Robotic System for Sorting Sample Tubes

Abstract

A robotic system is provided for accurately and quickly sorting sample tubes within or between sample tube racks.

1 . A device for sorting sample tubes, comprising:
 a robotic assembly, comprising: a base that comprises a vertical lift shaft; a horizontal robotic arm comprising a proximal end and a distal end, wherein the proximal end of the robotic arm is configured to be lifted vertically by the lift shaft and is configured for pivotal movement around the base; and end of arm tooling at the distal end of the robotic arm that is configured to pick up and hold a sample tube when a vacuum is applied and to expel and deposit the sample tube into a designated slot in a tube rack when air is expelled through the tooling;   a vacuum source that is fluidly connected to the end of arm tooling and configured to pull a vacuum through the tooling;   an air source that is fluidly connected to the end of arm tooling and configured to expel air through the tooling;   a horizontal stage underneath the robotic arm and configured to hold a plurality of tube racks in a position from which the end of arm tooling may pick up and deposit sample tubes;   a vision system that is configured to record coded information on sample tubes and on the sides of tube racks in the device and to convey the coded information to a control system; and   a control system that tracks coded information provided by the vision system, and that controls the robotic assembly to pick up a coded sample tube from a first location in a first tube rack and to deposit the sample tube in a second location in a second tube rack, wherein the first tube rack and the second tube rack are the same or different.   
     
     
         2 . A device according to  claim 1 , further comprising a plurality of sample tubes in one or more tube racks, wherein each sample tube comprises a unique identification code that may be read by the vision system and conveyed to the control system. 
     
     
         3 . A device according to  claim 2 , comprising a plurality of tube racks, wherein each tube rack comprises a unique identification code that may be read by the vision system and conveyed to the control system. 
     
     
         4 . A device according to  claim 1 , wherein the robotic arm is a Selective Compliance Assembly Robot Arm (SCARA), comprising:
 a first horizontal arm segment comprising: a first proximal end that is configured to be lifted by the lift shaft and is configured for pivotal movement around the base, and a first distal end;   a second horizontal arm segment comprising: a second proximal end that is rotatably coupled to the first distal end, and a second distal end;   a third horizontal arm segment comprising: a third proximal end that is rotatably coupled to the second distal end, and a third distal end; and   the end of arm tooling connected to the third distal end.   
     
     
         5 .- 8 . (canceled) 
     
     
         9 . A device according to  claim 1 , wherein the coded information comprises one-dimensional, two-dimensional, or three-dimensional bar codes on sample tubes and/or on tube racks. 
     
     
         10 . A device according to  claim 1 , comprising at least one sample tube rack that comprises sample tubes, and wherein each sample tube in the rack comprises unique coded information on the bottom of the tube, wherein the tube rack comprises openings such that the coded information on the sample tubes is viewable through the bottom of the tube rack, wherein the vision system is configured beneath the bottom of the tube rack, and wherein the vision system records the locations of coded information when the tube rack is positioned above the vision system. 
     
     
         11 . A device according to  claim 1 , comprising at least one sample tube rack that comprises unique coded information on at least one side, wherein the sample tube rack and the vision system are configured such that the coded information is recorded by the vision system when the tube rack is positioned above the vision system. 
     
     
         12 . A device according to  claim 1 , wherein the vision system comprises three vision camera systems that are aligned to read coded information from a sample tube or sample tube rack when it is located in a position above the vision system. 
     
     
         13 . A device according to  claim 12 , comprising a vision system under each location on the stage on which a sample tube rack may be positioned. 
     
     
         14 . A device according to  claim 12 , comprising a single vision system, and comprising a track to move sample tube racks into position above the vision system for reading of coded information on sample tubes and/or on the tube rack. 
     
     
         15 . A device according to  claim 1 , comprising a sample tube rack comprising a plurality of sample tubes to be sorted, wherein each sample tube comprises a top and a bottom, wherein the top of the tube is configured and of a dimension such that the tube will be held by suction when picked up by the end of arm tooling of the robotic arm when a vacuum is applied therethrough, and wherein each sample tube comprises unique coded information on the bottom of the tube, wherein the vision system is configured to read and convey information about the locations of the coded information to the control system before and after sorting to desired locations in one or more tube rack. 
     
     
         16 . A device according to  claim 1 , wherein the vacuum source and the air source are produced with a vacuum pump that creates a vacuum through the venturi effect, wherein a vacuum is produced when compressed air flows through a venturi, and wherein positive air pressure is produced when the flow of compressed air is terminated. 
     
     
         17 . A device according to  claim 1 , further comprising a tube sensor that senses whether a sample tube has been picked up by the end of arm tooling when the vacuum is applied. 
     
     
         18 . A device according to  claim 1 , wherein the stage is in the form of a deck or a track on a conveyer belt. 
     
     
         19 . A device according to  claim 1 , wherein the device is configured to sort 20 or more sample tubes per minute. 
     
     
         20 . A method for sorting sample tubes, comprising a device according to  claim 1 , and further comprising at least one sample tube rack that comprises sample tubes,
 wherein a sample tube in a first location is sorted to a second location on the same or different sample tube rack,   wherein the control system moves the robotic arm to configure the end of arm tooling above the first location,   wherein a vacuum is applied via the vacuum source, thereby providing a suction force through the end of arm tooling, wherein the sample tube is picked up from the first location and retained by the end of arm tooling via vacuum suction,   wherein the control system moves the robotic arm to configure the end of arm tooling with the retained sample tube above the second location,   wherein the vacuum is terminated and positive air pressure is applied through the end of arm tooling to expel the sample tube in the second location, and   wherein the presence of the sample tube in the first location and/or second location is determined by reading of coded information on the sample tube by the vision system.   
     
     
         21 . A method according to  claim 20 , wherein the control system lowers the robotic arm before the sample tube is picked up, raises the robotic arm when it is moved to configure the end of arm tooling above the second location, and lowers the robotic arm before the sample tube is expelled in the second location. 
     
     
         22 . A method according to  claim 20 , wherein the robotic arm is a SCARA, comprising:
 a first horizontal arm segment comprising: a first proximal end that is configured to be lifted by the lift shaft and is configured for pivotal movement around the base, and a first distal end;   a second horizontal arm segment comprising: a second proximal end that is rotatably coupled to the first distal end, and a second distal end;   a third horizontal arm segment comprising: a third proximal end that is rotatably coupled to the second distal end, and a third distal end; and   the end of arm tooling connected to the third distal end.   
     
     
         23 .- 26 . (canceled) 
     
     
         27 . A method according to  claim 20 , wherein the vacuum source and the air source are produced with a vacuum pump that creates a vacuum through the venturi effect, wherein a vacuum is produced when compressed air flows through a venturi, providing a suction force whereby the sample tube is picked up from the first location, and wherein positive air pressure is produced when the flow of compressed air is terminated, thereby expelling the sample tube in the second location. 
     
     
         28 . A method according to  claim 20 , wherein the coded information comprises one-dimensional, two-dimensional, or three-dimensional bar codes on sample tubes and/or on sample racks. 
     
     
         29 . A method according to  claim 20 , wherein each sample tube in the tube rack comprises unique coded information on the bottom of the tube, wherein the tube rack comprises openings such that the coded information on the sample tubes is viewable through the bottom of the tube rack, wherein the vision system is configured beneath the bottom of the tube rack, and wherein the vision system records the locations of coded information when the tube rack is positioned above the vision system. 
     
     
         30 . A method according to  claim 20 , wherein each sample tube rack comprises unique coded information on at least one side, wherein the sample tube rack and the vision system are configured such that the coded information is recorded by the vision system when the tube rack is positioned above the vision system. 
     
     
         31 . A method according to  claim 20 , wherein the vision system comprises three vision camera systems that are aligned to read coded information from a sample tube or sample tube rack when it is located in a position above the vision system. 
     
     
         32 . A method according to  claim 20 , wherein the device further comprises a tube sensor that senses whether a sample tube has been picked up by the end of arm tooling when the vacuum is applied. 
     
     
         33 . A method according to  claim 20 , wherein 20 or more sample tubes per minute are sorted. 
     
     
         34 . A device according to  claim 1 , wherein the control system comprises a laboratory information management system (LIMS).