METHOD FOR OPERATING A LABORATORY AUTOMATION SYSTEM AND LABORATORY AUTOMATION SYSTEM

Description

[0001] The invention relates to a method of operating a laboratory automation system and to a laboratory automation system.

[0002] Laboratory automation systems can be used in order to provide for a partial or full automation of a laboratory. For that purpose, a laboratory automation system typically comprises a number of laboratory stations and a laboratory sample distribution system.

[0003] A typical laboratory sample distribution system is shown in document WO 2013 / 064656 A1. Such a laboratory sample distribution system provides for a high throughput and for reliable operation.

[0004] EP 2 887 071 A1 discloses a storage and supply of vessel holders.

[0005] WO 2013 / 064662 A1 discloses a storage module for a laboratory automation system according to the preamble of claim 1.

[0006] DE 10 2014 202 843 B3 discloses a laboratory automation system and a corresponding sample container carrier.

[0007] US 2005 / 0260102 A1 discloses an automatic system for conserving samples at a controlled temperature.

[0008] US 2013 / 0034410 A1 discloses a laboratory automation system comprising a plurality of laboratory stations and a laboratory sample distribution system. The laboratory sample distribution system comprises: a number of sample container carriers, wherein the sample container carriers are adapted to carry one or more sample containers, wherein the sample containers comprise samples to be analyzed by means of the laboratory stations, a transport plane, wherein the transport plane is adapted to support the sample container carriers, drive means, wherein the drive means are adapted to move the sample container carriers on the transport plane, and a control device, wherein the control device is configured to control the drive means such that the sample container carriers move over the transport plane along predetermined transport paths.

[0009] Typical laboratory sample distribution systems are adapted to transport samples to be analyzed to the laboratory stations and away from the laboratory stations. However, it is common that reagents, disposables, labels or other items needed by the laboratory stations are provided to them externally, for example by manual operation or by separate supply means. This requires additional effort and high storage capacity.Objects and solutions

[0010] It is thus an objection of the invention to provide for a method of operating a laboratory automation system that is able to further integrate and / or optimize supply of items to laboratory stations. It is a further object to provide for a laboratory automation system.

[0011] These objects are solved by a method according to claim 1 and a laboratory automation system according to claim 7.

[0012] The invention relates to a method of operating a laboratory automation system. The laboratory automation system comprises a plurality of laboratory stations, a laboratory sample distribution system and a storage module.

[0013] The method comprises the steps detecting that (if) at least one type of items is missing or is running short at one of the laboratory stations, in response to the detecting, disposing a number of such items from one of a number of storage means of the storage module, and transporting the items to the laboratory stations using (by means of) the laboratory sample distribution system.

[0014] Thus, the laboratory sample distribution system can be advantageously used in order to automatically supply reagents, disposables or other items to the laboratory stations. There is no need to install separate supply systems and there is further no need for manual intervention or control. It can be assured that the laboratory stations are supplied with needed items.

[0015] According to an embodiment, the items are transported by means of sample container carriers of the laboratory sample distribution system. According to another embodiment, the items are transported by means of transport carriers.

[0016] The method according to the present invention comprises the steps detecting that at least one storage means is empty or is running short of items, and in response to the detecting, generating a signal indicating that the storage means should be filled and / or replaced.

[0017] This allows not only for an automatic supply of the laboratory stations, but also for an automatic filling or replacement of the storage means. Filling can, for example, mean that liquids or other items are placed into a fixed container. Replacement can, for example, mean that a container storing liquids or other items is replaced as a whole.

[0018] According to an embodiment, at least some of the items are reagents, tubes, tips, pipetting heads, labels, cartridges comprising a set of reagents used in the laboratory stations and / or other consumables used by the laboratory stations.

[0019] According to an embodiment, at least some of the items are calibration substances and / or substances required for preparation calibration substances.

[0020] According to an embodiment, at least some of the items are liquids and are transported using containers of the transport carriers. This allows for an efficient distribution of liquids.

[0021] According to an embodiment, detecting that a type of items is running short comprises detecting that a number or amount of such an item is less than 10% of a maximum capacity. Such a value has been proven suitable in typical applications, wherein it should be noted that also other values can be used, for example 5%, 8%, 12% or 15%.

[0022] The invention relates further to a laboratory automation system comprising a plurality of laboratory stations and a laboratory sample distribution system.

[0023] The laboratory sample distribution system comprises a number of sample container carriers, wherein the sample container carriers are adapted to carry one or more sample containers, wherein the sample containers comprise samples to be analyzed by means of the laboratory stations. The laboratory sample distribution system comprises a transport plane, wherein the transport plane is adapted to support the sample container carriers. The laboratory sample distribution system comprises drive means, wherein the drive means are adapted to move the sample container carriers on the transport plane. The laboratory sample distribution system further comprises a control device. The control device is configured to control the drive means such that the sample container carriers move over the transport plane along predetermined transport paths.

[0024] The laboratory automation system further comprises a storage module that is attached (coupled, assigned) to the laboratory sample distribution system.

[0025] The laboratory automation system further comprises process control unit. The process control unit is configured to control the laboratory stations, the laboratory sample distribution system and the storage module such that a method according to the invention is performed. The process control unit can be different from the control device of the laboratory sample distribution system, but can also be implemented in the same device as the control device, for example in a control unit embodied as a microprocessor and corresponding program storage.

[0026] The sample containers are typically designed as tubes made of glass or transparent plastic and typically have an opening at an upper end. The sample containers can be used to contain, store and transport samples such as blood samples or chemical samples.

[0027] The transport plane can also be denoted as transport surface. The transport plane supports the sample container carriers, what can also be denoted as carrying the sample container carriers.

[0028] The drive means can comprise electro-magnetic actuators. The electro-magnetic actuators are typically built as electromagnets, having a solenoid surrounding a ferromagnetic core. These electro-magnetic actuators may be energized in order to provide for a magnetic field that can be used to move or drive the sample container carriers. For that purpose, at least one magnetically active device can be comprised in each sample container carrier, wherein the magnetically active device may be a permanent magnet. Alternatively or additionally, an electromagnet can be used. Accordingly, at least one magnetically active device can be comprised in each transport carrier, wherein the magnetically active device may be a permanent magnet. Alternatively or additionally, an electromagnet can be used.

[0029] The control device is typically a microprocessor, a microcontroller, a field-programmable gate array, a standard computer or a similar device. In a typical embodiment, the control device comprises processor means and storage means, wherein program code is stored in the storage means in order to control the behavior of the processor means when the storage code is executed on the processor means. The same applies for the process control unit.

[0030] The sample container carriers and the transport carriers are typically adapted to move in two dimensions on the transport plane. For that purpose, electro-magnetic actuators may be arranged in two dimensions below the transport plane. The electro-magnetic actuators may be arranged in a grid or matrix having rows and columns along which the electro-magnetic actuators are arranged.

[0031] The laboratory automation system comprises a number of transport carriers being adapted to carry one or more items, wherein the drive means are adapted to move the transport carriers on the transport plane, and wherein the control device is configured to control the drive means such that the transport carriers move over the transport plane along predetermined transport paths.

[0032] It should be noted that alternatively to the embodiment as described above with respect to the drive means having electro-magnetic actuators also self-driving transport carriers or sample container carriers can be used. For example, such transport carriers or sample container carriers can have wheels propelled by motors and / or being controllable with respect to a respective angle in order to control movement of the respective carrier. Sample container carriers can also be equipped with means for determining the respective position.

[0033] The laboratory stations can, for example, be pre-analytical, analytical and / or post-analytical (laboratory) stations, and a laboratory sample distribution system as described above can be adapted to transport the sample container carriers and / or sample containers between the stations. The stations will be arranged adjacent to the laboratory sample distribution system.

[0034] Pre-analytical stations may be adapted to perform any kind of pre-processing of samples, sample containers and / or sample container carriers.

[0035] Analytical stations may be adapted to use a sample or part of the sample and a reagent to generate a measuring signal, the measuring signal indicating if and in which concentration, if any, an analyte is existing.

[0036] Post-analytical stations may be adapted to perform any kind of post-processing of samples, sample containers and / or sample container carriers.

[0037] The pre-analytical, analytical and / or post-analytical stations may comprise at least one of a decapping station, a recapping station, an aliquot station, a centrifugation station, an archiving station, a pipetting station, a sorting station, a tube type identification station, a sample quality determining station, an add-on buffer station, a liquid level detection station, and a sealing / desealing station.

[0038] The storage module provides for a means for central storing of disposables, reagents, labels or other items that are needed by the laboratory stations. The storage module is further adapted to seamlessly integrate with the laboratory sample distribution system such that the laboratory sample distribution system can be used to transport items or disposables from the storage module to the laboratory stations.

[0039] The sample container carriers are available due to the normal functionality of the laboratory sample distribution system. Thus, these entities can also be used for transporting the stored items from the storage module to the laboratory stations or to other entities.

[0040] The transport carriers are typically entities that are specifically adapted to transport the items from the storage module to the laboratory stations or other entities. The transport carriers are typically not used to transport samples to, from or between the laboratory stations.

[0041] It is noted that the transport carriers can, for example, be handled by the control device like the sample container carriers. For example, the transport carriers can be included in the conventional planning or distribution of transport paths, a task that is typically performed for the sample container carriers. However, it should be noted that it is possible to specifically handle the transport carriers, for example taking into account different sizes or maximum speeds. At least one handling means is assigned to the storage means. The handling means are adapted to effect the disposal of the stored items to the sample container carriers or to the transport carriers by loading the items from the storage means on / to the sample container carriers or on / to the transport carriers.

[0042] Such handling means can be used in order to extract stored items from the storage module in order to transport them to the laboratory stations. Manual intervention is typically not necessary for that purpose.

[0043] According to an embodiment, the storage module comprises processing means, wherein the processing means are adapted to process the stored items, especially before they are transported by means of the laboratory sample distribution system.

[0044] The processing of the stored items may comprise shaking and / or mixing and / or heating and / or cooling the stored item and / or adding another item to the stored item and / or labeling or capping and / or uncapping the container of the stored item.

[0045] According to an embodiment, the processing means comprise a temperature control unit and / or a shaker unit and / or a mixer unit and / or an aliquoter unit and / or a label unit and / or a capping unit and / or a calibration substance preparation unit being adapted to prepare a calibration substance.

[0046] The temperature control unit may be adapted to control the temperature of the stored item by cooling or heating.

[0047] The aliquoter may be adapted to aliquot the stored item.

[0048] The label unit may label a container comprising the stored item.

[0049] The capping unit may decap or recap a cap from / to the container comprising the stored item.

[0050] The calibration substance preparation unit may prepare the calibration substance required for calibration of at least one of the laboratory stations.

[0051] According to a further embodiment, the processing means are adapted to plan, cause and / or control the processing of the stored items.

[0052] A processing of the stored items may be required after a specific time period. The time period may be the time after an event, e.g. the last processing of the stored items or the last calibration of the laboratory stations. The processing means may initiate the processing of the stored items.

[0053] The processing means may be adapted to provide the prepared calibration substance to the laboratory sample distribution system, wherein the laboratory sample distribution system is then adapted to transport the prepared calibration substance to the laboratory station to be calibrated.

[0054] The processing means may be adapted to initiate a calibration process of a laboratory station.Short description of the drawing

[0055] The invention will be described in detail with respect to the drawing schematically depicting an embodiment of the invention. In detail: Fig. 1shows a laboratory automation system comprising a storage module being adapted to perform a method according to the invention. Fig. 2schematically shows a further embodiment of a laboratory automation system comprising a storage module being adapted to perform a method according to the invention. Detailed description of the embodiment

[0056] Fig. 1 shows a laboratory automation system 10 according to the invention. The laboratory automation system 10 comprises a laboratory sample distribution system 100, a first laboratory station 20, a second laboratory station 25 and a storage module 200. The laboratory stations 20, 25 and the storage module 200 are operatively connected to the laboratory sample distribution system 100. It should be noted that the two shown laboratory stations 20, 25 are only shown exemplarily and that typical laboratory automation systems 10 can have more than two laboratory stations.

[0057] The laboratory sample distribution system 100 comprises a transport plane 110. Below the transport plane 110, a plurality of electro-magnetic actuators 120 are provided. Each electro-magnetic actuator 120 comprises a ferromagnetic core 125.

[0058] Over the transport plane 110 a plurality of position sensors 130 are distributed. These position sensors 130 are embodied as Hall sensors.

[0059] On the transport plane 110, sample container carriers 140 can move. For exemplary purposes, there are shown two sample container carriers 140, each carrying a respective sample container 145. It should be noted that these two sample container carriers 140 are shown only exemplarily and that typical laboratory automation systems 10 comprise more than two sample container carriers.

[0060] Each sample container carrier 140 comprises a permanent magnet that is not visible in fig. 1. Thus, the sample container carriers 140 can be driven by magnetic fields generated by the electro-magnetic actuators 120.

[0061] The sample distribution system 100 further comprises a control device in the form of a control unit 150 that is operatively connected to the electro-magnetic actuators 120 and to the position sensors 130. Thus, the control unit 150 can drive the electro-magnetic actuators 120 such that they generate respective magnetic fields in order to propel the sample container carriers 140 and to propel transport carriers 230 along respective transport paths. Further, the control unit 150 monitors the position of the sample container carriers 140 and the position of the transport carriers 230 by means of the position sensors 130. The control unit 150 also acts as a process control unit to control the entire laboratory automation system 10.

[0062] The storage module 200 comprises a first storage means in the form of a first container 210, a second storage means in the form of a second container 220 and processing means 225. The processing means 225 may comprise a calibration substance preparation unit and / or a temperature control unit. The first container 210 is adapted to store a pulverized item 212, wherein the second container 220 is adapted to store a liquid item 222. The temperature control unit is adapted to heat or cool the item 212 and / or the item 222. The items 212, 222 are used by the laboratory stations 20, 25 during analyzing of samples and / or during calibration.

[0063] The calibration substance preparation unit may be adapted to prepare a calibration substance, e.g. by mixing the items 212 and 222. The calibration substance may be used by the laboratory stations 20 and 25 for calibration purposes without any further modification.

[0064] The first container 210 comprises a first handling means in the form of a slide 214. By means of the slide 214, the first item 212 can be disposed on a carrier standing on the transport plane 110 in a specific position besides the storage module 200.

[0065] For transporting the first item 212, the transport carrier 230 is provided on the transport plane 110. The transport carrier 230 also comprises a permanent magnet and can be handled by the control unit 150 as if it would be a sample container carrier 140. However, the transport carrier 230 is not adapted to transport a sample container 145, but has a recess 235 in which the first item 212 can be stored. Thus, the first item 212 can be transported to the laboratory stations 20, 25 by means of the transport carrier 230.

[0066] The second container 220 comprises a second handling means in the form of a standpipe 224. The standpipe 224 has a height such that a sample container 145 contained in a sample container carrier 140 can be placed below it. This allows a filling of the sample container 145 with the liquid second item 222. Thus, the second item 222 can be transported to the laboratory stations 20, 25 using sample container carriers 140 carrying sample containers 145.

[0067] The storage means 200 in general provides for a central storage of items 212, 222 such that no further supply means is required for the laboratory stations 20, 25. It allows further to automate replacement of items in the laboratory stations 20, 25, because the laboratory stations 20, 25 can easily report to the control unit 150 that a specific item is running short or that calibration is required, and refilling or the preparation of said item 212, 222 can easily be accomplished by processing and / or disposal of the specific item 212, 222 at the storage module 200 and by transporting the specific item 212, 222 to the respective analyzing station 20, 25. For this purpose, the sample distribution system 100 can be used without further modification.

[0068] It should be noted that the two items 212, 222 are only shown exemplarily in the embodiment, and that in a typical laboratory automation system 10, more than two items are to be provided to the laboratory stations 20, 25. This can be accomplished in a similar way.

[0069] Fig. 2 schematically shows a further embodiment of the laboratory automation system 10 according to the invention.

[0070] The laboratory automation system 10 comprises the laboratory sample distribution system 100, the first laboratory station 20, the second laboratory station 25 and the storage module 200.

[0071] According to this embodiment, the storage module 200 comprises a number (e.g. 7) of processing means 225, e.g. incorporating a temperature control unit and / or a shaker unit and / or a mixer unit and / or an aliquoter unit and / or a label unit and / or a capping unit and / or a calibration substance preparation unit being adapted to prepare a calibration substance. The storage module 200 further comprises an internal transfer unit 111 e.g. for transporting substances required for the preparation of the calibration substance to a specific processing means 225 forming the calibration substance preparation unit. The internal transfer unit 111 may be a revolving transfer machine, a carousel machine or may use a transport mechanism corresponding to the laboratory sample distribution system 100.

[0072] The storage module 200 further comprises a transfer unit 226 for filling of a sample container with the processed calibration substance. The sample container is contained in the sample container carrier 140. The transfer unit 226 may use a transport mechanism corresponding to the laboratory sample distribution system 100.

[0073] Thus, the processed calibration substance may be transported to the laboratory station 20 and / or to the laboratory station 25 for calibration using the sample container carriers 140.

Claims

1. Method of operating a laboratory automation system (100), - wherein the laboratory automation system (100) comprises a plurality of laboratory stations (20, 25), a laboratory sample distribution system (100) and a storage module (200), wherein the method comprises the steps - detecting that at least one type of items (212, 222) is missing or is running short at one of the laboratory stations (20, 25), - in response to the detecting, disposing a number of such items (212, 222) from one of a number of storage means (210, 220) of the storage module (200), - transporting the items (212, 222) to the laboratory stations (20, 25) using the laboratory sample distribution system (100), the method being characterised in: - detecting that at least one storage means (210, 220) is empty or is running short of items (212, 222) stored by means of the storage means (210, 220), and - in response to the detecting, generating a signal indicating that the storage means (210, 220) should be filled and / or replaced.

2. Method according to claim 1, characterized in that - the items (212, 222) are transported - by means of sample container carriers (140) of the laboratory sample distribution system (100), or - by means of transport carriers (230).

3. Method according to claim 1 or 2, characterized in that - at least some of the items (212, 222) are reagents, tubes, tips, pipetting heads, labels, cartridges comprising a set of reagents used in the laboratory stations and / or other consumables used by the laboratory stations (20, 25).

4. Method according to one of claims 1 to 3, characterized in that - at least one of the items (212, 222) is a calibration substance, and / or - at least some of the items (212, 222) are substances required for preparation of the calibration substance.

5. Method according to one of claims 1 to 4, characterized in that - at least some of the items (212, 222) are liquids and are transported using containers of the transport carriers (230).

6. Method according to one of claims 1 to 5, characterized in that - detecting that a type of items (212, 222) is running short comprises detecting that a number or amount of such an item is less than 10 % of a maximum capacity.

7. Laboratory automation system (10), comprising - a plurality of laboratory stations (20, 25), - a laboratory sample distribution system (100), comprising - a number of sample container carriers (140), wherein the sample container carriers (140) are adapted to carry one or more sample containers (145), wherein the sample containers (145) comprise samples to be analyzed by means of the laboratory stations (20, 25), - a transport plane (110), wherein the transport plane (110) is adapted to support the sample container carriers (140), - drive means (120), wherein the drive means (120) are adapted to move the sample container carriers (140) on the transport plane (110), and - a control device (150), wherein the control device (150) is configured to control the drive means (120) such that the sample container carriers (140) move over the transport plane (110) along predetermined transport paths, - a storage module (200) attached to the laboratory sample distribution system (100), wherein the storage module (200) comprises number of storage means (210, 220) for storing items (212, 222), - a number of transport carriers (230) being adapted to carry one or more of the items (212, 222), - wherein the drive means (120) are adapted to move the transport carriers (230) on the transport plane (110), - wherein the control device (150) is configured to control the drive means (120) such that the transport carriers (230) move over the transport plane (110) along predetermined transport paths, - wherein handling means (214, 224) are assigned to the storage means (210, 220) of the storage module (200), - wherein the handling means are adapted to effect the disposal of the stored items (212, 222) to the sample container carriers (140) or to the transport carriers (230) by loading the items (212, 222) from the storage means (210, 220) on the sample container carriers (140) or on the transport carriers (230), and - a process control unit (150), wherein the process control unit (150) is configured to control the laboratory stations (20, 25), the laboratory sample distribution system (100) and the storage module (200) such that a method according to one of the preceding claims is performed.

8. Laboratory automation system (10) according to claim 7, characterized in that - the storage module (200) comprises processing means (225), wherein the processing means (225) are adapted to process the stored items (212, 222).

9. Laboratory automation system (10) according to claim 8, - wherein the processing means (225) comprise a temperature control unit and / or a shaker unit and / or a mixer unit and / or an aliquoter unit and / or a label unit and / or a capping unit and / or a calibration substance preparation unit being adapted to prepare a calibration substance.

10. Laboratory automation system (10) according to claim 9, characterized in that - the processing means (225) are adapted to plan and / or cause and / or control the processing of the stored items (212, 222) and / or are adapted to cause disposal of the prepared calibration substance to the sample container carriers (140) and / or to the transport carriers (230).