distribution system and to control the drive such that the sample container carriers can move along the pre-calculated routes after the initialization of the laboratory sample distribution system.

The sample container carriers can comprise at least one magnetically active device such as, for example, at least one permanent magnet. The drive can comprise a plurality of electro-magnetic actuators being stationary arranged in rows and columns below the transport plane. The electro-magnetic actuators can be adapted to apply a magnetic force to the sample container carriers. The control unit can be adapted to activate the electromagnetic actuators such that the sample container carriers can move simultaneously and independently from one another along the pre-calculated routes. The electro-magnetic actuators may define corresponding nodes of a graph in the sense of Graph Theory. A node may be defined or located on the transport plane above the corresponding electro-magnetic actuator. The transfer locations may be formed above a corresponding electro-magnetic actuator. The so defined grid-shaped graph may be used by an informed search algorithm such as, for example, an A*-algorithm or a D*-algorithm, to calculate a traversable path from initial node, or an initial transfer, location to a goal node, or a goal transfer location.

The laboratory automation system comprises a plurality (e.g., 2 to 50) of laboratory stations such as, for example, pre-analytical, analytical and/or post-analytical stations, and a laboratory sample distribution system as described above.

Pre-analytical stations may be adapted to perform any kind of pre-processing of samples, sample containers and/or sample container carriers. Analytical stations may be adapted to use a sample or part of the sample and a reagent to generate a measuring signal, the measuring signal indicating if and in which concentration, if any, an analyte exists. Post-analytical stations may be adapted to perform any kind of post-processing of samples, sample containers and/or sample container carriers.

The pre-analytical, analytical and/or post-analytical stations may comprise at least one of a decapping station, a recapping station, a centrifugation station, an archiving station, a pipetting station, a sorting station, a tube type identification station, and a sample quality determining station.

The pre-calculated routes can be visualized on the transport plane, such that an operator can control the pre-calculated routes and, if necessary, manually adjust the pre-calculated routes. In order to visualize the pre-calculated routes visualizing means e.g., in the form of light emitting devices such as LEDs can be arranged below the transport plane. The transport plane can be at least partially translucent. For example, for each electro-magnetic actuator, a corresponding LED may be provided placed adjacent to the electro-magnetic actuator. The visualizing means may further be used to visualize the operating state of the corresponding electro-magnetic actuator and may, for example, indicate if the corresponding electro-magnetic actuator is defective. Additionally, if the transport plane is segmented into a number of separate modules, defective modules may be signalized by the visualizing means located inside the defective module.

Referring initially toFIG. 1,FIG. 1schematically shows a laboratory automation system10in a perspective view. The laboratory automation system10can comprise three laboratory stations20,21,22, e.g., pre-analytical, analytical and/or post-analytical stations, and a laboratory sample distribution system100. Self-evidently, the laboratory automation system10may comprise more than three laboratory stations20,21,22.

The laboratory sample distribution system100can comprises a plurality of sample container carriers140. For the sake of explanation, only a single sample container carrier140is depicted. Self-evidently, the laboratory sample distribution system100can comprise a plurality of sample container carriers140, e.g., 50 to 500 sample container carriers140. The sample container carriers140can respectively comprise a magnetically active device141in the form of a permanent magnet.

The sample container carriers140can be adapted to carry one or more sample containers145. The sample containers145can comprise samples to be analyzed by the laboratory stations20,21,22.

The laboratory sample distribution system100can further comprises a transport plane110. The transport plane110can be adapted to support or carry the sample container carriers140.

Positions sensors130, e.g., in form of Hall sensors, can be distributed over the transport plane110, such that a location of a respective sample container carrier140can be detected.

Referring toFIG. 2, the transport plane110can comprise a plurality of logical transfer locations30,31,32. The transfer location30can be logically allocated to the laboratory station20, the transfer location31can be logically allocated to the laboratory station21and the transfer location32can be logically allocated to the laboratory station22. The transport plane110can comprises a plurality of logical buffer areas50,51,52. The buffer area50can be logically allocated to the laboratory station20, the buffer area51can be logically allocated to the laboratory station21, and the buffer area52can be logically allocated to the laboratory station22. Samples waiting to be analyzed by the laboratory stations20,21,22can be buffered in the respective buffer areas50,51,52. Sample container carriers140can enter the buffer areas50,51,52or can be removed from the buffer areas50,51,52exclusively over the corresponding transfer locations30,31,32.

Referring toFIG. 1again, the laboratory sample distribution system100can further comprises a drive. The drive can comprise a plurality of electro-magnetic actuators120being stationary arranged in rows and columns below the transport plane110. The electro-magnetic actuators120can respectively comprise a coil surrounding a ferromagnetic core125. The electro-magnetic actuators120can be adapted to apply a magnetic drive force to the container carriers140.

The laboratory sample distribution system100can further comprise a control unit150. The control unit150can, inter alia, control the electro-magnetic actuators120such that the sample container carriers140may move simultaneously and independently from one another over the transport plane110.

The method of operation of the laboratory sample distribution system100will be described with respect toFIGS. 2 and 3.

FIG. 2schematically shows the laboratory automation system10ofFIG. 1in a top view. During an initialization, or start-up phase, of the laboratory sample distribution system100, the control unit150can pre-calculate routes40,41,42between the transfer locations30,31,32. In addition, during the initialization of the laboratory sample distribution system100, the buffer areas50,51,52can be logically allocated to the laboratory station20,21,22, respectively.

After the initialization of the laboratory sample distribution system100, the control unit150can control the electro-magnetic actuators120such that the sample container carriers140can move along the pre-calculated routes40,41,42, if the sample container carriers140have to be distributed between the laboratory stations20,21,22.

The routes40,41,42can be calculated using an A*-algorithm. The routes40,41,42can be, inter alia, calculated such that a number of intersections between different routes40,41,42can be minimized. In the embodiment depicted, no intersections occur.

Referring toFIGS. 2 and 3, the transport plane110can be logically segmented into equally-sized, substantially square shaped logical fields111. Each logical field11can be assigned to, i.e., covers, a corresponding electro-magnetic actuator120.

In a time-prioritized reservation scheme, a plurality of, for example 10, logical fields111lying on the routes40′ and41′ can be reserved for sample container carriers to be moved on the routes40′ and41′. In other words, the logical fields111can be reserved in a first come, first serve manner for each sample container140carrier to be moved.

Given that for a sample container carrier to be moved on route40′ the logical fields111on the route40′ have been reserved before the logical fields111on the route41′ have been reserved for another sample container carrier to be moved on route41′, the sample container carrier moving on route41′ can stop before reaching the field in the intersection of the routes40′ and41′, thus avoiding a potential collision. The reserved fields111can be released when the sample container carriers have passed the reserved fields111.

After the initialization of the laboratory sample distribution system100, operating data of the laboratory sample distribution system100can be collected. The operating data can comprise information regarding a volume of traffic on the routes40,41,42. During a next initialization of the laboratory sample distribution system100, the routes40,41,42can be pre-calculated additionally depending on the volume of traffic. For example, a number of lanes assigned to the routes40,41,42can be determined depending on the volume of traffic. As depicted inFIG. 3, respective single lanes of logical fields111can be assigned to the routes40′ and41′. If, for example, the volume of traffic on route40′ would be above a given threshold, a second (third, etc.) lane of logical fields111can be assigned to the route40′.