STATE ESTIMATION USING SPARSE Hall SENSOR BASED SENSING

Abstract

A system and method for tracking a container mover within a liquid handler system using a sparse sensor assembly. The method comprises: mapping the received sensor signal to a pre-characterized function; and determining a position of the container mover relative to a single sensor from the sensor assembly accordingly. Sensors in a sparse sensor assembly may be positioned with no or minimal overlap between their sensing ranges.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 373,357, filed on August 24, 2022, entitled “STATE ESTIMATION USING SPARSEHALL SENSOR-BASED SENSING,” the disclosure of which is incorporated herein by reference in its entirety for all purposes. Background Art

[0002] Liquid handler is designed to distribute and handle the robot system of reagent, sample or other liquid of selected amount.Some liquid handlers are additionally adapted to use, for example, immunoassay and / or clinical chemistry techniques to analyze samples.Liquid handlers of this type can be referred to as "analyzer" or "analyzer system".Some liquid handlers can include multiple modules (also referred to as stations) and transport systems to move samples between various modules.It is highly desirable that liquid handler transport systems move sample containers in a smooth manner, avoid making sample containers collide with each other and otherwise prevent liquids from overflowing from their containers during transportation.Especially, liquid overflows waste reagents and / or samples (which may potentially affect the integrity of any test being performed), and if overflow occurs on track, liquid may also cause obstacles that may negatively damage the movement of subsequent sample containers.

[0003] Liquid handlers are often used in in vitro diagnostic (IVD) applications. IVD allows laboratories to assist in the diagnosis of diseases based on assays performed on patient fluid samples. IVD includes various types of analytical tests and assays related to patient diagnosis and treatment that can be performed by analysis of liquid samples obtained from the patient's body fluids or abscesses. These assays are typically performed using an automated clinical chemistry analyzer to which a fluid container (such as a tube or vial) containing a patient sample has been loaded. The analyzer extracts a liquid sample from a vial and combines the sample with various reagents in a special reaction cup or tube (generally referred to as a reaction vessel). In some traditional systems, modular solutions are used for analyzers. Laboratory automation systems can shuttle samples between a sample processing module (module) and another module. A module can include one or more stations, including a sample processing station and an analyzer module / test station (e.g., a unit that can specialize in certain types of assays), or a module can otherwise provide testing services to a larger analyzer, which can include an immunoassay (IA) and a clinical chemistry (CC) station. Some traditional IVD automated track systems include systems designed to transport samples from a completely independent module to another independent module. This allows specialization in different types of tests in two different stations / modules, or allows two redundant stations to be linked to increase the amount of available sample throughput. However, these laboratory automation systems are often bottlenecks in multi-station analyzers. Relatively speaking, traditional laboratory automation systems lack a large degree of intelligence or autonomy to allow samples to move independently between stations.

[0004] Conventional liquid handler systems use a sensor assembly consisting of a relatively large number of sensors with overlapping sensing ranges to track container movers and the liquid samples carried thereby throughout a track system that interconnects the modules. In some conventional liquid handler systems, an individual track segment may have up to 20 Hall effect sensors. This redundancy is intended to provide robustness in tracking the liquid samples as they move along the track system between the various modules of the liquid handler system. However, the large number of sensors utilized substantially increases the cost of the liquid handler system. Further, utilizing such a large number of sensors is computationally expensive, particularly when the signals from all sensors are multiplexed, and therefore, there is a need in the art for a simplified sensing scheme that reduces the number of sensors utilized to track the container movers so as to reduce costs and reduce the computational requirements of the container mover tracking system. Summary of the invention

[0005] Described herein are systems and methods for tracking container movers and / or liquid samples carried thereby in a liquid handler system using a sparse sensor assembly.

[0006] In one embodiment, the present disclosure relates to a tracking system for tracking a container mover in a liquid handling machine system having a container tracking system, the container tracking system including a sensor assembly associated with a track system. The sensor assembly has: a plurality of Hall effect sensors positioned along the track system, configured to detect a magnet positioned with the container mover, and positioned such that a signal from each of the Hall effect sensors does not overlap with an adjacent Hall effect sensor beyond a threshold of less than 6 dB of the sensor peak. A control system coupled to the sensor assembly is configured to: receive a signal from each of the plurality of Hall effect sensors; determine within which of the plurality of Hall effect sensors the container mover falls within a sensing range to define a sensing Hall effect sensor; map the signal from the sensing Hall effect sensor to a function; and determine a position of the container mover based on the mapping of the signal from the sensing Hall effect sensor to the function. The function is configured to: relate the strength of the signal to a distance relative to the sensing Hall effect sensor.

[0007] In another embodiment, the present disclosure is directed to a liquid handler system for processing a liquid sample, having one or more modules configured to process the liquid sample and a track system interconnecting the one or more modules, the track system being configured to support one or more container movers thereon, each container mover having a magnet and configured to receive the liquid sample. A sensor assembly is associated with the track system and has a plurality of Hall effect sensors positioned along the track system, the plurality of Hall effect sensors being configured to detect a magnet positioned with the container mover and being positioned such that a signal from each of the Hall effect sensors does not overlap with an adjacent Hall effect sensor beyond a threshold of less than 6 dB of a sensor peak. A control system is coupled to the sensor assembly and is configured to: receive a signal from each of the plurality of Hall effect sensors; determine within which of the plurality of Hall effect sensors the container mover falls within a sensing range to define a sensing Hall effect sensor; map the signal from the sensing Hall effect sensor to a function; and determine a position of the container mover based on the mapping of the signal from the sensing Hall effect sensor to the function. The function is configured to: relate the strength of the signal to a distance relative to the sensing Hall effect sensor.

[0008] In another embodiment, the present disclosure is directed to a method of tracking a container mover in a liquid handler system for processing a liquid sample, the liquid handler system having: one or more modules configured to process the liquid sample; and a track system interconnecting the one or more modules and configured to support one or more container movers thereon, each container mover having a magnet and configured to receive the liquid sample. A sensor assembly is associated with the track system and includes a plurality of Hall effect sensors positioned along the track system, each Hall effect sensor configured to detect a magnet positioned with the container mover, and positioned such that a signal from each of the Hall effect sensors does not overlap with an adjacent Hall effect sensor beyond a threshold of less than 6 dB of a sensor peak. A method performed by a control system coupled to the sensor assembly includes the steps of: receiving a signal from each of the plurality of Hall effect sensors; determining within which of the plurality of Hall effect sensors the container mover falls within a sensing range to define a sensing Hall effect sensor; mapping the signal from the sensing Hall effect sensor to a function; and determining a position of the container mover based on the mapping of the signal from the sensing Hall effect sensor to the function. The function is configured to relate the strength of the signal to the distance relative to the sensing Hall effect sensor.

[0009] According to one aspect of these embodiments, the control system is configured to fuse multiple singularized signals via an extended Kalman filter. According to another aspect, the control system is configured to fuse multiple singularized signals via at least one of weighted estimation and cascade estimation. According to another aspect, the signal overlap from each adjacent pair of the Hall effect sensors is more than 6dB compared to the background noise. According to another aspect, the function is one of the group consisting of a Lorentz function, a Sinc function, and a Gaussian function. According to another aspect, the sensor assembly is divided into segments, each segment having a circuit board. According to another aspect, the control system determines that the container mover is close to the junction of two adjacent segments to initiate a switch of control of the container mover between segments. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are incorporated in and form part of the specification, illustrate embodiments of the present invention and, together with the written description, serve to explain the principles, characteristics, and features of the present invention. In the drawings: Figure 1 is a top-down view of an exemplary sample processing module according to at least one aspect of the present disclosure.

[0011] Figure 2 is a perspective view of an exemplary sample processing module according to at least one aspect of the present disclosure.

[0012] Figure 3 is a diagrammatic view of an exemplary integrated modular automated track system according to at least one aspect of the present disclosure.

[0013] Figure 4 is a perspective view of an exemplary automated track system according to at least one aspect of the present disclosure.

[0014] Figure 5 is a perspective view of an exemplary automated track system according to at least one aspect of the present disclosure.

[0015] Figure 6 is a cross-sectional view of an exemplary automated track system according to at least one aspect of the present disclosure.

[0016] Figure 7 is a top-down view of an exemplary automated track system according to at least one aspect of the present disclosure.

[0017] Figure 8 is a diagram of a track segment of a liquid handler system according to at least one aspect of the present disclosure.

[0018] Fig. 9 is a diagram of a container mover actuator according to at least one aspect of the present disclosure.

[0019] Fig.10 is a diagram of a liquid handler system including a container tracking system according to at least one aspect of the present disclosure.

[0020] Fig.11A is a diagram of a conventional sensor assembly arrangement for a track segment of a liquid handling machine system.

[0021] Fig. 11B It is a diagram for Fig.10 A is a graph of the sensor output of a conventional sensor assembly.

[0022] Fig.12 is a diagram of a sparse sensor assembly arrangement for a liquid handling machine system track segment according to at least one aspect of the present disclosure.

[0023] Fig.13 is a flow chart of a process for tracking the position of a container mover in a liquid handler system via a sparse sensor assembly according to at least one aspect of the present disclosure.

[0024] Fig.14 is a series of plots of Hall sensor signals modeled using Lorentz functions in accordance with at least one aspect of the present disclosure. DETAILED DESCRIPTION

[0025] The present disclosure is not limited to the specific systems, devices, and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope.

[0026] As used herein, the terms "algorithm", "system", "module", "engine" or "architecture" are used herein without limiting any specific implementation for completing and / or performing the actions, steps, processes, etc. that may be attributed to and / or performed thereby. Algorithms, systems, modules, engines and / or architectures may be, but are not limited to, software, hardware and / or firmware or any combination thereof that performs a specified function, including but not limited to any use of general and / or specialized processors in conjunction with appropriate software loaded or stored in a machine-readable memory and executed by the processor. Further, unless otherwise specified, any names associated with a particular algorithm, system, module and / or engine are used for the purpose of convenient reference and are not intended to be limited to a specific implementation. In addition, any functionality attributed to an algorithm, system, module, engine and / or architecture may be equivalently performed by multiple algorithms, systems, modules, engines and / or architectures that are incorporated into and / or combined with the functionality of another algorithm, system, module, engine and / or architecture of the same or different type, or distributed across one or more algorithms, systems, modules, engines and / or architectures of various configurations.

[0027] Automated Liquid Handler Systems A liquid handler or liquid handling robot is a system designed to dispense and handle any type of liquid, including reagents and patient samples. Liquid handlers are particularly adapted to automate workflows in life science laboratories, such as clinical or research laboratories. Some liquid handlers, which may be referred to as "analyzers" or "analyzer systems," are additionally adapted to handle and perform tests on samples using, for example, immunoassays and / or clinical chemistry techniques.

[0028] The liquid handler can include an automation system, either as a whole or as a module coupled to the liquid handler. Some liquid handler systems can include multiple modules or stations adapted to perform different tasks or tests. In these embodiments, the automation system can include: a transport system adapted to transport containers of samples and / or reagents between the various modules or stations. As mentioned above, the transport system can include a friction-based mobile system, a conveyor belt, and a magnetically driven mobile system. The automation system can further include: a sensor assembly for detecting parameters associated with the container or other aspects of the transport system; and a control system configured to control the movement of the container accordingly.

[0029] In some embodiments, the liquid handler system can utilize a modular system including an automated clinical chemistry analyzer module and an automated immunoassay analyzer module, with sample loading capabilities for transporting patient samples to and from the analyzer module(s), where in vitro diagnostic assay analysis is performed. The system can be scalable in multiple configurations of modules that allow for customer annual throughput needs ranging from low volume to very high volume / mega segment markets (i.e., 500,000 to 5M or more tests per year).

[0030] In some embodiments, the automation system may be described as a process control manager (PCM) that manages the processing of samples. This includes providing input and output for samples into and out of the system, temporary storage of samples while awaiting processing, scheduling of samples for processing at various analyzers attached to the PCM, facilitation of movement of samples throughout the automation track (including onto and off the automation track), and in some embodiments, maintenance of the automation system. In various embodiments, the PCM may include a variety of different modules, including a sample handler and a container mover.

[0031] The sample processor provides a means for the user to load and unload regular samples, STAT samples, and control / calibrator vials onto the system. Within the sample processor, the robotic subsystem is responsible for moving these tubes between other subsystems and modules including the sample I / O (drawer trays), control reservoirs, and container movers.

[0032] The container mover subsystem handles the material distribution. Under normal conditions, laboratory technicians never directly operate the container mover track. The container mover manages the carriers on the automated track that move samples or reagents, and each carrier has a dedicated type of bracket. In certain embodiments, the liquid handler system may include: a reagent carrier that is configured to receive a test kit and transport the test kit to a position accessible to the one or more analyzer modules via the automated track. In certain embodiments, the reagent carrier may be adapted to handle reagents from both the immunoassay module and the clinical chemistry module.

[0033] Figure 1A top-down view of an exemplary sample processing machine 10 that can be used in some embodiments is shown. In this figure, the sample processing machine 10 is oriented so that the front side (i.e., the side that the operator interacts with) is at the bottom of the page, and the back side of the automated track is at the top of the page. The sample processing machine 10 includes a tube characterization station 12 at the robot / track interface. When the tubes are placed on the carriers on the track 14, the tube characterization station 12 characterizes the tubes and the carriers. This allows information to be ascertained about the identification of the tubes placed in each carrier and the physical condition of each tube (e.g., the size of the tube, the liquid level, whether there is a tube top cup, etc.). A control / calibrator storage area 14 is located adjacent to the tube characterization station 12. This allows long-term refrigerated storage of control and calibrator fluids near the track, thereby allowing these fluids to be easily placed into the carriers on the track for movement to relevant locations in the analyzer. The location of the storage 16 also allows the input / output drawer 18 to be placed in front of the sample processing machine 10. In this example, there are four adjacent drawers 18 that can be opened and pulled out individually.

[0034] The robotic arm 20 can move in two dimensions to pick up any of the tubes in the drawer 18 and move those tubes to and from the reservoir 16 and the carriers on the track 14. The robotic arm 20 can be positioned by moving the gantry from the front to the back of the sample processor 10 as the slide carriage moves along the gantry from side to side. The opposable end effector can then be moved vertically to extend downward to pick up the tube, closing them when the end effector is properly positioned to engage the tube.

[0035] To help the robot arm 20 successfully engage each tube, a drawer vision system 22 is placed above the drawer at the opening to the drawer. This allows a series of images to be taken, looking down at the tubes in the tray as the tray is moved through the drawer vision system. By strobing a series of cameras, multiple images can be captured in the buffer, with each tube appearing in multiple images. These images can then be analyzed to determine the physical characteristics of each tube. For example, the diameter and height of each tube can be determined. Similarly, the capping or uncapping status of each sample can be quickly determined. In addition, the presence or absence of the tube top cup (a small plastic well that is placed on the top of the tube to allow the tube to transport a much smaller volume with a greater sample depth to allow aspiration to occur more easily) can be ascertained. Similarly, the characteristics of any cap can be ascertained by the image. This can include certain color markings on the cap to identify a given sample as a higher priority (STAT) sample.

[0036] The module manager PC can utilize this information to schedule samples to be moved from each tray in the drawer 18 to the carriers on the track 14. The module manager PC can also instruct the robotic arm 20 how to interact with each tube, including identifying the appropriate height for the end effector before engagement and the appropriate force or distance to use when engaging the end effector to accommodate multiple diameters of the tube.

[0037] Figure 2 is a perspective view of the sample processing machine 10. In this example, the track 14 is generally parallel to the front of the drawer 18, and the refrigerated storage 16 is a large physical object between the drawer 18 and the track 14. At the same time, much above the height of the drawer 18 and the refrigerated storage 16, the robotic arm 20 is moved on a support. In some embodiments, the sample processing machine 10 may include a tube characterization station 12 and a drawer vision system 22; however, from Figure 2 The view in omits these stations to allow a better understanding of the interior of the sample processing machine 10.

[0038] Figure 3 The container mover component of PCM is illustrated, and this PCM moves sample from input area to analyzer module, helps to process those samples in analyzer, and returns process sample to the output area of ​​sample processing machine.Multi-module analyzer system 30 comprises multiple interconnected modules.In this example, system 30 comprises multiple sample processing machines 10.By utilizing multiple sample processing machines, more sample trays can be placed in system, thereby allowing to start larger batches at the beginning of displacement.In addition, this allows twice more samples to be placed on track and taken away from track.This means: for the larger system with multiple analyzer modules that can operate in parallel, input / output throughput can match the analysis throughput of parallel analyzer.For example, if analyzer module can process 500 samples per hour and three analyzer modules are used, the input / output demand for feeding these modules can be up to 1500 samples per hour.In some embodiments, single sample processing machine may not be able to handle this demand, thereby making it necessary to add multiple sample processing machines to keep up with the input / output demand of analyzer module.

[0039] Furthermore, in some embodiments, one of the sample processors may be set up to be used as an input, while the other sample processor may be set up as an output.Using a modular approach, a single sample processor 10 may be used, but for larger systems, two or more sample processors may be used.

[0040] In the exemplary system 30, two analyzer modules are utilized. Analyzer module 32 is an immunoassay (IA) analyzer. Analyzer module 34 is a clinical chemistry (CC) analyzer. The two analyzer modules perform different assays, testing different characteristics of a patient sample.

[0041] Track 14 is a multi-branch track that forms the core of the container mover system. As can be seen, track 14 includes branches and lengths that are integral to sample processing machine 10 and analyzer modules 32 and 34. Figure 5 and 6 Explain the functionality of the individual branches. In addition to the track segments provided by these modules, additional modules 38, 40 and 42 provide short specialized track segments that can be bolted to track sections provided by other modules. Track modules 36, 38, 40 and 42 provide powered track segments without additional hardware associated with the sample handler module or analyzer module. Whereas modules 10, 32 and 34 can be full cabinets extending from the laboratory floor to the height of track 14 and above, track segment modules 36, 38, 40 and 42 can be bolted-on segments extending from the cabinets of other modules without the need for floor-length support. Leveling hardware can be used to modularly connect the sample handler module and the analyzer module to the cabinet. Figure 3 Each of the modules in the container mover system is bolted together so that each track segment between adjacent modules forms a nearly seamless track for a carrier to traverse the container mover system.

[0042] In the exemplary system 30, it can be seen that the section 44 of the track of the analyzer module 32 may need to be changed from the corresponding section of the analyzer module 34. In some embodiments, the track sections of the analyzer module are in the same configuration as shown in the analyzer module 34 when they are shipped from the factory. This allows multiple analyzers to be placed in series, thereby simply bolting their corresponding track sections together to form a long chain. In some embodiments where there is an offset between the back track section of the sample processing machine module and the analyzer module, as shown in the system 30, an S-shaped bend may be required to allow the carrier to move from the back track section of the analyzer module to the back track section of the sample processing machine module. In this example, the S-shaped bend is provided by bolting the changed track section in the track section 42 and the area 44. Therefore, it should be understood that the track section in the analyzer module, although indispensable to those modules, can be widely modified when installed, thereby allowing multiple configurations of the track section in the analyzer module. However, it should be understood that these track sections are still very indispensable to those analyzer modules. In some embodiments, the backs of the analyzer modules 32 and 34 are flush with the back of the sample processor 10 , thereby eliminating the need to completely modify the track segments 44 and sections 42 .

[0043] Track segments 38 and 40 are U-shaped track segments that provide a return between the front track segment and the back track segment, allowing traffic to move around the track 14 without crossing the inner chord segments within the sample processing machine or analyzer module. This allows the track 14 to form an outer loop with the main traffic moving along the periphery of the analyzer module. At the same time, the inner track segment bypasses the main loop, providing a direct path between the two sides of each analyzer module (front to back), which acts as a route for local traffic. These chord segments may also be referred to as inner segments / track segments, bypass segments / track segments, or in some cases local track segments. These chord segments bypass the outer loop to provide access to the pipette. This allows the small physical queues associated with each sample processing machine or analyzer module to utilize those inner chord segments without blocking the overall flow of the track 14.

[0044] Specialized track segment modules 36 facilitate sample returns and branches within the track 14 to allow the central computer system of the PCM to direct traffic in a flexible manner. The outer track portion provides a track segment for samples to move from the sample processing machine module 10 to the analyzer module 32 and vice versa. At the same time, the inner chord of the track segment module 36 provides a branch by which the sample can move from the analyzer 32 to the analyzer 34 (in a counterclockwise manner) without moving into the sample processing machine module 10. This facilitates multiple tests on a single sample tube, allowing the sample tube to move freely between the analyzer modules, regardless of how they are arranged on the right hand side of the system 30. This gives the PCM scheduling software flexibility in terms of how the sample is arranged for testing within the analyzer module without increasing the traffic on the track segment associated with sample processing. The track segment 36 provides a boundary between the source and sink (e.g., the sample processing machine module 10) and the processor (e.g., the analyzer modules 32 and 34) by providing a branch loop within the segment 36 (and in some embodiments, the segment 42). The loop allows the sample carrier to move between the source, sink and processor, including allowing the sample to loop without returning to the source and sink.

[0045] exist Figure 3 The central computer including the system instrument manager software component is not shown. The instrument manager software merges information from lower level modules (such as, sample processing machine 10 and analyzer modules 32 and 34) to present the information to the operator. The instrument manager receives information from other modules via a network (e.g., an internal Ethernet network) within the system. Information can be requested and provided asynchronously between the modules and the central computer. The central computer can also work between the LIS and the container mover system to schedule samples and their movement within the system. The central computer can also work between the container mover system and the individual modules to switch the control of the samples and initiate the testing of the samples once they arrive at the location.

[0046] Additional information related to in vitro diagnostic systems can be found in U.S. patent application Ser. No. 16 / 319,306, filed on Jan. 18, 2019, entitled AUTOMATED CLINICAL ANALYZER SYSTEM AND METHOD, published as U.S. Patent Application Publication No. 2019 / 0277869A1, which is hereby incorporated by reference in its entirety.

[0047] Automated PCB-based track configuration Various liquid handlers can include a variety of different transport systems, including electromagnetic drive systems, friction-based track systems, or conveyor belts. For example, some liquid handlers include tracks with multiple synchronously controlled electromagnetic coils. The container mover is typically composed of a permanent magnet array in this case, and the field of the permanent magnet array interacts with the field generated by the electromagnetic coil array on the track. In these analyzer systems, the automated track is configured to move the sample carrier via the synchronously controlled electromagnetic coils that advance the sample carrier along the track section of the analyzer system. However, traditional electromagnetically driven transport systems use metal substrates for automated tracks. Metal substrates have several disadvantages, including cost and weight, as discussed generally above. Accordingly, embodiments of the transport system described herein include PCB-based substrates for automated tracks. In these embodiments, each track segment may include: one or more PCBs, having a coil array configured to electromagnetically actuate the container mover to transport the container mover along them.

[0048] In some embodiments, the track section is divided into multiple coil plates. The coil plate includes a linear array of coils that can be mounted to the PCB substrate of the track. For the straight section of the track, each coil plate is straight, and in a corner or curve, the coil plate includes a coil of appropriate layout to match the curve. All coil plates are controlled by a mainboard and a node controller. In some embodiments, each mainboard can control up to eight different coil plates. At the same time, the node controller is centralized. A single node controller can control the entire container mover track. In some embodiments, multiple distributed node controllers can be used for scalability. For example, in a larger system where the track extends for several meters, multiple node controllers can be used, and as the carrier traverses different areas of the track network, control of them can be switched.

[0049] Figure 4 Shown is a perspective view of the track system 160. The track system 160 is configured with a single sample handler unit and two analyzer modules. Figure 5A track system 160 is shown in a fully operational analyzer system 162 including a sample processing machine module 10 and two analyzer modules 32 and 34. As can be seen, the track system 160 is contained within the module itself so that the track is not easily accessible to the operator. However, track 160 and analyzer system 162 utilize modular design, whereby track components reside in each module, and each module can be easily linked together to link track segments by placing adjacent modules nearby and linking them. The cover above track 160 can be removed during installation or maintenance to facilitate the linking of the track. In certain embodiments, the track segments are expanded by placing modules adjacent to each other and bolting the track segments of each module together, thereby forming a single multi-branch track system, such as track 160. Signal cables can be daisy-chained together for convenient expansion control.

[0050] Figure 6 A cross-sectional view of a track segment 170 is shown. Track segment 170 may be a track segment used in track 160. In this embodiment, the carrier rides on a track surface 174 between rails 172. In some embodiments, rails 172 are aluminum extrusions that also include vertical sides outside of the track components below track surface 174. These aluminum extrusions may include brackets to easily bolt internal components to these side pieces to form a track unit. In the embodiments described herein, track surface 174 is a PCB. In various embodiments, PCB track surface 174 may include one or more coatings or other components. A substrate 176 resides at the bottom of the side components of rail 172. Substrate 176 may be mounted to a module containing track segment 170 and provide support for the track system.

[0051] Below the track surface 174 resides a series of coils 180. The longitudinal direction of the track section 170 enters the page; as you travel along the track section 170, you encounter additional coils 180. The coils 180 are preferably mounted to coil plates 182, and are preferably transversely rectangular to allow for greater coil density in the longitudinal direction of the track. In some embodiments, the coil plate 182 is a printed circuit board (PCB) that includes several coils 180 in the longitudinal direction. An exemplary coil plate is 250mm in length, thereby accommodating all the coils 180 required for a 250mm track. Therefore, a typical track section will have several coil plates 182, including dozens of coil plates 182 to form the entire track system. In some embodiments, the coil plate 182 receives a control signal to indicate the track of the carrier and 24VDC power supply to be applied to the coil plate. In some embodiments, the PCB coil plate itself forms the track (riding) surface. The coil plate 182 includes: coils 180; a motor driver for driving those coils; and one or more sensors for detecting the presence of a carrier traversing the track surface on the coil plate by detecting the magnet of the carrier. These sensors may include Hall effect sensors to detect the presence and position of a carrier traveling along the coil plate. Accordingly, there may be more sensors than coils, thereby allowing fine resolution of the position of a carrier traversing the track surface 174. In addition, an RFID receiver may be utilized to receive an RFID signal identifying a carrier traveling along the track surface. In some embodiments, a magnetic feature unique to each carrier may be detected by a Hall effect sensor to magnetically determine the identification of the carrier. For example, a carrier traversing an array of Hall effect sensors may be characterized at the time of manufacture to identify the unique features of the carrier based on the rise time and signal artifacts detected by the Hall effect or sensor array as the magnet in the carrier travels over the array. In some embodiments, a magnet smaller than the main drive magnet may be placed in the bottom portion of the carrier to intentionally create a unique feature for each carrier at the time of manufacture. The magnetic feature may be associated with the identification of each carrier in the software for the container mover system. An exemplary linear synchronous motor drive system is described in US Patent No. 9,346,371.

[0052] Figure 7A top view of an exemplary track system 160 is shown in which individual track segments are identified. There are generally four types of track segments that make up the modular design of the track system 160. A switching segment 184 is a branch in the track. The track surface for the switching segment 184 is generally T-shaped with a rounded inner edge. At the same time, the track of the switching segment 184 includes a straight track (the top of the T), a rounded track (an inner corner of the T), and a rounded track (another inner corner of the T) including a switching mechanism. The switching mechanism is a movable track component that can be tuned to a predetermined degree to act as a switch (e.g., 20-30 degrees, depending on the geometry). On one side of the track component, it acts as a straight track. On the other side of the track component, the track presents itself as a rounded track that forms an outer corner of a turn. By switching the movable track component, the movable track component can provide an outer side of a turn or a simple straightaway track. Therefore, the moving component provides a binary switch, whereby, depending on the control signal, the switching segment 184 presents itself as a turn or a straight segment. This can be used to turn individual carriers based on the state of the switching segment. It should be noted that although the track can be bidirectional, only one end of the T can be connected to the central portion of the T to form a turn. Therefore, although the switching segment 184 can have three ports, in essence, one port can be switched to either of the other two ports, but those two ports cannot be coupled together.

[0053] The simplest type of track segment is a straight segment, such as the outer straight segment 186 or the inner straight segment 188. The basic components of the straight segments 186 and 188 are the track surface and rails with a series of coil plates that provide linear power along the direction of the straight segment. Figure 7 Straight segments 186 and 188 are separately identified in the figure because in some embodiments the internal straight segment 188 can be operated under the control of a local module rather than a container mover controller that controls the entire track 160. This allows each local module to independently operate the track segment 188 to act as a local random access queue. The container mover controller can switch control to the local module after moving the carrier from the switching segment 184 to the local internal straight segment 188. Similarly, when the local module has completed the wish on the sample residing on the internal straight segment 188, the module can move the sample carrier into the switching segment 184 and switch control to the container mover controller. In some embodiments, the internal track segment 188 is still operated under the control of the container mover controller that controls the entire track system 160. In order to control the local queue on the internal straight segment 188, the local module can communicate directly with the container mover controller to request the movement of the carrier in the track segment 188. This allows the local module to indicate the control of the carrier in its queue by using a request to affirmatively respond to the communication system, thereby allowing the container mover controller to have expertise in moving individual carriers and operating the track system 160.

[0054] The fourth type of track segment is a curved track segment 190. The curved track segment 190 provides a 90° bend (or other angle bend) with a predetermined diameter. The radius is preferably the same as the radius used in the turn when the switching track segment 184 is switched to a curve. The radius is selected to minimize the spatial impact of the curve while allowing the carrier to move quickly around the curve without encountering sharp lateral forces. Therefore, the space requirements and speed requirements of the automation track 160 can determine the radius of the curved segment 190.

[0055] Electrically, the curved segment 190 is substantially identical to the straight segments 186 and 188. Each of these segments includes a plurality of coils that are activated in sequence to provide a linear motor in conjunction with magnets in the base of the carrier. Each coil is activated to provide a push or pull force on a drive magnet placed in the base of each carrier. The speed at which the coils are activated in sequence determines the speed of the carrier on that section of the track. In addition, the carrier can be moved into position and stopped at a predetermined position with high resolution by activating the coils at that position.

[0056] Figure 8 An illustrative embodiment of a track segment 201 of an automated track system 200 is shown, such as an Figure 4-7 . As generally described above, the automated track system 200 is configured to support one or more container movers 202, which are configured to receive containers 204 (also referred to as "carriers" or "sample carriers") therein. The track segment 201 may include: a riding surface 206, which is an upper surface of the track segment 201, which supports the container mover 202 thereon and along which the container mover 202 is transported between modules or components of the automated track system 200. In some embodiments, the riding surface 206 may include an active area 207 along which the container mover 202 is intended to move. As shown, the active area 207 is the area between the dotted lines. The active area 207 may generally correspond to the inner portion of the riding surface 206. If any liquid contaminants are present on the active area 207, they may negatively affect or otherwise impair the movement of the container mover 202, as mentioned above. In some embodiments, the track segment 201 may include a PCB substrate, as generally described above.

[0057] Furthermore, if Fig. 9As shown in , the track system 200 may include one or more coil arrays 208 associated with each track segment 201. The coil arrays 208 may be configured to generate a magnetic field that interacts with magnets 203 located within the base of the container mover 202. The coil arrays 208 and the container mover magnets 203 may together define a linear electromechanical actuator. By synchronously controlling the coil arrays 208, the track system 200 may advance the container mover 202 (and therefore, the container 204 containing any sample or other liquid held thereby) across the track segments 201 to a desired module or other component of the liquid handler system.

[0058] Additional information regarding transport systems for liquid handling machines may be found in US Patent Application No. 16 / 319,306, incorporated by reference above.

[0059] Sensing based on sparse Hall sensors As generally described above and as Fig.10 As shown in , the liquid handler system 250 may include: one or more modules 252 configured to process liquid samples; a track system 200 interconnecting the various modules 252; a container mover 202 that receives the liquid sample and transports the liquid sample between the various modules 252 along the track system 200; and a coil array 340 associated with the track system 200, which is configured to drive the container mover 202 along the track system 200. The liquid handler system 250 may further include: a tracking system 258 configured to monitor the position of the container mover 202 along the track system 200 and control the movement and / or routing of the container mover 202 accordingly. The tracking system 258 may further include: a control system 254; and a sensor assembly 256 (e.g., one or more Hall effect sensors) associated with the track system 200 and configured to detect the container mover 202 along the track system 200. The control system 254 can be coupled to the coil array 340 and configured to control the coil array 340 in order to control the movement and routing of the container mover 202 along the track system 200, which in turn allows the container mover 202 to transport liquid samples between modules 252 in a specific order and with specific timing depending on the type of liquid samples being processed by the liquid handler system 250. The control system 254 can include hardware, software, firmware, or any combination thereof capable of performing the functions described. In the illustrated embodiment, the control system 254 includes a processor 260 coupled to a memory 262 storing instructions that, when executed by the processor 260, cause the control system 254 to perform the described processes, steps, and / or functions.

[0060] Reference now Fig.11A, shows a diagram of a conventional arrangement of a sensor assembly 256 for a track segment of a liquid handling machine system 250. As can be seen, the sensor assembly 256 includes a series of Hall effect sensors 256a positioned longitudinally along the illustrated track segment of the track system 200. In this particular embodiment, the Hall effect sensors 256a are located below the coil array 340 that extends along the lower surface of the track system 200; however, the Hall effect sensors 256a may be arranged differently in other embodiments. In an illustrative embodiment, the sensor assembly 256 may include 20 Hall effect sensors 256a per track segment. Now referring to Fig. 11B , showing the depiction of Fig.11A 256a in the sensor assembly 256. As can be seen, the signal distribution for each Hall effect sensor 256a overlaps with the sensor distribution of one or more adjacent Hall effect sensors 256a. For example, region 280 generally corresponds to the overlap of the sensor distribution between the first and second Hall effect sensors 256a. The remaining Hall effect sensors 256a in the sensor assembly 256 overlap with the adjacent Hall effect sensors 256a to a similar extent. Accordingly, conventional position estimation schemes for the container mover 202 based on signals from the Hall effect sensors 256a use a combination of outputs from two or more adjacent sensors 256a.

[0061] Compared to Fig.11A and 11B The present disclosure generally relates to sparse Hall effect sensor assemblies. For example, Fig.12 An illustrative sensor assembly 256 for a track segment of a liquid handling machine system 250 is shown, wherein the sensor assembly 256 is comprised of a sparse arrangement of Hall effect sensors 256a (which may be particularly useful with Fig.11A). In one embodiment, the sensor assembly 256 for each track segment of the track system 200 may include: a Hall effect sensor 256a, which is positioned so that the signal distribution from each of the Hall effect sensors 256a does not overlap with the adjacent Hall effect sensor 256a beyond a threshold distance. In one embodiment, the threshold distance may be close to 0, that is, the signal distribution of the Hall effect sensor 256a does not overlap to any extent. However, in practice, in some embodiments, the threshold distance causes the signal distribution of the sensors to overlap at a level that is at least 6dB greater than the background noise but at least 6-10dB less than the peak of the signal distribution. In some other cases, the signal distributions from adjacent Hall sensors may be spatially separated. The position information required for motion control in this case can be extracted from a suitable state estimation method during the transit through the non-overlapping zone. However, in applications such as laboratory automation track systems, due to the presence of disturbances caused by friction and other factors, the disturbance may require continuous sensing without the following period: during this period, no sensory input is available for feedback to the controller. Therefore, in such applications, a sparse sensor configuration is generally used to ensure a minimum sufficient overlap between the sensor receptive fields. The present disclosure describes a solution for ensuring a smooth transition through this overlap / switching region between sensor ranges, such that a smooth estimate of the motion state is made available to the controller. This is described in detail below. In one embodiment, a sparse arrangement of Hall Effect sensors 256a may consist of five sensors 256a per track segment of the track system 200 (which may represent, for example, a reduction to 1 / 4 of a conventional implementation).

[0062] Conventional synchronous linear motor tracks utilize a 3-phase motor design, laid out in a linear repeating structure. In an exemplary prior art system, the coils are laid out and operated 120 degrees out of phase. Hall effect sensors are typically placed at linear positions corresponding to 120 or 90 degrees in this relationship (e.g. Fig.11A This results in substantial overlap in the signals between the sensors (such as Fig. 11B That is, when a magnet is placed equidistantly between two sensors in a conventional linear motor system, the sensor value will be substantially (e.g., 90%) near the sensor value of the peak signal that would occur for that magnet if it were directly on top of the sensor. Exemplary embodiments place sensors in locations that are not guided by coil phases, and instead place sensors sparsely based on the effective view of the sensors. Using the principles described herein, the overlap of signal windows of adjacent windows can be substantially less than Fig. 11B. Exemplary embodiments allow for sensor spacing such that sensors can be placed more than 180 degrees apart (in terms of motor phase). Exemplary embodiments allow for sensor spacing where the signal at equidistant points between sensors is less than half the peak signal (-6db). (This is to remove Fig. 11B ) In some embodiments, the signal at equidistant points is at least -10db of the peak signal. In some embodiments, further separation between sensors is used. A natural limitation on how sparse sensors can be placed is that the signal at equidistant points should be at least 6db greater than the noise floor.

[0063] In various embodiments, the Hall Effect sensors are positioned so that the signal from each of the Hall Effect sensors does not overlap with an adjacent Hall Effect sensor beyond a threshold. This can be viewed as the signal level observed by each adjacent sensor at a location equidistant from one another, where the signal level is the same for each sensor. In conventional systems, the signal level at this intersection location is quite high relative to the maximum signal level (when the mover's magnet is directly at the location of the sensor). For example, Fig. 11B The Hall Effect sensor overlap is around 90% (defined by the signal level of the sensor at the crossover point relative to the peak). In various embodiments, this overlap should be less than -6db of the peak; some embodiments use an overlap threshold of less than -10db. The threshold should be large enough so that the overlap is greater than 6db of the noise floor.

[0064] Sparse sensor assemblies 256 can be beneficial because it can reduce the costs associated with liquid handler systems 250 because it can allow them to function with a smaller number of components (i.e., Hall effect sensors 256a). Further, adjacent track segments in a track system 200 for a conventional liquid handler system 250 should be communicatively coupled together because position tracking relies on proximity signals from adjacent Hall effect sensors 256a, which may be present on separate track segment plates in the event that a container mover 202 approaches the end of a track segment and / or crosses over onto a new track segment. Therefore, the track segments should be communicatively coupled together so that data and / or signals from the Hall effect sensors 256a can be shared across track segments in order to properly track the container mover 202 throughout the track system 200. The electrical and / or electronic interconnections required to achieve communication through and between the sensor assemblies 256 of the various track segments create a significant amount of additional uncertainty, which increases the cost for setting up liquid handler systems 250 and may limit their flexibility in some instances.

[0065] To implement such a sparse sensor assembly 256 where adjacent track segments need not be communicatively coupled together, embodiments of the container tracking system 258 described herein are configured to track the position of the container mover 202 based on signals from a single Hall Effect sensor 256a. Fig.13 An illustrative embodiment of a process 300 for tracking the position of a container mover 202 using a sparse sensor assembly 256 is shown in FIG. The process 300 may be performed by, for example, combining Fig.10 The control system 254 described is executed. In one embodiment, the process 300 can be embodied as instructions stored in the memory 262, which, when executed by the processor 260, causes the control system 254 to perform the described process 100 and / or its steps. The embodiment can utilize the full range of the receptive field of each Hall sensor in the array. This can maximize the sensing range of the sensor compared to the traditional sensing scheme. This allows the sensor at the end of the array on each segment to sense the container mover when approaching the junction between the segments. As the container mover transitions from one segment to another, this allows its autonomous sensing without the need for inter-segment communication of sensory signals or information related to the state of the container mover estimated by the controller on either or both of the two adjacent segments. Relative to the traditional scheme, this significantly reduces the data communication overhead and reduces the resulting complexity. The sparse sensor array is configured so that the sensor at the end of the segment can sense the container mover located on the adjacent segment at a sufficiently large range to activate the appropriate autonomous series control action on either of the two segments so as to smoothly transition the container mover across the junction between the adjacent track segments.

[0066] Accordingly, the control system 254 performing the process 300 may receive 302 signals from each of the Hall effect sensors 256a of the sensor assembly 256 and determine 304 which of the Hall effect sensors 256a the container mover 202 is within a sensing range of. In one embodiment, the control system 254 may determine which of the Hall effect sensors 256a the container mover 202 is within a sensing range of by identifying which Hall effect sensor 256a exhibits a response signal (i.e., indicating that a particular Hall effect sensor 256a is sensing the magnet 203 of the container mover 202). This may be accomplished, for example, by peak detection across an array of signals from the Hall sensors. In the case of multiple movers on a segment, a closest sensor association may be made for each of the container movers on the track segment by specifying a minimum spacing threshold between peaks and / or setting a threshold for a signal amplitude difference between adjacent peaks.

[0067] Accordingly, the control system 254 may map 306 the determined sensor signal of the Hall effect sensor 256a (which may be referred to as the "sensing Hall effect sensor," i.e., the Hall effect sensor 256a within whose sensing range the container mover 202 is located) to a function configured to relate the strength of the signal to the distance relative to the sensing Hall effect sensor. In some embodiments, the control system 254 may retrieve one or more pre-characterized sensor signals corresponding to different distances and select the pre-characterized sensor signal that most closely maps to the received sensor signal. Since the retrieved pre-characterized sensor signals are already related to the pre-characterized distances from the Hall effect sensor 256a, the control system 254 may accordingly determine the distance of the container mover 202 from the Hall effect sensor 256a based on which of the pre-characterized sensor signals the received sensor signal is mapped to. In various embodiments, the function to which the received sensor signal is mapped may include a variety of different measurement models, including a Lorentzian function, a Gaussian function, or a Sinc function. In some embodiments, the function can be one of a rational polynomial transfer function, a piecewise cubic or Hermitian polynomial, a Bessel spline function. The exact function selected can depend on the sensor type and sensor placement. In some embodiments, the system has several functions to choose from, and the function can be selected during a calibration sequence before using the container mover system during normal operation. In some embodiments, a lookup table can be used. For example, the expected response of the sensor to a changing magnetic field as the mover moves can be mapped to a predetermined curve with values ​​in a table, allowing a lookup of the current value in the table to approximate the position of the mover.

[0068] The control system 254 can be configured to perform a regression-based analysis to determine which of the measurement models the received sensor signals most closely map to. In some embodiments, the mapping of mover positions to sensor signals can be performed offline, and the mapping can then be stored as a lookup table or parameterized function on a microprocessor. For example, Fig.14Various plots of Hall sensor signals modeled using Lorentz functions are illustrated. As shown in the plots, the Lorentz regression fit of the Hall sensor signal as a function of container mover position is sufficiently accurate (e.g., RMS fit error <0.04 compared to the normalized maximum value of 1.0 for the sensor signal) that the control system 254 can determine that the received signal maps to a particular function and parameters. Because the distance associated with the particular mapped function is pre-characterized or known, the control system 254 can determine the position of the container mover 202 relative to the Hall effect sensor 256a, and accordingly determine 308 the position of the container mover 202 along the track system (since the position of the particular Hall effect sensor 256a is known). Embodiments utilizing Lorentz functions can be beneficial because the Lorentz function and its Jacobian (i.e., partial derivatives with respect to the state variables) are relatively inexpensive to the control system 254 to compute, which can provide significant advantages for real-time or online state estimation.

[0069] In some embodiments, the container tracking system 258 can use a variety of different systems and / or techniques to further track the position and / or velocity (i.e., motion state) of the container mover 202 across the track system 202 as the container mover 202 moves in and out of the sensing range of the individual Hall effect sensors 256a. For example, the control system 254 can implement an extended Kalman filter or other alternative state estimator to fuse the outputs from the sensor assembly 256 in order to estimate and track the state of the container mover 202 across different individual Hall effect sensors 256a. In one embodiment, the control system 254 can be configured to perform weighted estimation to fuse the sensor outputs and determine the state of the container mover 202. In another embodiment, the control system 256 can be configured to perform cascade estimation to fuse the sensor outputs and determine the state of the container mover 202.

[0070] In this embodiment, a state estimator using an extended Kalman filter is algorithmically set up to utilize the sensor signal from a single closest sensor when the container mover is within the receptive field exclusive to that sensor, and to use the signals from all two adjacent sensors in a suitable combination when the mover is in the overlapping region. In some configurations, the sensor array is arranged to have a minimum expected overlap in the receptive fields of adjacent sensors to facilitate a smooth transition between sensor fields. This provides a continuous and smooth estimate of position and velocity in a mathematical sense. In this case, when the mover state is in the overlapping region of the sensor field, a fusion algorithm is applied to extract the most accurate state estimate. It is worth noting that in an ideally sparse sensor configuration, the overlap between the receptive fields of adjacent sensors is in the tail region of the signal distribution of each of the sensors. The reduced value of the sensor signal relative to the signal variance (noise) may therefore lead to inaccuracies in the state estimate. To address this problem, some embodiments use one of two schemes - in the overlap region, (1) apply appropriate weighting of the two sensor signals to define the observation / measurement signal within the estimator; or (2) apply the two sensed signals serially to the measurement update step of the extended Kalman filter (or other similar state estimator) to utilize "evidence" from both signals to update the state of the container mover motion. For method (1), the weights can be fixed (e.g., equal) based on a prior (previous time step) estimate of the mover position relative to the sensor or based on some measure of the relative strength of the two sensor signals. The weighting is based on the state estimate from the prior time step to bias the measurement update that simultaneously utilizes both signals toward the stronger sensor signal or, alternatively, toward the signal from the sensor that is believed to be closer to the container mover.

[0071] Motion state estimation for full state feedback can be implemented in a variety of ways. One embodiment includes using a mapping between sensor signals and mover position to estimate the container mover position, feeding it into a reduced order observer or optimal filter to estimate velocity. Another embodiment includes incorporating the sensing model into a full order observer or state estimator (such as an extended Kalman filter) and estimating position and velocity simultaneously.

[0072] In some embodiments, a weighted estimation scheme is used. The estimator is initially 0. The processor determines the index (relative position on the track segment) of the sensor closest to the magnet in the container mover based on the position estimate at t0. An array of sensor values ​​for the sensor at that index is created. If the index is not the first or last sensor on the segment, the sensor values ​​of the directly adjacent sensors are added to the array of sensor values. Weights are then assigned to neighboring sensor values ​​calculated based on an estimate of the relative proximity of the magnet to each of those neighboring sensors (e.g., based on a motion state model). An extended Kalman filter prediction step is applied. If the index is not the first or second sensor on the track segment, the processor performs a separate measurement update for each of the sensor measurements in the array. The processor calculates a weighted average of the state error covariance matrix and the new state estimate. If the index is the first or last sensor in the track segment, the measurement update step applies an enhanced Kalman filter to a single sensor value.

[0073] In some embodiments, cascaded estimation is used. The processor approaches sensor fusion in the same manner as for the weighted estimation embodiment, except for how the extended Kalman filter is applied to the sensor values ​​of the neighboring sensors in the array. In this embodiment, the measurement update step uses the sensor value corresponding to the sensor index. The other sensor values ​​in the array (i.e., neighboring sensors) are then updated using the predicted state as a result of this update step. This results in cascaded or recursive update steps as the processor applies the extended Kalman filter to the sensor values ​​in the array.

[0074] Accordingly, the systems and methods described herein provide end-to-end position sensing based on the sensor assembly 256 located on the track segment over which the container mover 202 is currently moving, without requiring Hall effect sensor signals from adjacent track segments to estimate the position of the container mover 202 when the container mover 202 is near either end of the track segment. Further, the systems and methods described herein provide a significant reduction in the number of Hall effect sensors 256a required per track segment (e.g., to 1 / 4), and thus provide significant component cost savings and reduced complexity associated with circuit layout and signal multiplexing.

[0075] The Hall sensors used in some embodiments may be out-of-plane 1D sensors, in-plane 1D, in-plane 2D, or one out-of-plane and two out-of-plane (3D) sensors. In the case of out-of-plane Hall sensors and a magnet array that generates a field that is symmetric in either of two directions along the axis of motion of the mover, sensing using a single sensor may require uncertainty regarding the relative + / - position of the mover with respect to the sensor. This uncertainty may be resolved as follows. At startup, the mover may be moved in a set direction (e.g., left / right, Fig.12 ) moves the mover a small amount. The trend (decrease / increase) in the sensor signal or the polarity of the change in the position estimate corresponding to the two mover placements then yields the orientation of the mover along the axis of motion relative to the sensor. As the container mover moves, the state estimator should converge on the true position and orientation of the mover relative to the sensor as it collects more observations ("evidence") over several consecutive time steps. Alternatively, the in-plane sensor can make the uncertainty in the placement (left / right or up / down or + / -) of the mover along the axis of motion relative to the sensor clear. During normal operation (once the state is initialized correctly following this method), the prior information / estimates of position and velocity can be used by the state estimator to accurately estimate the absolute position of the mover relative to the coordinate reference system of the segment. When the mover is in motion, the changing polarity of the Hall signal in consecutive time steps can be used to determine whether the mover is to the left or right of the sensor. For example, if the sensor signal polarity change is positive for two or more consecutive time steps, it will imply that the mover is moving toward the sensor. This information can be used to determine whether the mover is to the left or right of the sensor, depending on the direction of the mover's movement.

[0076] In some embodiments, the methods described herein can be used to use alternative sensors to the Hall Effect sensor. Alternative sensors include magnetoresistive (MR and variants such as GMR & TMR), electric field sensors, optical sensors, and photoelectric sensors. The methods described herein can be applied to sensors that sense a field whose intensity decays with distance.

[0077] In some embodiments, other estimators besides those described herein may also be used. Alternative estimators that may be used in various embodiments include nonlinear observers, particle filters, ensemble Kalman filters, dynamic Bayesian models, weighted least squares estimators, and recursive least squares estimators.

[0078] Although various illustrative embodiments incorporating the principles of the present teachings have been disclosed, the present teachings are not limited to the disclosed embodiments. Instead, the present application is intended to cover any variation, use, or adaptation of the present teachings, and to use their general principles. Further, the present application is intended to cover such departures from the present disclosure that are within known or customary practices in the art to which these teachings belong.

[0079] In the above detailed description, reference is made to the accompanying drawings that form a part thereof. In the accompanying drawings, similar symbols typically identify similar parts, unless the context dictates otherwise. The illustrative embodiments described in the present disclosure are not intended to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It should be readily understood that the various features of the present disclosure as generally described herein and as illustrated in the figures may be arranged, replaced, combined, separated, and designed in many different configurations, all of which are expressly contemplated herein.

[0080] This article describes aspects of the technical solution with reference to flowchart illustrations and / or block diagrams of methods, devices (systems) and computer program products according to embodiments of the technical solution. It should be understood that each frame of the flowchart illustration and / or block diagram and the combination of frames in the flowchart illustration and / or block diagram can be implemented by computer-readable program instructions.

[0081] These computer-readable program instructions may be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device to produce a machine such that the instructions executed via the processor of the computer or other programmable data processing device create means for implementing the functions / actions specified in the flowchart and / or one or more block diagram blocks. These computer-readable program instructions may also be stored in a computer-readable storage medium that can direct a computer, a programmable data processing device, and / or other device to function in a particular manner, such that the computer-readable storage medium having the instructions stored therein includes an article of manufacture that includes instructions for implementing aspects of the functions / actions specified in the flowchart and / or one or more block diagram blocks.

[0082] Computer-readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other device to produce a computer-implemented process, so that the instructions executed on the computer, other programmable apparatus, or other device implement the functions / actions specified in the flowchart and / or one or more block diagram boxes.

[0083] The flow charts and block diagrams in each figure illustrate the architecture, function and operation of the possible implementation of the system, method and computer program product according to the various embodiments of the present technical solution. In this regard, each frame in the flow chart or block diagram can represent a module, segment or instruction portion, which includes one or more executable instructions for realizing (one or more) specified logical functions. In some alternative implementations, the function pointed out in the frame may not occur in the order pointed out in each figure. For example, depending on the function involved, the two frames shown in succession can in fact be substantially executed simultaneously, or the frame can sometimes be executed in reverse order. It should also be noted that each frame of the block diagram and / or flow chart diagram and the combination of the frames in the block diagram and / or flow chart diagram can be realized by a dedicated hardware-based system that performs a specified function or action or implements a combination of special hardware and computer instructions.

[0084] A second action may be said to be "responsive to" a first action, regardless of whether the second action results directly or indirectly from the first action. A second action may occur at a substantially later time than the first action and still be responsive to the first action. Similarly, a second action may be said to be responsive to a first action even if intervening actions occur between the first and second actions and even if one or more of the intervening actions directly cause the second action to be performed. For example, if a first action sets a flag and a third action later initiates the second action whenever the flag is set, the second action may be responsive to the first action.

[0085] The present disclosure should not be limited in terms of the specific embodiments described in this application, which are intended to be illustrations of various figures. Without departing from its spirit and scope, many modifications and variations can be made, as will be apparent to those skilled in the art. In addition to those methods and devices listed herein, functionally equivalent methods and devices within the scope of the present disclosure will also be apparent to those skilled in the art from the above description. It should be understood that the present disclosure is not limited to ad hoc methods, reagents, compounds, components or biological systems, which can certainly vary. It should also be understood that the terms used herein are only used to describe the purpose of specific embodiments, and are not intended to be limited.

[0086] With respect to the use of substantially any plural and / or singular terms herein, those skilled in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. Various singular / plural permutations may be expressly set forth herein for the sake of clarity.

[0087] Those skilled in the art will appreciate that, in general, the terms used herein are generally intended as "open" terms (e.g., the term "comprising" should be interpreted as "including but not limited to", the term "having" should be interpreted as "having at least", the term "including" should be interpreted as "including but not limited to", etc.). Although various compositions, methods, and apparatus are described in terms of "comprising" various components or steps (interpreted to mean "including but not limited to"), the compositions, methods, and apparatus may also "consist essentially of" or "consist of" various components and steps, and such terms should be interpreted as defining groups of substantially closed members.

[0088] As used in this document, the singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise. Unless otherwise defined, all technical and scientific terms used herein have the same meanings as commonly understood by those skilled in the art. Nothing in this disclosure should be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention.

[0089] In addition, even if specific numbers are explicitly stated, those skilled in the art should recognize that such a statement should be interpreted as meaning at least the stated number (e.g., a bare statement without other modifiers in "two statements" means at least two statements or two or more statements). In addition, in those instances where a convention similar to "at least one of A, B, and C, etc." is used, generally, such a construction is intended to be made in the sense that a person skilled in the art will understand the convention (e.g., "a system having at least one of A, B, and C" will include but is not limited to systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention similar to "at least one of A, B, or C, etc." is used, generally, such a construction is intended to be made in the sense that a person skilled in the art will understand the convention (e.g., "a system having at least one of A, B, or C" will include but is not limited to systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Those skilled in the art will further appreciate that, whether in the description, sample embodiments or drawings, almost any disjunctive word and / or phrase presenting two or more alternative terms should be understood to contemplate the possibility of including one of the terms, either one of the two terms, or both of the two terms. For example, the phrase "A or B" should be understood to include the possibility of "A" or "B" or "A and B".

[0090] In addition, where features of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also specifically described in terms of any individual member or subgroup of members of the Markush group.

[0091] As those skilled in the art will appreciate, for any and all purposes, such as for providing a written description, all scopes disclosed herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof. Any listed range can be easily considered to fully describe the same range and enable the same range to be decomposed into at least equal half, one-third, one-quarter, one-fifth, one-tenth, etc. As a non-limiting example, each range discussed herein can be easily decomposed into lower third, middle third, and upper third, etc. As those skilled in the art will also appreciate, all languages ​​such as "up to", "at least", etc. include the recorded numbers and refer to the scope of the sub-ranges that can be subsequently decomposed into as discussed above. Finally, as those skilled in the art will appreciate, the scope includes each individual member. Therefore, for example, a group with 1-3 components refers to a group with 1, 2 or 3 components. Similarly, a group with 1-5 components refers to a group with 1, 2, 3, 4 or 5 components, and the like.

[0092] Various of the above disclosed and other features and functions or their alternatives can be combined into many other different systems or applications. Various currently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be covered by the disclosed embodiments.

Claims

1. A container tracking system for tracking a container mover in a liquid handling machine system, the liquid handling machine comprising a track system, the container tracking system comprising: a sensor assembly associated with the track system, the sensor assembly comprising: a plurality of Hall effect sensors positioned along the track system, wherein the Hall effect sensors are configured to detect a magnet positioned with the container mover, wherein the Hall effect sensors are positioned such that a signal from each of the Hall effect sensors does not overlap an adjacent Hall effect sensor beyond a threshold of less than 6 dB of a sensor peak; and a control system coupled to the sensor assembly, the control system being configured to: receiving a signal from each of the plurality of Hall effect sensors; determining within which of the plurality of Hall effect sensors the container mover falls within a sensing range to define a sensing Hall effect sensor; mapping a signal from the sensing Hall effect sensor to a function, wherein the function is configured to relate the strength of the signal to the distance relative to the sensing Hall effect sensor; and The position of the container mover is determined based on a mapping of the signal from the sensing Hall effect sensor to the function.

2. The container tracking system of claim 1, wherein the control system is configured to fuse the plurality of singulated signals via an extended Kalman filter. 3 . The container tracking system of claim 1 , wherein the control system is configured to fuse the plurality of singulated signals via at least one of weighted estimation and cascade estimation.

4. The container tracking system of any one of claims 1 to 4, wherein the signal overlap from each adjacent pair of the Hall Effect sensors is more than 6 dB above the noise floor.

5. The container tracking system according to any one of claims 1, wherein the function is one of the group consisting of a Lorentz function, a Sinc function, and a Gaussian function.

6. A liquid handling system for processing a liquid sample, the liquid handling system comprising: one or more modules configured to process the liquid sample; a track system interconnecting the one or more modules, the track system configured to support one or more container movers thereon, the one or more container movers including magnets and configured to receive the liquid sample; a sensor assembly associated with the track system, the sensor assembly comprising a plurality of Hall effect sensors positioned along the track system, wherein the Hall effect sensors are configured to detect a magnet positioned with the container mover, wherein the Hall effect sensors are positioned such that a signal from each of the Hall effect sensors does not overlap an adjacent Hall effect sensor beyond a threshold of less than 6 dB of a sensor peak; as well as a control system coupled to the sensor assembly, the control system being configured to: receiving a signal from each of the plurality of Hall effect sensors; determining within which of the plurality of Hall effect sensors the container mover falls within a sensing range to define a sensing Hall effect sensor; mapping a signal from the sensing Hall effect sensor to a function, wherein the function is configured to relate a strength of the signal to a distance relative to the sensing Hall effect sensor; as well as The position of the container mover is determined based on a mapping of the signal from the sensing Hall effect sensor to the function.

7. The liquid handler system of claim 6, wherein the control system is configured to fuse the plurality of singulated signals via an extended Kalman filter.

8. The liquid handler system of claim 6, wherein the control system is configured to fuse the plurality of singulated signals via at least one of weighted estimation and cascade estimation.

9. The liquid handler system of any one of claims 6, wherein the signal overlap from each adjacent pair of the Hall Effect sensors is more than 6 dB above the noise floor.

10. The liquid handler system of any one of claims 6, wherein the function is one of the group consisting of a Lorentz function, a Sinc function, a Gaussian function, and a rational polynomial transfer function.

11. A method for tracking a container mover in a liquid handler system for processing liquid samples, the liquid handler system comprising: one or more modules configured to process the liquid sample; a track system interconnecting the one or more modules and configured to support one or more container movers thereon, the one or more container movers including magnets and configured to receive the liquid sample; a sensor assembly associated with the track system and including a plurality of Hall effect sensors positioned along the track system, wherein the Hall effect sensors are configured to detect magnets positioned with the container movers, wherein the Hall effect sensors are positioned such that a signal from each of the Hall effect sensors does not overlap with an adjacent Hall effect sensor beyond a threshold of less than 6 dB of a sensor peak, the method comprising: receiving, by a control system coupled to the sensor assembly, a signal from each of the plurality of Hall effect sensors; determining, by the control system, within which of the plurality of Hall effect sensors the container mover falls within a sensing range to define a sensing Hall effect sensor; mapping, by the control system, a signal from the sensing Hall effect sensor to a function, wherein the function is configured to relate a strength of the signal to a distance relative to the sensing Hall effect sensor; and The position of the container mover is determined by the control system based on a mapping of the signal from the sensing Hall effect sensor to the function.

12. The method of claim 11, wherein the control system is configured to fuse the plurality of singulated signals via an extended Kalman filter.

13. The method of claim 11, wherein the control system is configured to fuse the plurality of singulated signals via at least one of weighted estimation or cascaded estimation.

14. The method of any one of claims 11, wherein the signals from each adjacent pair of the Hall Effect sensors overlap by more than 6 dB compared to the noise floor.

15. The method of any one of claims 11, wherein the function is one of the group consisting of a Lorentz function, a Sinc function, and a Gaussian function.

16. The method of any one of claims 11, wherein the sensor assembly is divided into segments, each segment comprising a circuit board, and the method further comprises: The proximity of the container mover to a junction of two adjacent segments is determined by the control system to initiate a switch of control of the container mover between segments.

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