Patent Publication Number: US-2006018791-A1

Title: Storage system and method of operating thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application claims priority from the provisional U.S. patent application entitled, “Method and Apparatus for Configuring a Storage Cell,” filed Jul. 16, 2004 and having Ser. No. 60/588,339, the disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates generally to storage systems. The present invention also relates generally to storage methods that may be implemented using storage systems.  
     BACKGROUND OF THE INVENTION  
      Drug discovery and many of the methods used in processes associated with drug discovery are slowly becoming automated. As a result of this increase in automation, drugs often get introduced into the marketplace faster. However, the increase in automation has created at least two issues in laboratories throughout the world.  
      The first issue is that space is now at an all-time premium. Therefore, the ability to expand storage and/or to have the storage conform to the available lab space would be highly desirable, as would be units that can be expanded at a later date. The second issue is that, with the increasing amount of automation in drug discovery, more and more experiments are being run in a much shorter period of time. This has resulted in a proliferation of sample-holding plates that require either short-term or long-term shortage and incubation for temporal analysis.  
      One currently-available method used to reduce the time associated with drug discovery involves the use of machines that automatically perform protein crystallography and then collect the related data. Currently, these machines are limited in the types of configurations available.  
      Prior art solutions to the above-mentioned space constraint problem involved interconnecting two storage cells via carousels or conveyor belts. However, use of carousels configured to receive a stored plate from a first storage cell, to rotate the plate and to hand the plate off to a second storage cell have relatively large footprints. Therefore, potential storage positions are sacrificed.  
      Further, carousels must maintain environmental conditions that are similar to those found in the storage cells to which the carousels connect. However, the geometry of carousels limits the ability to regulate the environmental conditions therein unless the carousels are attached linearly to the storage cells. Therefore, the use of carousels limits the configuration of storage cells to linear arrangements.  
      The use of conveyor belts, like the use of carousels, restricts configurations to being linear. Also, a plate must be precisely located by the conveyor belt to affect a transfer from one storage cell to another. Further, when using conveyor belts, a large amount of potential storage space is wasted to accommodate the presence of the conveyor belt. Even further, the use of conveyor belts makes it difficult and costly to maintain environmental conditions similar to those found in the storage cells during the conveyance operation.  
      At least in view of the above-discussed factors, it would be desirable for novel storage systems and methods to be developed that would allow for the addition of portable modular cells to existing systems in almost any geometric configuration.  
     SUMMARY OF THE INVENTION  
      The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect thereof, a transfer mechanism is provided. The transfer mechanism includes a supporting section configured to be movable between a first position inside of a first labware storage module and a second position outside of the first labware storage module. The supporting section is further configured to receive a piece of labware from a first mobile device in the first labware storage module when in the first position. In addition, the supporting section is also configured to avail the piece of labware to transfer to a second mobile device in a second labware storage module when in the second position. The transfer mechanism also includes an actuator operably connected to the supporting section and configured to move the supporting section between the first position and the second position.  
      According to another embodiment of the present invention, a storage system is provided. The storage system includes a primary storage module configured to store an item. The storage system also includes a first auxiliary storage module positioned adjacent to the primary storage module and configured to store the item. The storage system further includes a first transfer mechanism integrated into the primary storage module and configured to transfer the item from the primary storage module to the first auxiliary storage module.  
      According to yet another embodiment of the present invention, a method of storage is provided. The method includes introducing an item into a primary storage module. The method also includes transferring the item to a first auxiliary storage module located adjacent to the primary storage module using a transfer mechanism integrated in the primary storage module.  
      According to still another embodiment of the present invention, another transfer mechanism is provided. The transfer mechanism includes supporting means for supporting a piece of labware. The supporting means is movable between a first position inside of a first labware storage module and a second position outside of the first labware storage module. The supporting means is configured to receive the piece of labware from a first mobile device when in the first position and to avail the piece of labware to transfer to a second mobile device when in the second position. The transfer mechanism also includes moving means connected to the supporting means and configured to move the supporting means between the first position and the second position. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective view of a storage system according to an embodiment of the present invention.  
       FIG. 2  is a perspective view of the interior of a portion of a storage module according to an embodiment of the present invention.  
       FIG. 3  is a perspective view of an interior region of the primary storage module illustrated in  FIG. 1  according to certain embodiments of the present invention.  
       FIG. 4  is another perspective view of the interior region of the primary storage module illustrated in  FIG. 1 .  
       FIG. 5  is a perspective view of a portion of a laboratory positioning robot that may be used according to certain embodiments of the present invention, wherein a spatula, used for supporting the labware to be stored, is in an extended position.  
       FIG. 6  is a perspective view of the portion of the laboratory positioning robot illustrated in  FIG. 5 , wherein a spatula, used for supporting the labware to be stored, is in a retracted position.  
       FIG. 7  is a perspective view of two prongs, a spatula and a laboratory plate during a handoff operation from a robot to a transfer mechanism, or vice versa. 
    
    
     DETAILED DESCRIPTION  
      The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout.  
       FIG. 1  is a perspective view of a storage system  10  according to an embodiment of the present invention. The storage system  10  includes a primary storage module  12  configured to store an item, such as a piece of labware (i.e., a plate, a vial, a tube, a bottle, a lab-on-a-chip device, etc.). The storage system  10  also includes a first auxiliary storage module  14  that may be either positioned adjacent to the primary storage module  12  or that may be disconnected from the primary storage module  12  and positioned at a remote location. The first auxiliary storage module  14  is also configured to store the above-mentioned item.  
      The storage system  10  further includes a second auxiliary storage module  16  that may be positioned adjacent to either the first auxiliary storage module  14  or to the primary storage module  12  when the first auxiliary storage module  14  is not adjacent to the primary storage module  12 . Also, the second auxiliary storage module  16  may be disconnected from the primary storage module  12  and/or the first auxiliary storage module  14  and positioned at a remote location.  
      Also as illustrated in  FIG. 1  is a transfer mechanism  18  that is integrated into the primary storage module  12 . The transfer mechanism  18  is typically configured to transfer the above-mentioned item (e.g., a piece of labware) from the primary storage module  12  to either the first auxiliary storage module  14  or any other storage module that is adjacent or linked to the primary storage module  12  at any given time.  
      Also illustrated in  FIG. 1  is a second transfer mechanism  20  that is integrated into the first auxiliary storage module  14 . The second transfer mechanism  20  is typically configured to transfer the above-mentioned item from the first auxiliary storage module  14  to either the second auxiliary storage module  16  or any other storage module that is positioned adjacent to the first auxiliary storage module  14  at a given time.  
      Typically, when two or more auxiliary storage modules are connected to the primary storage module  12 , either directly or indirectly, each module, with the possible exception of the last module in a chain, includes one or more transfer mechanisms that are similar to the first transfer mechanism  18  and second transfer mechanism  20 . As such, a large number of auxiliary storage modules may be operably connected to the primary storage module  12 .  
      The first auxiliary storage module  14  and the second auxiliary storage module  16  may be chosen to have different geometries. For example, the first auxiliary storage module  14  may be longer and/or wider and/or taller than the second auxiliary storage module  16 , or vice-versa. Therefore, when a plurality of auxiliary storage modules are connected to the primary storage module  12  illustrated in  FIG. 1 , the geometries of the auxiliary storage modules may be selected so as to fill up substantially all available floor space in a designated portion of a laboratory.  
      Typically, the primary storage module  12  and any auxiliary storage modules in the storage system  10  are configured to store laboratory samples under specified environmental conditions (i.e., controlled temperature, humidity, etc.). As such, the first auxiliary storage module  14  illustrated in  FIG. 1  is configured to maintain environmental conditions that are substantially identical to those found in the primary storage module  12 , even when detached from the primary storage module  12 , so long as experimental samples are stored in the first auxiliary storage module  14 . The second auxiliary storage module  16  illustrated in  FIG. 1  and any other auxiliary storage module that may be included in the storage system  10  are also typically configured to maintain environmental conditions that are substantially identical to those found in the primary storage module  12  whether or not they are connected to the primary storage module  12 , so long as samples are stored therein.  
      As illustrated in  FIG. 1 , the primary storage module  12  includes a primary controller  22  that takes the form of a computer operably connected to the primary storage module  12 . Typically, the primary controller  22  is configured to control the operation of at least the first transfer mechanism  18  in the primary storage module  12 . The primary controller  22  may also be configured to locate the above-mentioned item in either the primary storage module  12  or any auxiliary storage modules connected thereto. Further, the primary controller  22  is typically configured to effectuate retrieval of the item from any storage module in the system  10  upon request from a user.  
      As illustrated in  FIG. 1 , a secondary controller  21  is operably connected to the first auxiliary storage module  14 . Also, additional auxiliary storage modules included in the storage system  10  typically have individual controllers operably connected thereto. The secondary controller  21  and any additional controllers are typically configured to locate an item when the item is being stored in the auxiliary storage module to which the controller in question is operably connected. For example, when the primary controller  22  attempts to effectuate the retrieval of an item upon receiving a request from a user, the primary controller  22  typically first determines whether the primary storage module  12  is currently storing the item. Then, if the item is not stored in the primary storage module  12 , the primary controller  22  typically interacts (e.g., exchanges electronic signals) with the secondary controller in the first auxiliary storage module  14  and/or other controllers in other auxiliary storage modules to determine the location of the item in the storage system  10 . At that point, the primary controller  22  generally operates in conjunction with controllers in the auxiliary storage modules to transfer the item back to the primary storage module  12 . A user may then retrieve the item from an Input/Output system  24  (e.g., a door) included in the primary storage module  12 , as illustrated in  FIG. 1 .  
      In order to expedite the location and retrieval of an item in the storage system  10 , a database  26  is operably connected to the primary storage module  12 . However, according to other embodiments of the present invention, the database  26  may be operably connected to any or all of the storage modules in the storage system  10 . Typically, the database  26  is configured to store data related to where an item is located in the storage system  10  at a specified time.  
      The database  26  is commonly configured to receive signals from either the primary controller  22  in the primary storage module  12  or from any other controller in any of the auxiliary storage modules operably connected to the primary storage module  12 . These signals generally inform the database  26  either that an item has been moved to a new position in the storage system  10  or may simply periodically update the database  26  regarding the location of some or all items storage in the storage system  10 .  
      According to certain embodiments of the present invention, the primary storage module  12  includes an analysis region  28  that is configured to analyze an item in the storage system  10  in some manner. For example, the analysis region  28  may take the form of an imager configured to take a image of an item in the storage system  10 . Because the analysis region  28  illustrated in  FIG. 1  is located within the primary storage module  12 , an item stored anywhere in the storage system  10  may be analyzed in the analysis region  28  without ever leaving the environmental conditions that are preserved throughout all of the storage modules in the storage system  10 .  
       FIG. 2  is a perspective view of the interior of a portion of a storage module  32  according to an embodiment of the present invention. The portion of the storage module  32  may be incorporated into the primary storage module  12  or any auxiliary storage module in the storage system  10 . As illustrated in  FIG. 2 , the primary storage module  12  includes a plurality of labware storage hotels  30 . Once introduced into the storage system  10  illustrated in  FIG. 1 , an item is typically stored in one of the slots  34  of a labware storage hotel  30 . Typically, a labware positioning robot is used to place an item into a slot  34  and to move items between any of the slots  34  illustrated in  FIG. 2 . The labware positioning robot may take the form of any mechanical device that can move a piece of labware in three-dimensional space between the slots  34  of one or more labware storage hotels  30  in a storage module  32 .  
      In the storage system  10  illustrated in  FIG. 1 , the robot in the primary storage module  12  is configured to be operated (i.e., controlled) by the primary controller  22 . Also, the robots in the first auxiliary storage module  14  and the second auxiliary storage module  16  are configured to be operated by the controllers operably connected to each of those modules, respectively. However, according to certain embodiments of the present invention, the primary controller  22  is configured to control all robots in the storage system  10 .  
       FIG. 3  is a perspective view of an interior region of the primary storage module  12  illustrated in  FIG. 1  according to certain embodiments of the present invention. Interior regions similar or identical to the interior region illustrated in  FIG. 3  may be included, for example, in any of the auxiliary storage modules in the storage system  10  illustrated in  FIG. 1 .  
      In  FIG. 3 , the first transfer mechanism  18  in the primary storage module  12  is illustrated in a first position that does not extend beyond the interior of the primary storage module  12 . As illustrated in  FIG. 3 , the first transfer mechanism  18  includes a supporting section  38  that takes the form of a fork having a first prong  40  and a second prong  42 .  
       FIG. 4  is another perspective view of the interior region of the primary storage module  12  illustrated in  FIG. 1 . In  FIG. 4 , the first transfer mechanism  18  is in a second position that extends beyond the interior of the primary storage module  12 . In other words, the first transfer mechanism  18  illustrated in  FIG. 3  extends beyond the casing  23  of the primary storage module  12  illustrated in  FIG. 1 .  
      As illustrated in  FIGS. 3 and 4 , an actuator  44 , which often takes the form of a mechanical motor, is operably connected to the supporting section  38  and is configured to move the supporting section  38  between the first position illustrated in  FIG. 3  and the second position illustrated in  FIG. 4 . According to certain embodiments of the present invention, the actuator  44  is configured to rotate the supporting section  38  about an axis (e.g., the central axis of rotation  43  in  FIGS. 3 and 4 ) when moving the supporting section  38  between the first position and the second position. However, according to other embodiments of the present invention, the supporting section  38  may be translated between the first and second positions or may undergo some other form of motion.  
      As discussed previously, the storage modules in the storage system  10  illustrate in  FIG. 1  typically each include a labware positioning system (e.g., a robot) that can move labware around within a given module. According to certain embodiments of the present invention, the supporting section  38  illustrated in  FIGS. 3 and 4  is configured to receive a plate from a robot configured to position experimental sample plates in a storage hotel. In these embodiments, a robot in the primary storage module  12  may retrieve a plate or other piece of labware from within the primary storage module  12  and may place the piece of labware onto the forks  40 , 42  of the supporting section  38 . In  FIGS. 3 and 4 , the supporting section  38  is configured to receive a piece of labware from a first mobile device (e.g., a robot) in the primary storage module  12  when in the first position that does not extend beyond the primary storage module  12  (see  FIG. 3 ).  
      Once the supporting section  38  is in the second position that extends beyond the primary storage module  12  (see  FIG. 4 ), the supporting section  38  is configured to avail the piece of labware supported thereby to transfer to a second mobile device in an auxiliary storage module  14  (i.e., a labware positioning robot in an auxiliary storage module).  
       FIGS. 5 and 6  are perspective views of a portion of a laboratory positioning robot  46  that may be used according to certain embodiments of the present invention. In  FIG. 5 , a spatula  48  included in the portion  46  and used for supporting the labware to be stored is illustrated in an extended position and in  FIG. 6  the spatula is illustrated in a retracted position.  
      In  FIG. 5 , the spatula  48  protrudes from the portion  46 . In operation (i.e., when a piece of labware is being moved), the spatula  48  typically has a piece of labware on top thereof. When no piece of labware is being supported by the spatula  48 , the spatula  48  retracts into the portion  46 , as illustrated in  FIG. 6 .  
       FIG. 7  is a perspective view of two prongs  40 ,  42 , a spatula  48  and a laboratory plate  50  during a handoff operation from a robot to a transfer mechanism, or vice versa. As illustrated in  FIG. 7 , the spatula  48  carrying the laboratory plate  50  is configured to be able to travel between the first prong  40  and the second prong  42  of the supporting section  38  illustrated in  FIGS. 3 and 4 . Therefore, when the spatula  48  travels from a position above the prongs  40 ,  42  to a position below the prongs  40 ,  42 , the laboratory plate  50  is deposited onto the prongs  40 ,  42  of the supporting section  38 . Pursuant to this transfer, the supporting section  38  may move to a position that extends beyond the primary storage module  12  and that allows another spatula from a laboratory positioning robot in an auxiliary storage module to pick the laboratory plate  50  up from the supporting section  38 . Then, the laboratory plate  50  may be stored in a storage hotel of an auxiliary storage module.  
      In operation, the storage system  10  illustrated in  FIG. 1  may be used to store one or move piece of labware. Typically, when storing labware in the storage system  10 , the labware is introduced into the primary storage module  12 . For example, a laboratory plate may be introduced through the input/output system  24  of the primary storage module  12 . Then, the plate is transferred to a first auxiliary storage module that is located adjacent to the primary storage module. This transferring step typically includes using a transfer mechanism integrated in the primary storage module, such as the first transfer mechanism  18  illustrated in  FIGS. 3 and 4 .  
      According to certain embodiments of the present invention, the plate or, more generally, the item, may be transferred to a second auxiliary storage module that is located adjacent to the first auxiliary storage module. Typically, a second transfer mechanism that is integrated into the first auxiliary storage module is used.  
      In some embodiments of the present invention, the location of the item in the primary storage module and the first auxiliary storage module is determined from the primary storage module. Retrieval of the item may be effectuated upon receiving a request from a user. The primary controller  22  is used in combination with any of a plurality of other controllers (e.g., secondary controller  21 ) in the storage system  10  and/or the database  26  to determine the position of a piece of labware in the storage system  10  and execute the retrieval. This retrieval often requires controllers in auxiliary storage modules to control robots therein such that the robots transfer the piece of labware to each other and, ultimately, to the primary storage module  12  using transfer mechanisms.  
      In certain laboratory situations, it is desirable to detach and move the first auxiliary storage module away from the primary storage module. For example, when only a small amount of storage space is available in a first area in a lab and a large amount of space is available in a second area, a plurality of items may be placed into an auxiliary storage module at the first area and the auxiliary storage module may then be moved to the second area, usually after a second auxiliary storage module is positioned adjacent to the primary storage module. In such instances, additional items may be transferred to the second auxiliary storage module using the transfer mechanism integrated into the primary storage module  
      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.