Patent Publication Number: US-2006013730-A1

Title: Method and apparatus for handling labware within a storage device

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application claims priority to and is a continuation of provisional U.S. patent application entitled, METHOD AND APPARATUS FOR HANDLING LABWARE WITHIN A STORAGE DEVICE, filed Jul. 16, 2004, having a Ser. No. 60/588,338, the disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates generally to handling devices. More particularly, the present invention relates to a microplate handler compatible with SBS (Society for Biomolecular Screening) and non-SBS microplate formats. The microplate handler is configured to transport the microplates to and from a storage location.  
     BACKGROUND OF THE INVENTION  
      Determining and achieving the proper conditions that allow a protein to crystallize from solution often requires many attempts before the proper concentrations of protein and reagents are determined and achieved. Furthermore, even when the conditions permit crystallization, the rate of crystallization is often very slow, at times on the order of weeks or even months. As a result, manually performing protein crystallization experiments is a very labor and time intensive process. One method of increasing the chances of obtaining protein crystals in the first experiment, thus saving a significant amount of time, is to try as many different protein and reagent concentrations as possible in the initial experiment.  
      Because protein crystallization experiments have traditionally been carried out in labware, such as microplates, labware storage hotels have been developed to store the numerous types of labware prepared during the course of the experiment. Furthermore, because the preparing of the vast number of microplates and the periodic checking of each microplate for protein crystals are so labor intensive, robotic microplate handlers have been developed.  
      Unfortunately there is a myriad of different microplate vendors and therefore a large variation in microplate formats used in the industry. These varying microplate sizes exist despite the Society for Biomolecular Screening&#39;s (SBS) attempt to standardize a single microplate format.  
      Because of the varying sizes of microplates, handlers have difficulty handling them. These handlers are not effective if the scientist operating them has to retool the handler for each microplate in the system. In order to streamline the experiment and allow for maximum efficiency, automated equipment, such as robotic microplate handlers, should be designed to accept both SBS and non-SBS formats. Without such devices, scientists spend their valuable time changing out tooling or reprogramming the robotic microplate handlers for each different microplate.  
      Accordingly, it is desirable to provide a method and apparatus capable of handling SBS and non-SBS microplates, along with other varying types of labware.  
     SUMMARY OF THE INVENTION  
      The foregoing needs are met, to a great extent, by the present invention, wherein an embodiment in accordance with the present invention provides a method and apparatus capable of transporting SBS and non-SBS microplates, along with other varying types of labware, to and from a storage facility without requiring retooling or reprogramming.  
      In accordance with one embodiment of the present invention is an apparatus for handling a labware located within a storage system, comprising: an arm movable between an extended and a retracted position; an abutment disposed on the arm, having a number of steps, and configured to support the labware; a guide having a number of rails and configured to center the labware; and a clamp movable between an open and a closed position and configured to bias the labware against the abutment.  
      In accordance with another embodiment of the present invention, is a method for handling a labware, comprising: providing an arm configured to handle the labware, wherein the arm comprises an abutment having at least two sets of steps; moving the arm from a retracted position to a position proximate to the labware; opening a clamp so as to provide an opening configured to house the labware; disposing the labware in the opening; moving the arm having the labware located thereon from the extended position toward the retracted position; and closing the clamp so as to bias the labware against at least a portion of one of the sets of steps.  
      In accordance with yet another embodiment of the present invention, is an apparatus for handling a labware, comprising: means for supporting the labware, wherein the means for supporting is configured to translate between an extended position and a retracted position; means for securing the labware onto the means for supporting; means for centering the labware; and means for biasing the labware configured to bias the labware against the means for securing.  
      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.  
      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.  
      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  
       FIG. 1  is a perspective view of the present invention illustrating the labware handler in an extended position.  
       FIG. 2  is a perspective view of the present invention illustrating the labware handler in a retracted position.  
       FIG. 3  is a perspective view of the present invention incorporated in a vertical drive system.  
    
    
     DETAILED DESCRIPTION  
      The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides a method and apparatus capable of transporting SBS and non-SBS microplates, along with other varying types of labware, to and from a storage facility without requiring retooling or reprogramming.  
      An embodiment of the present inventive apparatus and method is illustrated in  FIG. 1 . The present invention is a microplate handler  10  that transports varying types of labware without necessitating tooling changes, adjustments, reprogramming, or retrofitting. The microplate handler  10  includes an arm  12 , an abutment  14 , a clamp  16 , a guide  18 , a drive system  20 , and a bar code reader  22 .  
      The arm  12  is movable between an extended position and a retracted position. In an embodiment, a motorized rack and pinion drives the arm  12  between the extended position and the retracted position.  FIG. 1  illustrates the arm  12  in an extended position. The arm  12  has a first  11  and second  12  end and a low profile, as illustrated by thickness T. T is sized such that the arm  12  is suitable for, and effective in, varying environments. For example, T enables arm  12  to extend into storage locations having a limited access space. The limited space, for example, can be the result of a slight distinction between the dimensions of the storage cell opening and the dimensions of the microplate stored therein. Also, T is thin such that a thick microplate may be transported, via arm  12 , into the microplate handler  10  without interference with other handler  10  components.  
      Abutments  14  are disposed on the arm  12  and configured to secure the microplates on the arm  12 . In an embodiment the arm  12  is rectangular, and an abutment  14 , for example, is disposed on each corner of the arm  12 . Thus, in an embodiment, four abutments are disposed on the arm  12 . Each abutment  14  includes abutting surfaces or steps  30  and  32 .  
      When handling a SBS formatted microplate, abutting surfaces  30  combine to create a securing surface that encompasses the outer perimeter of the SBS microplate or a portion thereof. Further securing the SBS microplate, by supporting its weight, is a flat surface  34  of the arm  12 . Together, the abutting surfaces  30  and flat surface  34  provide a nest for securing the SBS microplate on the arm  12 .  
      Likewise, handling a non-SBS formatted microplate, abutting surfaces  32  combine to create a securing surface that encompasses the outer perimeter of the non-SBS microplate. Further securing the non-SBS microplate, by supporting its weight, are flat surfaces  36  of the abutments  14 . Together, the abutting surfaces  32  and flat surfaces  36  provide a nest for securing the SBS microplate on the arm  12 .  
      It should be appreciated that each abutment  14  includes steps in addition to steps  30  and  32 . The additional steps can be located on either or both sides of steps  30  and  32 . For example, some non-SBS formatted microplates are smaller than SBS formatted microplates. Therefore, the abutment  14  includes steps located inside of steps  30  so as to secure the non-SBS formatted plate.  
      In an embodiment, there exists a corresponding number of abutting and flat surfaces because the abutting and flat surfaces combine to create a nest for the microplate while on the arm  12 . It should be appreciated that abutments  14  comprise steps in addition to steps  30  and  32 . Accordingly, it should also be appreciated that additional flat surfaces will be provided to support the weight of the microplates.  
      A clamping device  16  is at least partially disposed on the arm  12 . The clamping device  16  is configured to align and further secure microplates of SBS and non-SBS formats. The clamping device  16  comprises abutting surfaces or steps  40  and  42 . Steps  40  and  42  correspond with and move relevant to steps  30  and  32 . It should be appreciated that the clamping device  16  and the abutment  14  include an equal number of steps relative to each other.  
      The clamping device  16  includes a cam (not shown) configured to open when the arm  12  extends and close when the arm  12  retracts. The position of the clamping device  16  is directly related to the position of the cam. For example, the clamping device  16  opens as the cam opens and the clamping device  16  closes as the cam closes. Simply put, the clamping device  16  closes as the arm  12  retracts and the clamping device  16  opens as the arm  12  extends.  FIG. 1  illustrates the clamping device  16  in an open position and  FIG. 2  illustrates the clamping device  16  in a closed position.  
      When closing, the clamping device  16  functions similar to a forward active crowder. For example, the clamping device  16 , as it moves from an open to a closed position, forces or biases the microplate against the corresponding abutting surface  30  or  32 , thereby securing the microplate for transporting. Specifically, when the clamping device  16  closes, abutting surfaces  40  and  42  move toward the first end  11  of the arm  12  and the inside of abutting surfaces  30  and  32 , which are disposed proximate to the second end  13  of the arm  12 .  
      In other words, when the clamping device is closed, abutting surfaces  40  and  42  are closer to the first end  11  of the arm  12  than abutting surfaces  30  and  32  of the second end  13  of the arm  12 . Once the clamping device  16  is closed, abutting surface  40  or  42  contacts the microplate and, in doing so, biases the microplate against abutting surfaces  30  or  32 , which is disposed proximate to the first end  11  of the arm  12 .  
      If the microplate, for example, is of SBS format, step  40  of the clamping device  16  biases the microplate against step  30  of the abutments  14  located proximate to the first end  11  of the arm  12 . Similarly, if the microplate is of non-SBS format, step  42  of the clamping device  16  biases the microplate against step  32  of abutments  14  located proximate to the first end  11  of the arm  12 . It should be appreciated that the clamping device  16  includes steps in addition to steps  40  and  42 . The additional steps can be located on either or both sides of steps  40  and  42 . For example, some non-SBS formatted microplates are smaller than SBS formatted microplates. Therefore, the clamping device  16  includes steps located inside of step  40  so as to secure the non-SBS formatted plate.  
      When opening, the clamping device  16  moves from a closed, forward crowding position, toward an open position. When the clamping device  16  opens, steps  40  and  42  move toward the second end  13  of the arm  12  and beyond steps  30  and  32 . In other words, when the clamping device  16  is open, steps  40  and  42  are closer to the second end  13  of the arm  12  than steps  30  and  32  of the abutments  14  located proximate to the second end  13  of the arm  12 . Thus, when the clamping device  16  is open, a SBS microplate can nest, unobstructed, on flat surface  34  because step  40  is retracted out of the way. Similarly, when the clamping device  16  is open, a non-SBS microplate can nest, unobstructed, on flat surfaces  36  because step  42  is retracted out of the way.  
      It should be appreciated that, when the clamping device  16  is fully open, flat surfaces  34  and  36  are long enough to provide ample clearance for disposal of the microplates thereon. The ample clearance provides a comfortable margin of error when loading microplates onto the arm  12 . In other words, for example, because of the ample clearance, the arm  12  does not have to be perfectly aligned with a SBS microplate for the microplate to fit within space provided between the steps  30  of the first end  11  of the arm  12  and the steps  30  of the second end  13  of the arm  12 . Also, the ample clearance enables a non-SBS microplate to fit comfortably within the space provided between the steps  32  of the first end  11  of the arm  12  and the steps  32  of the second end  13  of the arm  12 .  
      Now turning to  FIG. 2 , the guide  18  includes tapered rails  46  and  48 , each having corresponding side surfaces  50  or  52  and top surfaces  54  or  56 . In an embodiment configured to handle SBS microplates, the top surfaces  54  of the tapered rails  46  correspond to the flat surface  34  of the arm  12 . Accordingly, when the arm  12  is in a retracted position inside the microplate handler  10 , the flat surface  34  is proximately inline with the top surfaces  54 . In this embodiment, the flat surface  34  and the top surfaces  54  combine to provide a flat surface on which a SBS microplate can rest during transport.  
      When the arm  12  is retracted inside the microplate handler  10 , side surfaces  50  contact, and thereby laterally stabilize, the SBS microplate disposed therein. As such, side surfaces  50  of the tapered rails  46  are a part of the nest in which the SBS microplate is secured. Additionally, the side surfaces  50  move the SBS microplate to the center of the flat surface  34 .  
      For example, a SBS microplate can be disposed in the nest created by abutting surfaces  30  and  40  and flat surface  34 . As the arm  12 , having the SBS microplate disposed thereon, is retracted into the microplate handler  10 , where the top surfaces  54  and the side surfaces  50  combine to further support the SBS microplate. Further, because the tapered rails  46  are tapered inward, the side surfaces  50  contact and thereby move the SBS microplate toward the center of the arm  12  as the arm  12  retracts into the microplate handler  10 .  
      In an embodiment configured to handle non-SBS microplates, the top surfaces  56  of the tapered rails  48  correspond to the flat surfaces  36  of the abutment  14 , which is disposed on the arm  12 . Accordingly, when the arm  12  is in a retracted position inside the microplate handler  10 , the flat surfaces  36  are proximately inline with the top surfaces  56 . In this embodiment, the flat surfaces  36  and the top surfaces  54  combine to provide flat surfaces on which the non-SBS microplate can rest during transport.  
      When the arm  12  is retracted inside the microplate handler  10 , side surfaces  52  contact and thereby laterally stabilize the non-SBS microplate. As such, side surfaces  52  of the tapered rails  48  are a part of the nest in which the non-SBS microplate is transported. Additionally, the side surfaces  52  move the non-SBS microplate in the center of the arm  12 .  
      For example, a non-SBS microplate can be disposed in the nest created by abutting surfaces  32  and  42  and flat surfaces  36 . As the arm  12 , having the non-SBS microplate disposed thereon, is retracted into the microplate handler  10 , where the top surfaces  56  and the side surfaces  52  combine to further support the non-SBS microplate. Further, because the tapered rails  48  are tapered inward, the side surfaces  52  contact and thereby move the non-SBS microplate toward the center of the arm  12  as the arm  12  retracts to a transporting position inside the microplate handler  10 .  
      It should be appreciated that the guide  18  includes rails in addition to tapered rails  46  and  48 . The additional rails can be located on either or both sides of rails  46  and  48 . For example, some non-SBS formatted microplates are smaller than SBS formatted microplates. Therefore, the guide  18  includes rails located inside of rails  46  so as to secure the non-SBS formatted plate.  
      In another embodiment, top surfaces  54  and  56  are tapered in an upward and retracting direction, in addition to side surfaces  50  and  52  tapering inward. As the arm  12  retracts into the microplate handler  10 , the microplate progresses, in an upward direction, along the tapered portion of the top surfaces  54  or  56 . This progressive, upward, movement smoothly transitions the weight of the microplate from the arm  12  to the guide  18 . It is advantageous to rest the microplate on the guide  18 , instead of the arm  12 , during transporting because the guide  18  is more secure than the arm  12 .  
      The tapered portions of the side and top surfaces  50 ,  52 ,  54  and  56  prevent imperfections of the microplate handler  10  from disabling the overall function of the microplate handler  10 . For example, the tapers at the entryway of the guide  18  provide tolerance for error in the relationship between the arm  12  and the guide  18  and, as a result, the arm  12  does not have to perfectly deliver the microplate inline with the guide  18 . In other words, the tapers provide a large opening for the for the microplate to enter the guide  18 , and as the microplate progresses into the handler  10 , the rails  46  and  48  taper inward and upward so as to funnel the microplate to a secure, nested, and central position inside the microplate handler  10 .  
      Tapered top surfaces  54  and  56  are also advantageous when extending the arm from a retracted position inside the microplate handler  10 . As the arm  12  extends from the microplate handler  10 , the microplate progresses, in a downward and extending direction, along the tapered portion of the top surfaces  54  or  56 . This progressive, downward, movement smoothly transitions the weight of the microplate from the guide  18  to the arm  12 .  
      The total vertical increase of the upward taper of rails  46  and  48  is slightly less than the vertical increase of abutting surfaces  34  and  36 . This ensures that, when the arm  12  is extending out of the microplate handler  10 , the abutting surfaces  34  or  36  extend far enough from the arm  12  so as to contact the microplate and thereby move the microplate along the top surfaces  54  or  56 . If the vertical increase of the upward taper is more than the vertical increase of abutting surfaces  34  and  36 , then the abutting surfaces  34  and  36  will not extend far enough from the arm  12  to contact the microplate when the microplate is secured inside the plate handler  10 , atop the top surfaces  54  or  56 . Thus, when the arm extends, the abutting surfaces  30  or  32  will not contact the microplate and therefore pass underneath the microplate, leaving the microplate nested on the guide  18 .  
      A barcode scanner  22  is disposed integral with the microplate handler  10 . The barcode scanner  22  scans barcodes located on the microplates and the storage location. Information obtained via the barcode scanner  22  is utilized to efficiently and effectively facilitate the experiment. An adjustable bracket  60  fastens the barcode scanner  22  to the microplate handler  10 . The adjustable bracket  60  enables inline positioning of the barcode scanner  22  relative to locations where barcodes are subject to scanning. The bracket  60  is lockable to promote repetition. Once the barcode scanner  22  is locked into position by the adjustable bracket  60 , no further adjustments are necessary because a single position can serve both SBS and non-SBS microplates.  
      As shown in  FIG. 3 , the microplate handler  10  includes a belt-pulley drive system  20 . For example, a shaft  62  is passed though each cylinder  64 . A belt  66 , fastened to the microplate handler  10 , is looped around pulleys  68 . At least one of the pulleys  68  is powered by a motor. The motor rotates the pulley  68  and thus the belt  66  travels along all of the pulleys  68 . Because the microplate handler  10  is fastened to the belt  66 , the microplate handler  10  travels in sync with the belt  66 . Therefore, the microplate handler  10  travels parallel to the axis of the shafts  62 . It should be appreciated that the plate handler  10  can be driven by a geared drive system or a motorized rack and pinion.  
      The microplate handler  10  is equipped with sensors to detect whether a microplate is present in the intended storage location. The sensors also detect whether the microplate is present in the microplate handler  10 . Additionally, the microplate handler  10  includes a sensor configured to automatically align the position of the plate handler  10  with the center of each storage location.  
      In operation, when the microplate handler  10  begin the retrieval process, the arm  12  first moves from a retracted position, inside the microplate handler  10 , to an outward position proximate to the stored microplate. As the arm  12  extends outward away from the microplate handler  10 , a cam moves the clamp  16  in an opposite, inward direction. As a result of the clamp  16  movement, abutting surfaces  40  and  42  are positioned outside of the area between the abutting surfaces  30  and  32  on the first end  11  of the arm  12  and the abutting surfaces  30  and  32  on the second end  13  of the arm  12 . This avails the entire flat surfaces  34  and  36  to the microplate, and thus provides ample clearance for the microplate to nest on the arm  12 .  
      Next, the microplate handler  10  moves in a direction perpendicular to the direction in which the arm  12  moves. This movement disposes the microplate on the arm  12 . Once the microplate is disposed on the arm  12 , the arm  12  moves from the extended position toward the retracted position inside the microplate handler  10 .  
      As the arm  12  retracts, the cam moves the clamp  16  in an opposite, outward direction so as to bias the microplate against the abutting surfaces  30  or  32  located, opposite the clamp  16 , on the first end  11  of the arm  12 . This biasing action not only provides a positive clamp for the microplate during transfer, but also results in an accurate and repeatable position for placing the microplate back into the storage location.  
      Also as the arm  12  retracts, the microplate contacts the tapered portion of the flat surfaces  54  or  56  and the tapered portion of the side surfaces  50  and  52 . The retracting arm  12  moves the microplate along the surfaces  50  or  52 , and  54  or  56  until the microplate is centrally and securely nested inside the microplate handler  10 .  
      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, falling within the scope of the invention.